WA 320-6 Shop Manual

SEN03911-02

WHEEL LOADER

-6 WA320 WA320PZ -6 SERIAL NUMBERS

WA320- 70001 WA320PZ-70001

and up

SEN03920-02

WHEEL LOADER WA320-6 WA320PZ-6 (KA SPEC.) 1SHOP MANUAL

Machine model WA320-6 WA320PZ-6 (KA SPEC.)

Serial number 70001 and up 70001 and up

00 Index and foreword

00

100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents............................................................................................................................................. 4

WA320, 320PZ-6 (KA SPEC.)

00-100

1

SEN03920-02

100 Index Composition of shop manual

Composition of shop manual

1

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs ..................................................................... SEN03911-02 00 Index and foreword .................................................................................................................... SEN03912-02 100 Index .................................................................................................................................. SEN03920-02 q 200 Foreword and general information ..................................................................................... SEN03921-01 01 Specification ............................................................................................................................... SEN03913-01 100 Specification and technical data......................................................................................... SEN03922-01 10 Structure, function and maintenance standard........................................................................... SEN03914-02 100 Engine and cooling system ................................................................................................ SEN03923-01 200 Power train......................................................................................................................... SEN03924-01 300 Steering system ................................................................................................................. SEN03925-01 400 Brake system ..................................................................................................................... SEN03926-00 500 Undercarriage and frame ................................................................................................... SEN03927-00 600 Hydraulic system................................................................................................................ SEN03928-00 700 Work equipment................................................................................................................. SEN03929-01 800 Cab and its attachments .................................................................................................... SEN03930-00 910 Electrical system, Part 1 .................................................................................................... SEN03931-01 920 Electrical system, Part 2 .................................................................................................... SEN03932-02 q 20 Standard value table................................................................................................................... SEN03915-00 100 Standard service value table.............................................................................................. SEN03933-00 30 Testing and adjusting ................................................................................................................. SEN03916-02 110 Testing and adjusting, Part 1.............................................................................................. SEN03934-02 q 120 Testing and adjusting, Part 2.............................................................................................. SEN03935-02 q 130 Testing and adjusting, Part 3.............................................................................................. SEN03936-01 40 Troubleshooting.......................................................................................................................... SEN03917-02 100 Failure code table and fuse locations ................................................................................ SEN03937-01 200 General information on troubleshooting............................................................................. SEN03938-02 q 310 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN03939-00 320 Troubleshooting by failure code (Display of code), Part 2 ................................................. SEN03940-00 330 Troubleshooting by failure code (Display of code), Part 3 ................................................. SEN03941-01 340 Troubleshooting by failure code (Display of code), Part 4 ................................................. SEN03942-01 00-100

2


100 Index Composition of shop manual

350 360 370 400 500 600

SEN03920-02

Troubleshooting by failure code (Display of code), Part 5..................................................SEN03943-01 Troubleshooting by failure code (Display of code), Part 6..................................................SEN03944-01 Troubleshooting by failure code (Display of code), Part 7..................................................SEN03945-00 Troubleshooting of electrical system (E-mode) ..................................................................SEN03946-01 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN03947-01 Troubleshooting of engine (S-mode) ..................................................................................SEN03948-01

50 Disassembly and assembly ........................................................................................................SEN03918-02 100 General information on disassembly and assembly...........................................................SEN03949-01 200 Engine and cooling system ................................................................................................SEN03950-02 q 310 Power train, Part 1..............................................................................................................SEN03951-00 320 Power train, Part 2..............................................................................................................SEN03952-00 400 Undercarriage and frame ...................................................................................................SEN03953-00 500 Hydraulic system ................................................................................................................SEN03954-00 600 Work equipment .................................................................................................................SEN03955-00 700 Cab and its attachments.....................................................................................................SEN03956-00 800 Electrical system ................................................................................................................SEN03957-00 90 Diagrams and drawings..............................................................................................................SEN03919-01 100 Hydraulic diagrams and drawings ......................................................................................SEN03958-01 200 Electrical diagrams and drawings.......................................................................................SEN03959-01


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Table of contents

100 Index Table of contents

1

00 Index and foreword 100 Index SEN03920-02 Composition of shop manual......................................................................................................................... 2 Table of contents ........................................................................................................................................... 4 200 Foreword and general information SEN03921-01 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN03922-01 Specification dimension drawing ................................................................................................................... 3 Specifications ................................................................................................................................................ 4 Weight table .................................................................................................................................................. 8 Table of fuel, coolant and lubricants.............................................................................................................. 10 10 Structure, function and maintenance standard 100 Engine and cooling system SEN03923-01 Engine mount and transfer mount................................................................................................................. 2 Damper ......................................................................................................................................................... 3 Cooling system.............................................................................................................................................. 4 Cooling system hydraulic piping diagram...................................................................................................... 5 Cooling fan motor.......................................................................................................................................... 7 200 Power train SEN03924-01 Power train .................................................................................................................................................... 3 Power train system diagram.......................................................................................................................... 4 Drive shaft ..................................................................................................................................................... 6 HST hydraulic piping diagram ....................................................................................................................... 7 HST pump ..................................................................................................................................................... 8 HST motor..................................................................................................................................................... 16 Transfer ......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential ..................................................................................................................................................... 36 Torque proportioning differential.................................................................................................................... 41 Limited slip differential................................................................................................................................... 44 Final drive...................................................................................................................................................... 48 300 Steering system SEN03925-01 Steering piping diagram ................................................................................................................................ 3 Steering column ............................................................................................................................................ 4 Priority valve.................................................................................................................................................. 5 Orbit-roll valve ............................................................................................................................................... 8 Cushion valve................................................................................................................................................ 16 Steering cylinder............................................................................................................................................ 17 Emergency steering piping diagram.............................................................................................................. 19 Emergency steering valve............................................................................................................................. 20 Steering relief valve....................................................................................................................................... 23

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400 Brake system SEN03926-00 Brake piping diagram..................................................................................................................................... 3 Charge valve ................................................................................................................................................. 4 Brake valve.................................................................................................................................................... 8 Inching valve.................................................................................................................................................. 12 Accumulator (for brake) ................................................................................................................................. 13 Slack adjuster ................................................................................................................................................ 14 Brake ............................................................................................................................................................. 16 Parking brake control..................................................................................................................................... 21 Parking brake ................................................................................................................................................ 22 500 Undercarriage and frame SEN03927-00 Axle mount and center hinge pin ................................................................................................................... 2 Tires............................................................................................................................................................... 7 600 Hydraulic system SEN03928-00 Work equipment hydraulic piping diagram .................................................................................................... 2 Work equipment control lever linkage ........................................................................................................... 6 Hydraulic tank................................................................................................................................................ 10 4-gear pump .................................................................................................................................................. 12 Work equipment control valve ....................................................................................................................... 14 Cut-off valve .................................................................................................................................................. 40 PPC valve...................................................................................................................................................... 43 Lock valve...................................................................................................................................................... 58 Accumulator (for PPC circuit) ........................................................................................................................ 59 ECSS valve ................................................................................................................................................... 61 Accumulator (for ECSS) ................................................................................................................................ 63 700 Work equipment SEN03929-01 Work equipment linkage ................................................................................................................................ 2 Bucket............................................................................................................................................................ 6 Bucket positioner and boom kick-out............................................................................................................. 10 Work equipment cylinder ............................................................................................................................... 22 800 Cab and its attachments SEN03930-00 Cab ................................................................................................................................................................ 3 Air conditioner................................................................................................................................................ 4 910 Electrical system, Part 1 SEN03931-01 Machine monitor system................................................................................................................................ 2 Machine monitor ............................................................................................................................................ 6 920 Electrical system, Part 2 SEN03932-02 Electrical system (HST controller system)..................................................................................................... 2 HST controller................................................................................................................................................ 18 ECSS system ................................................................................................................................................ 20 KOMTRAX system ........................................................................................................................................ 22 Engine starting circuit .................................................................................................................................... 24 Engine stopping circuit .................................................................................................................................. 26 Preheating circuit........................................................................................................................................... 27 Engine output derating function..................................................................................................................... 28 Automatic warm-up function .......................................................................................................................... 28 Parking brake circuit ...................................................................................................................................... 30 Coupler plunger control system..................................................................................................................... 32 Multi-function knob ........................................................................................................................................ 33 Max. traction switch ....................................................................................................................................... 34 Sensor ........................................................................................................................................................... 35 20 Standard value table 100 Standard service value table SEN03933-00 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 3


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30 Testing and adjusting 110 Testing and adjusting, Part 1 SEN03934-02 Tools for testing, adjusting, and troubleshooting ........................................................................................... 3 Measuring engine speed............................................................................................................................... 8 Measuring exhaust gas color ........................................................................................................................ 10 Adjusting valve clearance ............................................................................................................................. 12 Measuring compression pressure ................................................................................................................. 14 Measuring blow-by pressure ......................................................................................................................... 17 Measuring engine oil pressure ...................................................................................................................... 18 Measuring intake air (boost) pressure........................................................................................................... 19 Handling fuel system equipment ................................................................................................................... 21 Releasing residual pressure in fuel system................................................................................................... 21 Measuring fuel pressure................................................................................................................................ 22 Measuring fuel return rate and leakage ........................................................................................................ 24 Bleeding air from fuel circuit.......................................................................................................................... 28 Checking leakage in fuel system................................................................................................................... 29 Handling cylinder cut-out mode operation..................................................................................................... 30 Handling no-injection cranking operation ...................................................................................................... 30 Handling controller voltage circuit ................................................................................................................. 31 Check of muffler and muffler stack for looseness and damage .................................................................... 31 Check of muffler function .............................................................................................................................. 32 Check of installed condition of cylinder head and manifolds......................................................................... 32 Check of engine piping for damage and looseness ...................................................................................... 33 Testing and adjusting air conditioner compressor belt tension...................................................................... 33 Replacing alternator belt ............................................................................................................................... 34 120 Testing and adjusting, Part 2 SEN03935-02 Checking operating force of accelerator pedal.............................................................................................. 3 Checking directional lever ............................................................................................................................. 4 Testing and adjusting HST oil pressure......................................................................................................... 5 Testing clutch control pressure...................................................................................................................... 9 Testing and adjusting steering wheel ............................................................................................................ 10 Testing and adjusting steering oil pressure ................................................................................................... 12 Bleeding air from steering circuit................................................................................................................... 14 Testing hydraulic fan ..................................................................................................................................... 15 Measuring brake pedal.................................................................................................................................. 17 Testing and adjusting brake pedal linkage .................................................................................................... 18 Measuring brake performance ...................................................................................................................... 19 Testing and adjusting accumulator charge pressure..................................................................................... 20 Testing wheel brake oil pressure................................................................................................................... 22 Testing wear of brake disc............................................................................................................................. 25 Bleeding air from wheel brake circuit ............................................................................................................ 26 Releasing residual pressure in brake accumulator circuit............................................................................. 27 Testing parking brake performance............................................................................................................... 28 Testing and adjusting parking brake control cable ........................................................................................ 29 Measuring and adjusting work equipment control lever ................................................................................ 30 Testing and adjusting work equipment hydraulic pressure............................................................................ 31 Testing work equipment PPC oil pressure .................................................................................................... 32 Bleeding air from hydraulic circuit ................................................................................................................. 34 Releasing remaining pressure in hydraulic circuit......................................................................................... 35 Testing and adjusting bucket positioner ........................................................................................................ 36 Testing and adjusting of boom kick-out switch .............................................................................................. 37 Checking proximity switch operation pilot lamp ............................................................................................ 38 Procedure for testing diodes ......................................................................................................................... 39 Preparation work for troubleshooting for electric system .............................................................................. 40 Starting KOMTRAX terminal operations........................................................................................................ 44 Indicator lamps of KOMTRAX terminal ......................................................................................................... 48 130 Testing and adjusting, Part 3 SEN03936-01 Adjusting machine monitor............................................................................................................................ 2 00-100

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SEN03920-02

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3 Special functions of machine monitor (EMMS).............................................................................................. 5 Pm clinic inspection chart .............................................................................................................................. 60 40 Troubleshooting 100 Failure code table and fuse locations SEN03937-01 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 8 200 General information on troubleshooting SEN03938-02 Points to remember when troubleshooting .................................................................................................... 2 Sequence of events in troubleshooting ......................................................................................................... 3 Testing before troubleshooting ...................................................................................................................... 4 Classification and procedures of troubleshooting.......................................................................................... 5 Information contained in troubleshooting table .............................................................................................. 8 Connection table for connector pin numbers................................................................................................. 10 T- branch box and T- branch adapter table ................................................................................................... 46 310 Troubleshooting by failure code (Display of code), Part 1 SEN03939-00 Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2 Failure code [6091NX] HST filter: Clogging................................................................................................... 4 Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 6 Failure code [AA1ANX] Air cleaner: Clogging ............................................................................................... 8 Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 10 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 12 Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 14 Failure code [B@BAZK] Engine oil: Low level............................................................................................... 15 Failure code [B@BCNS] Engine: Overheat................................................................................................... 16 Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 18 Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 20 Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 21 320 Troubleshooting by failure code (Display of code), Part 2 SEN03940-00 Failure code [CA111] Abnormality in engine controller .................................................................................. 3 Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 4 Failure code [CA122] Charge pressure sensor high error............................................................................. 6 Failure code [CA123] Charge pressure sensor low error .............................................................................. 8 Failure code [CA131] Throttle sensor high error ........................................................................................... 10 Failure code [CA132] Throttle sensor low error............................................................................................. 12 Failure code [CA144] Coolant sensor high error ........................................................................................... 14 Failure code [CA145] Coolant sensor low error............................................................................................. 16 Failure code [CA153] Charge temperature sensor high error ....................................................................... 18 Failure code [CA154] Charge temperature sensor low error......................................................................... 20 Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22 Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24 Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26 Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28 Failure code [CA227] Sensor power supply 2 high error............................................................................... 30 Failure code [CA234] Engine overspeed....................................................................................................... 31 Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32 Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33 Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34 Failure code [CA322] Injector #1 open/short error ........................................................................................ 36 Failure code [CA323] Injector #5 open/short error ........................................................................................ 38 Failure code [CA324] Injector #3 open/short error ........................................................................................ 40 Failure code [CA325] Injector #6 open/short error ........................................................................................ 42 Failure code [CA331] Injector #2 open/short error ........................................................................................ 44 Failure code [CA332] Injector #4 open/short error ........................................................................................ 46 Failure code [CA342] Calibration code inconsistency ................................................................................... 48 Failure code [CA351] Injectors drive circuit error .......................................................................................... 50


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Failure code [CA352] Sensor power supply 1 low error................................................................................ 52 Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54 330 Troubleshooting by failure code (Display of code), Part 3 SEN03941-01 Failure code [CA428] Abnormally high level in water sensor........................................................................ 4 Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6 Failure code [CA431] Idle validation switch error.......................................................................................... 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error ................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error ........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2............................................................................. 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28 Failure code [CA553] Common rail pressure high error 1............................................................................. 29 Failure code [CA559] Supply pump pressure very low error......................................................................... 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34 Failure code [CA757] All continuous data lost error...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46 Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50 Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54 340 Troubleshooting by failure code (Display of code), Part 4 SEN03942-01 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2 Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6 Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 24 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 32 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 37 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43 350 Troubleshooting by failure code (Display of code), Part 5 SEN03943-01 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8 Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 12 Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble................................................................................................................. 16 Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22 00-100

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SEN03920-02

Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24 Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short............................................... 28 Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................. 30 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 32 Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 36 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 38 360 Troubleshooting by failure code (Display of code), Part 6 SEN03944-01 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2 Failure code [DF10KB] Travel speed range selector switch: Hot short ......................................................... 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault .............................................................. 8 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................ 9 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short.......................................... 10 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault ............................................ 12 Failure code [DHH1KY] HST oil pressure sensor: Hot short ......................................................................... 14 Failure code [DHTCL6] HST filter clogging sensor: Functional defect .......................................................... 16 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short .............................................................. 18 Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20 Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26 Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30 Failure code [DW26KY] Motor 2 solenoid: Hot short..................................................................................... 32 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36 370 Troubleshooting by failure code (Display of code), Part 7 SEN03945-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2 Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3 Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4 Failure code [DX19KA] Motor 1 solenoid: Disconnection.............................................................................. 6 Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8 Failure code [DX19KY] Motor 1 solenoid: Hot short...................................................................................... 10 Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12 Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14 Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16 Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20 Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24 Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26 Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 26 Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 27 400 Troubleshooting of electrical system (E-mode) SEN03946-01 E-1 Engine does not start .............................................................................................................................. 4 E-2 Preheater does not operate normally...................................................................................................... 12 E-3 Travel speed is low or high ..................................................................................................................... 16 E-4 ECSS does not operate .......................................................................................................................... 22 E-5 ECSS keeps operating............................................................................................................................ 25 E-6 Defective boom kick-out function and cancellation ................................................................................. 28 E-7 Defective bucket positioner function and cancellation ............................................................................ 32 E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 36 E-9 Travel direction selection system does not function................................................................................ 40 E-10 Fan does not reverse ............................................................................................................................ 44 E-11 Fan keeps rotating in reverse................................................................................................................ 48 E-12 Wiper does not operate......................................................................................................................... 50 E-13 Windshield washer does not operate.................................................................................................... 54 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off ........................................................ 58 E-15 Working lamp does not light up or go off............................................................................................... 66 WA320, 320PZ-6 (KA SPEC.)

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E-16 Turn signal lamp and hazard lamp do not light up or go off.................................................................. 72 E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 78 E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 80 E-19 Backup alarm does not sound or it keeps sounding............................................................................. 83 E-20 Horn does not sound or it keeps sounding ........................................................................................... 86 E-21 Alarm buzzer does not sound or it keeps sounding.............................................................................. 88 E-22 Air conditioner does not operate or stop............................................................................................... 90 E-23 The KOMTRAX system does not work properly................................................................................... 94 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03947-01 Method of using troubleshooting chart .......................................................................................................... 3 Failure code and cause table ........................................................................................................................ 6 H-1 The machine does not start.................................................................................................................... 8 H-2 The travel speed is slow......................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11 H-5 Shift range is not shifted ......................................................................................................................... 12 H-6 The steering wheel does not turn ........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks............................................................................................................... 15 H-9 Machine deviates naturally to one side when traveling .......................................................................... 15 H-10 The brake does not work or does not work well ................................................................................... 16 H-11 The brake is not released or is dragged ............................................................................................... 17 H-12 The lift arm does not rise or lower ........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21 H-19 The bucket does not tilt back................................................................................................................ 22 H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27 600 Troubleshooting of engine (S-mode) SEN03948-01 Method of using troubleshooting charts ........................................................................................................ 2 S-1 Starting performance is poor .................................................................................................................. 6 S-2 Engine does not start.............................................................................................................................. 8 S-3 Engine does not pick up smoothly.......................................................................................................... 11 S-4 Engine stops during operations .............................................................................................................. 12 S-5 Engine does not rotate smoothly ............................................................................................................ 13 S-6 Engine lacks output (or lacks power)...................................................................................................... 14 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16 S-9 Oil becomes contaminated quickly ......................................................................................................... 17 S-10 Fuel consumption is excessive............................................................................................................. 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19 S-12 Oil pressure drops ................................................................................................................................ 20 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22 S-15 Abnormal noise is made ....................................................................................................................... 23 S-16 Vibration is excessive ........................................................................................................................... 24

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50 Disassembly and assembly 100 General information on disassembly and assembly SEN03949-01 How to read this manual................................................................................................................................ 2 How to read this manual................................................................................................................................ 2 Special tool list............................................................................................................................................... 7 Sketches of special tools ............................................................................................................................... 11 200 Engine and cooling system SEN03950-02 Removal and installation of fuel supply pump assembly ............................................................................... 2 Removal and installation of fuel injector assembly ........................................................................................ 4 Removal and installation of cylinder head assembly ..................................................................................... 12 Removal and installation of engine hood assembly ...................................................................................... 24 Removal and installation of radiator .............................................................................................................. 27 Removal and installation of air aftercooler..................................................................................................... 30 Removal and installation of hydraulic oil cooler assembly ............................................................................ 32 Removal and installation of engine assembly ............................................................................................... 34 Removal and installation of engine front oil seal assembly ........................................................................... 40 Removal and installation of engine rear oil seal assembly ............................................................................ 43 Removal and installation of cooling fan and fan motor assembly.................................................................. 46 Removal and installation of fuel tank assembly............................................................................................. 49 310 Power train, Part 1 SEN03951-00 Removal and installation of transfer .............................................................................................................. 2 Disassembly and assembly of transfer assembly.......................................................................................... 5 Removal and installation of parking brake assembly..................................................................................... 24 Disassembly and assembly of parking brake assembly ................................................................................ 25 320 Power train, Part 2 SEN03952-00 Removal and installation of front axle assembly ........................................................................................... 2 Removal and installation of rear axle assembly ............................................................................................ 4 Disassembly and assembly of axle housing assembly.................................................................................. 7 Disassembly and assembly of differential assembly ..................................................................................... 19 400 Undercarriage and frame SEN03953-00 Removal and installation of center hinge pin................................................................................................. 2 Removal and installation of counterweight .................................................................................................... 12 500 Hydraulic system SEN03954-00 Removal and installation of HST pump and 4-gear pump assembly............................................................. 2 Disassembly and assembly of HST pump assembly..................................................................................... 5 Removal and installation of HST motor 1 assembly ...................................................................................... 32 Removal and installation of HST motor 2 assembly ...................................................................................... 34 Disassembly and assembly of HST motor assembly .................................................................................... 36 Removal and installation of work equipment control valve assembly............................................................ 52 Removal and installation of hydraulic tank assembly .................................................................................... 54 Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 56 600 Work equipment SEN03955-00 Removal and installation of work equipment assembly ................................................................................. 2 700 Cab and its attachments SEN03956-00 Removal and installation of operator's cab and floor frame assembly .......................................................... 2 Removal and installation of operator's cab glass (Stuck glass)..................................................................... 8 Disassembly and assembly of operator's seat assembly .............................................................................. 16 Removal and installation of air conditioner unit ............................................................................................. 26 800 Electrical system SEN03957-00 Removal and installation of monitor panel..................................................................................................... 2 Removal and installation of engine controller assembly................................................................................ 4 Removal and installation of HST controller assembly ................................................................................... 5 Removal and installation of KOMTRAX terminal assembly........................................................................... 6


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SEN03920-02


90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN03958-01 Automatic greasing circuit diagram ............................................................................................................... 2 Hydraulic circuit diagram............................................................................................................................... 5 200 Electrical diagrams and drawings SEN03959-01 Electrical circuit diagram ............................................................................................................................... 3 Connector list and stereogram ...................................................................................................................... 29

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SEN03920-02

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SEN03920-02

WA320-6, WA320PZ-6 (KA SPEC.) Wheel loader Form No. SEN03920-02

©2009 KOMATSU All Rights Reserved Printed in Japan 07-09

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SEN03921-01




00 Index and foreword

00

200 Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36


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1

200 Foreword and general information Safety notice

SEN03921-01

Safety notice

(Rev. 2008/08)1

Important safety notice Proper service and repair are 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. 1.

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 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 warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

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7)

8)

9)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much



2.

3.

SEN03921-01

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

6)

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

11)


7)

8)

9)

10)

12)

13)

14)

15)

16)

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 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 and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 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. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 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. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

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SEN03921-01 4.

Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 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. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

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8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.



If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN03921-01 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.


7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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SEN03921-01 8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)

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a

Example of O-ring (Fitted to every joint of hoses and tubes)

a

For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.

6


200 Foreword and general information How to read the shop manual

How to read the shop manual q q q

1.

SEN03921-01

1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.


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200 Foreword and general information How to read the shop manual

SEN03921-01 3.

4.

Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)

q

Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

k

Safety

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

5.

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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200 Foreword and general information Explanation of terms for maintenance standard

SEN03921-01

Explanation of terms for maintenance standard

1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size

Tolerance –0.022 –0.126

120 a

The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

q

Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

Tolerance Shaft –0.030 –0.076


Hole +0.046 +0

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200 Foreword and general information Explanation of terms for maintenance standard

SEN03921-01 2.

Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

5.

q

3.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.

4.

Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

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Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q


200 Foreword and general information Handling of electric equipment and hydraulic component

SEN03921-01

Handling of electric equipment and hydraulic component

1

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).

Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and 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. 2.

Main failures occurring in wiring harness 1) 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. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

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 connection or breakage.


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SEN03921-01 3)

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.

4)

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. Accordingly, take care not to splash water over the connector. 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 short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

5)

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. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a 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.

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3.

SEN03921-01

Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. 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. a Never pull with one hand. 2] q

When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

q

When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

3]

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. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.


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SEN03921-01 2)

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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a 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. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

14



3)

Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks


SEN03921-01 q

Disconnection

q

Connection (Example of incomplete setting of (a))

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SEN03921-01 4)

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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. 1] Disconnect the connector and wipe off the water with a dry cloth. a 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 oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a 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. 3] 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. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

16



4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a 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. a If there is any change, there is probably defective contact in that circuit.


SEN03921-01

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17

SEN03921-01


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 check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

3.

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 onto the ground, but 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.

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18



5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (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 changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.


SEN03921-01

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19

200 Foreword and general information Handling of connectors newly used for engines

SEN03921-01

Handling of connectors newly used for engines a

1.

Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

1

Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

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20



3.

SEN03921-01

Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

q

114 engine

q

107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)

3)

While pressing lock (D), pull out connector (4) in the direction of the arrow.

107 engine

a

2)

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.


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21


SEN03921-01 q

4)

95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)

4.

Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

q

1)

Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

2)

Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.

Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

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22


200 Foreword and general information How to read electric wire code

SEN03921-01

How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type

Symbol

Low-voltage wire for automobile

AV

Thin-cover low-voltage wire for automobile

AVS

Heat-resistant low-voltAEX age wire for automobile

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator


Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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23


SEN03921-01 2.

Dimensions

(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

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24



3.

SEN03921-01

Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.

4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit

Others

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch


AEX

–

R B R D Y G L

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

WG

–

–

–

–

–

–

–

–

–

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

– –

–

YW GL

– – – –

Gr Br –

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25

200 Foreword and general information Precautions when carrying out operation

SEN03921-01

Precautions when carrying out operation

1

[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. q q q q q q q q q q

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit 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. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)

00-200

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

D 6 8 10 12 14 16 18 20 22 24

27

07049-02734

27

26

Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5

34



2. q q q q q q q q q q q q q

a

a 3.

SEN03921-01

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 and fix them with intermediate clamps, if there are any. 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. 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 idle. 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. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q 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. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.


00-200

27

SEN03921-01 4)

5)

00-200


Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.

28


200 Foreword and general information Method of disassembling and connecting push-pull type coupler

SEN03921-01

Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. 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.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a 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. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.


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SEN03921-01


Type 2 1.

2.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

q

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30



SEN03921-01

Type 3 1.

2.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

q


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31

200 Foreword and general information Standard tightening torque table

SEN03921-01

Standard tightening torque table 1.

1

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a

The following table applies to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 157 – 196 16 – 20 245 – 309 25 – 31.5 343 – 427 35 – 43.5 490 – 608 50 – 62 662 – 829 67.5 – 84.5 824 – 1,030 84 – 105 1,180 – 1,470 120 – 150 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table applies to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12 a Fig. A

Width across flats mm 10 12 14 17

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)

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2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN03921-01

Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52


Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

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SEN03921-01 5.

Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

02

19 22 24 27 32 36 41 46 55

03 04 05 06 (10) (12) (14)

6.

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).

Outer diameter of pipe (mm)

Width across flats (mm)

8 10 12 15 (16) 22 (20)

19 22 24 (27) 30 (32) 36

Tightening torque Nm {kgm} Range

Target

14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

7.

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts

Thread size mm 6 8 10 12 14

00-200

34

Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —



8.

Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

9.

SEN03921-01

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.

Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4


Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

00-200

35

200 Foreword and general information Conversion table

SEN03921-01

Conversion table

1

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), and 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 2 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 it 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.

Millimeters to inches

(A)

00-200

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 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

36

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 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



SEN03921-01

Millimeters to inches 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

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

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304


14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

00-200

37


SEN03921-01

Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

7 50.6 123.0 195.3 267.6 340.0

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

00-200

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4



SEN03921-01

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542


00-200

39


SEN03921-01 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 (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °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

177.8 179.6 181.4 183.2 185.0

–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 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-200

40




SEN03921-01

00-200

41

SEN03921-01


©2009 KOMATSU All Rights Reserved Printed in Japan 06-09 (01)

00-200

42

SEN03922-01




01 Specification

1

100 Specification and technical data Specification dimension drawing..................................................................................................................... 3 Specifications .................................................................................................................................................. 4 Weight table .................................................................................................................................................... 8 Table of fuel, coolant and lubricants.............................................................................................................. 10


01-100

1

SEN03922-01

01-100

2

100 Specification and technical data


100 Specification and technical data Specification dimension drawing

SEN03922-01

Specification dimension drawing

Item

1

Unit

WA320-6

WA320PZ-6

Machine weight

kg

14,085

15,200

Normal load

kg

4,480

4,320

Bucket capacity (heaped)

m

2.8

2.7

Engine model

—

Komatsu SAA6D107E-1 Diesel engine

kW{HP}/rpm

125 {167}/2,000 127.3 {171}/2,000

3

Engine rated output • Net [ISO 9249/SAE J1349] (*1) • Gross [SAE J1995] (*2) A Overall length

mm

7,515

7,770

B Overall height

mm

3,200

3,200

C Overall height with bucket lifted up

mm

5,325

5,475

D Overall width

mm

2,590

2,590

E Minimum ground clearance

mm

425

425

F

mm

2,740

2,750

Bucket width

G Dumping clearance (*3)

Bucket tip/BOC tip

mm

2,940/2,850

2,865/2,795

H Dumping reach (*3)

Bucket tip/BOC tip

mm

990/1,035

1,100/1,135

I

Bucket dump angle (max. height) Min. turning radius

Bucket tip/BOC tip Center of outside tire

45

48

mm

6,225/6,260

6,120/6,150

mm

5,380

5,380

kN {kg}

100 {10,200}

100 {10,200}

1st (forward/reverse)

4.0 – 13.0/4.0 – 13.0

4.0 – 13.0/4.0 – 13.0

2nd (forward/reverse)

13.0/13.0

13.0/13.0

18.7/18.7

18.7/18.7

38.0/38.0

38.0/38.0

Permissible towing load

Travel speed

degree

3rd (forward/reverse) 4th (forward/reverse)

km/h

*1: Indicates the value at the lowest cooling fan speed. *2: Indicates the value of the engine alone (without cooling fan). *3: Indicates the value at the 45° bucket dump angle. a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated output (net) at the maximum cooling fan speed. 117 kW {156 HP}/2,000 rpm a BOC: Abbreviation for Bolt-On Cutting edge


01-100

3

100 Specification and technical data Specifications

SEN03922-01

Weight

Specifications

1

Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Machine weight

kg

14,085

15,200

Machine weight (front wheel) in SAE travel posture

kg

5,730

6,940

Machine weight (rear wheel) in SAE travel posture

kg

8,355

8,260

Bucket capacity (heaped)

m3

2.8

2.7

Normal load

kg

4,480

4,320

km/h

4.0 – 13.0 13.0 18.7 38.0

4.0 – 13.0 13.0 18.7 38.0

km/h

4.0 – 13.0 13.0 18.7 38.0

4.0 – 13.0 13.0 18.7 38.0

kN{kg}

120 {12,200} 120 {12,200}

120 {12,200} 120 {12,200}

Gradeability

deg.

25

25

Min. turning radius (center of outside tire)

mm

5,380

5,380

Turning radius (cutting edge/BOC tip), SAE travel posture

mm

6,225/6,260

6,120/6,150

Overall length (with BOC)

mm

7,515

7,770

Overall width (chassis)

mm

2,590

2,590

Bucket width (with BOC)

mm

2,740

2,750

Overall height (cab top)

mm

3,200

3,200

Overall height with bucket lifted up

mm

5,325

5,475

Dimension

Performance

Travel speed • Forward 1st • Forward 2nd • Forward 3rd • Forward 4th • • • •

Reverse 1st Reverse 2nd Reverse 3rd Reverse 4th

Max. traction force • Forward • Reverse

Wheelbase

mm

3,030

3,030

Tread

mm

2,050

2,050

Minimum ground clearance

mm

425

425

Max. hinge pin height

mm

3,905

4,005

Dumping clearance (*1) (cutting edge/BOC tip)

mm

2,940/2,850

2,865/2,795

Dumping reach (*1) (cutting edge/BOC tip)

mm

990/1,035

1,100/1,135

Steering angle

deg.

38.5 (frame stopper 40)

38.5 (frame stopper 40)

Bucket tilt angle (operating posture/max. height)

deg.

47/62

47/66

Bucket dump angle (max. height)

deg.

45

48

Digging depth, 10° (cutting edge/BOC tip)

mm

250/295

330/370

*1: Indicates the value at the 45° bucket dump angle. a BOC: Abbreviation for Bolt-On Cutting edge

01-100

4



Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Model

SAA6D107E-1

Type

4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger and air-cooled aftercooler

No. of cylinders – bore x stroke

mm

6 – 107 x 124

l {cc}

6.69 {6,690}

kW{HP}/rpm

125 {167}/2,000 127.3 {171}/2,000

Nm{kgm}/rpm

660 {67.3}/1,500

g/kWh {g/HPh}

224 {167}

Max. speed at no load

rpm

2,250

Min. speed at no load

rpm

825

Performance

Total piston displacement

Engine

SEN03922-01

Rated output • Net [ISO 9249/SAE J1349] (*1) • Gross [SAE J1995] (*2) Max. torque (*1) Min. fuel consumption ratio

Starting motor

24 V, 5.5 kW

Alternator

24 V, 60 A

Battery (*3)

12 V, 140 Ah x 2 pieces

HST pump • Type • Pump capacity

Variable displacement swash plate type piston pump cc/rev

0 – 110

HST motor 1 Power train

• Type • Motor capacity

Variable displacement bent axis type piston motor cc/rev

HST motor 2 • Type • Motor capacity

Variable displacement bent axis type piston motor cc/rev

Reduction gear unit

Spiral bevel gear type, splash lubrication type

Differential

Straight bevel gear type, torque proportioning

Final drive

Planetary gear single reduction type, splash lubrication type

Drive wheel Axle

59 – 128 Counter-shaft double acting planetary type, spur gear constant-mesh type, switching between 2 power trains

Transfer

Front and rear wheel drive

Front axle

Fixed frame, semi-float type

Rear axle

Center pin support type, semi-float type

Size Tire

0 – 140

20.5 – 25 – 12PR

Rim size Inflation pressure • Front wheel • Rear wheel

25 x 17.00 – 1.7 kPa {kg/cm2}

330 {3.3} 280 {2.8}

*1: *2: *3: a

Indicates the value at the lowest cooling fan speed. Indicates the value of the engine alone (without cooling fan). The battery capacity (Ah) is indicated in the 5-hour rate value. The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated output (net) at the maximum cooling fan speed. 117 kW {156 HP}/2,000 rpm


01-100

5


SEN03922-01

Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Brake

Main

Braking method

4-wheel brake, independent front and rear wheel brakes

Type of brake

Enclosed wet multiple disc type

Drive method

Hydraulic drive

Operating method

Foot-operated (with hydraulic booster)

Parking

Braking method

Transmission output shaft brake

Type of brake

Wet multiple disc type

Drive method

Mechanical type

Steering

Operating method

Manual lever type

Steering method

Articulated chassis type

Drive method

Hydraulic drive

Steering pump • Type • Delivery

Gear type cm /rev

90.7

3

Hydraulic pump

Work equipment pump • Type • Delivery

Gear type cm /rev

32.0

3

Brake and cooling fan pump • Type • Delivery

Gear type cm /rev

18.1

3

Transfer lubrication pump • Type • Delivery

Gear type cm3/rev

12.0

Hydraulic equipment

Steering cylinder

Type Cylinder bore

Double-acting piston type mm

Piston rod outside diameter

mm

40

Stroke

mm

453

Max. distance between centers of pins

mm

1,271

Min. distance between centers of pins

mm

818

Lift cylinder

Cylinder

Type

Bucket cylinder

6

Double-acting piston type


Cylinder bore

mm

140

140


mm

75

75

Stroke

mm

740

729


mm

1,969

2,056


mm

1,229

1,327

Type

01-100

70



Cylinder bore

mm

160

180


mm

80

110

Stroke

mm

532

558


mm

1,559

1,912


mm

1,027

1,354



SEN03922-01

Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Coupler plunger

Cylinder

Type


mm

—

35


mm

—

20

Stroke

mm

—

214


mm

—

586


mm

—

372

Work equipment control valve Control valve

Hydraulic equipment

—

Cylinder bore

—

• Type • Set pressure

MPa{kg/cm2}

2-spool type

3-spool type

20.6 {210}

20.6 {210}

Steering valve • Type • Set pressure

Orbit-roll type 2

MPa{kg/cm }

20.6 {210}

Motor

Cooling fan motor

• Motor capacity Work equipment

Fixed displacement, swash plate, piston type

• Type

Type of link Shape of bucket cutting edge

cm3/rev

14.5 Z-bar link

Parallel movement type Z-bar link

Straight cutting edge with BOC

Straight cutting edge with BOC

a BOC: Abbreviation for Bolt-On Cutting edge


01-100

7

100 Specification and technical data Weight table

SEN03922-01

Weight table k

1

This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Engine (excluding coolant and oil)

625

625

Damper

6

6

Cooling assembly (excluding coolant and oil) • Radiator • Oil cooler • Aftercooler

82 14 14 10

82 14 14 10

Transfer oil cooler

5

5

Cooling fan motor

13

13

HST pump

85

85

HST motor 1

60

60

HST motor 2

64

64

Transfer

250

250

Front drive shaft

18

18

Rear drive shaft

7

7

Front axle • With torque proportioning differential • With limited slip differential

714 718

714 718

Rear axle • With torque proportioning differential • With limited slip differential

666 674

666 674

Axle pivot (Rear axle)

97

97

Wheel [25 x 17.00 – 1.7] (1 piece)

120

120

Tire [20.5 – 25 – 12 PR] (1 piece)

200

200

Hydraulic tank (excluding hydraulic oil)

89

89

4-gear pump

30

30

Work equipment control valve • 2-spool valve • 3-spool valve

65 —

— 91

Work equipment PPC valve

3

3

Attachment PPC valve

—

1

Priority valve

6

6

Orbit-roll valve

8

8

Cushion valve

4

4

Charge valve

6

6

Brake valve

10

10

Steering cylinder assembly (1 piece)

23

23

Lift cylinder assembly (1 piece)

109

112

Bucket cylinder assembly

124

206

01-100

8


100 Specification and technical data Weight table

SEN03922-01

Unit: kg Machine model name

WA320-6

WA320PZ-6

Serial No.

70001 and up

70001 and up

Front frame

1,100

1,252

Rear frame

973

973

1,695

1,950

255

220

Counterweight Additional counterweight (1 piece) Engine hood (including side panel)

269

269

Fuel tank (excluding fuel)

125

125

Lift arm (including bushing)

915

1,300

Bucket link

43

68

Bell crank

253

300

1,231 —

— 1,139

Operator's cab (including air conditioner and interior parts)

825

825

Operator seat

41

41

Air conditioner unit

5

5

Battery (1 piece)

47

47

Bucket • 2.8 m3 (including BOC) • 2.7 m3 (including BOC)

a BOC: Abbreviation for Bolt-On Cutting edge


01-100

9

100 Specification and technical data Table of fuel, coolant and lubricants

SEN03922-01

Table of fuel, coolant and lubricants a

1

For details of the notes (Note. 1, Note. 2…) in the table, see the Operation and Maintenance Manual.

Unit: l Specified capacity

Refill capacity

Engine oil pan

Reservoir

25.5

23.0

Transfer case

8

7.2

175

89

Axle (front/rear)

24

24

Cooling system

26.5

—

Fuel tank

245

—

Hydraulic system

01-100

10


100 Specification and technical data Table of fuel, coolant and lubricants


SEN03922-01

01-100

11

SEN03922-01



01-100

12

SEN03923-01




10 Structure, function and maintenance standard

10

100 Engine and cooling system Engine mount and transfer mount................................................................................................................... 2 Damper ........................................................................................................................................................... 3 Cooling system ............................................................................................................................................... 4 Cooling system hydraulic piping diagram ....................................................................................................... 5 Cooling fan motor............................................................................................................................................ 7


10-100

1

SEN03923-01

Engine mount and transfer mount

10-100

2

100 Engine and cooling system Engine mount and transfer mount

1


100 Engine and cooling system Damper

SEN03923-01

Damper

1

Unit: mm

No.

Check item

1

Distance between HST pump installation surface and boss tip

2

Wear on internal teeth of coupling (resin)

3. Coupling 4. Boss 5. HST pump input shaft 6. Cover 7. Flywheel


Criteria

Remedy

Standard size

Repair limit

74.9

±0.8 Repair limit: 1.0

Adjust Replace

Outline q The damper protects the drive systems on and after the engine from torsional vibrations by reducing the torsional vibrations of the engine due to the fluctuations in torque. q The power from the engine is transmitted to coupling (3) through flywheel (7) and torsional vibrations are absorbed in coupling (3). Then the power is transmitted to HST pump through boss (4).

10-100

3

100 Engine and cooling system Cooling system

SEN03923-01

Cooling system

1

1. Reservoir tank 2. Oil cooler 3. Radiator cap 4. Radiator

5. Aftercooler 6. Transfer oil cooler 7. Cooling fan 8. Cooling fan motor

Specifications

Core type Fin pitch (mm) Total heat dissipation area (m2) Pressure valve cracking pressure (kPa {kg/cm2}) Vacuum valve cracking pressure (kPa {kg/cm2})

Radiator

Oil cooler

Aftercooler

CF68-4 3.5/2 <8.0/2> 35.03 <24.36> 70.0 {0.7} 0 – 5.0 {0 – 0.05}

CF40-1 3.5/2 <8.0/2> 4.84 x 3 <3.25 x 3>

AL WAVE 4.0/2 <8.0/2> 12.79 <9.69>

—

—

—

—

Values in < > are shown for wide core type (if equipped).

10-100

4


100 Engine and cooling system Cooling system hydraulic piping diagram

SEN03923-01

Cooling system hydraulic piping diagram

1. Cooling fan motor 2. Strainer 3. Hydraulic tank 4. Brake and cooling fan pump 5. Charge valve


1

Outline q Cooling fan motor (1) installed in the machine rear side is driven by oil pressure from brake and cooling fan pump (4).

10-100

5

SEN03923-01

10-100

6

100 Engine and cooling system Cooling system hydraulic piping diagram


100 Engine and cooling system Cooling fan motor

SEN03923-01

Cooling fan motor

1

Type: LMF16

P: From pump through charge valve T: To hydraulic tank through return filter TC: To hydraulic tank 1. ER terminal 2. EF terminal 3. Solenoid proportional pilot valve 4. ON/OFF pilot valve


Specifications Type: LMF16 Capacity: 14.5 cm3/rev Rated speed: 1,800 rpm Rated flow rate: 26.1 l/min

10-100

7

SEN03923-01

10-100

8




SEN03923-01

1. Output shaft 2. Case 3. Thrust plate 4. Shoe 5. Piston 6. Cylinder block 7. Valve plate 8. End cover 9. Bearing 10. Center spring 11. Retainer shoe 12. Retainer guide 13. Bearing 14. Oil seal 15. Flow control spool 16. Suction safety valve 17. Reversible spool Unit: mm

No.

Item

Criteria

Remedy

Standard size

18 Spool return spring

19 Spool return spring


Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

44.84 x 12

33

58.8 N {6 kg}

—

47.1 N {4.8 kg}

35 x 8.5

34

44.1 N {4.5 kg}

—

35.3 N {3.6 kg}

If damaged or deformed, replace spring

10-100

9

SEN03923-01


1. Hydraulic motor Function q This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The pressurized oil from the hydraulic pump flows through valve plate (7) into cylinder block (5). q This pressurized oil flows to the only one side of the (Y - Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The pressurized oil sent to one side of cylinder block (5) pushes piston (4) (2 or 3 pistons). q A single piston generates the force F1 [F1 (kg) = P (kg/cm2) x xD2/4 (cm2)]. q This force works on thrust plate (2). q Since thrust plate (2) is fixed to the specific angle (a) to output shaft (1), the force is divided into components (F2) and (F3). q The radial component (F3) generates torque (T = F3 x ri) against the (Y -Y) line connecting the top dead center and bottom dead center. q The result of this torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4). q This cylinder block (5) is connected to output shaft (1) with the spline. q Output shaft (1) rotates to transmit the torque.

10-100

10



SEN03923-01

2. Suction safety valve 1) Suction function Function q If the fan pump stops, the pressurized oil does not flow into the motor. q Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the pressurized oil stops flowing in from inlet port (P), suction safety valve (1) sucks in the pressurized oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation.

(2) When the pump is stopped q When the engine stops, the input revolution of the pump becomes 0 rpm. q The pressurized oil from the pump is not supplied to port (P). q As the pressurized oil is not supplied to (MA) side of the motor, the motor speed lowers gradually to stop. q If the motor shaft is revolved by the force of inertia while the oil flow in port (P) is reducing, the oil in port (T) on the outlet side is sent by suction safety valve (1) to (MA) side to prevent cavitation.

Operation (1) When pump is started q The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure. q The starting torque is generated in the motor, the motor starts revolution. q The pressurized oil on motor outlet (MB) side of the motor returns through port (T) to the tank.


10-100

11

SEN03923-01


2) Safety function Function q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases. q Suction safety valve (1) is installed to protect the fan system circuit. Operation If the pressure in port (P) rises above the cracking pressure of suction safety valve (1), valve (2) of suction safety valve (1) opens to release the pressurized oil into port (T). q By this operation, generation of abnormally high pressure in port (P) is prevented. q

10-100

12



SEN03923-01

3. Operation of reversible valve 1) When the ON/OFF solenoid is de-energized q

q q q

When ON/OFF solenoid (1) is "de-energized", the pressurized oil from the pump is shut off by valve (2). Port (C) opens for the hydraulic tank circuit. Spool (3) is pushed to the right by spring (4). Port (MA) opens and pressurized oil flows in to revolve the motor in forward (clockwise).


2) When the ON/OFF solenoid is energized q q q q q

When ON/OFF solenoid (1) is "energized", valve (2) is switched. The pressurized oil from the pump flows to spool chamber (D) through port (C). The pressurized oil in chamber (D) compresses spring (4). Spool (3) moves to the left. Port (MB) opens and pressurized oil flows in to rotate the motor in reverse (counterclockwise).

10-100

13

SEN03923-01


4. Flow control valve (continuously-variable type) Function This valve supplies the necessary pump delivery to the motor, and returns the excessive oil to the hydraulic tank. q

q q

q

The motor speed increases in proportion to the increase of the incoming oil (Q) as shown in Fig. 1. When the incoming flow rate is (Q1), motor speed becomes (B) rpm. In order to reduce noise and loss of the motor, this valve keeps the fan speed constant independent of the flow rate to the motor. Even if the flow rate is increased from (Q0) to (Q1), the valve maintains the motor speed constant between points (A) and (C).

Operation q For the flow control valve, the upstream pressure of the orifice is conducted to the right side of spool (1) and the downstream pressure of the orifice is led to its left side. q The differential pressure before and after orifice (E) by the incoming flow rate to the motor works on spring (2). q In Fig. 1, when the flow rate (Q0) is increased beyond, the differential pressure before and after spool (1) becomes larger than the installed load of spring (2). q Spool (1) moves to the left and port (P) is connected to port (T). q The excessive oil in (Z) portion of Fig. 1 flows to the hydraulic tank through the flow control valve, and the motor speed is kept constant from (A) to (C). q This flow control valve is a continuously-variable type. q As shown in Fig. 2, it is possible to change the flow control valve continuously while maintaining the motor speed constant between (A') to ( C ') by c ha n g i n g t h e c o m m an d c u r r e n t between the motor speed (A) and (C).

10-100

14




SEN03923-01

10-100

15

SEN03923-01



10-100

16

SEN03924-01





10

200 Power train Power train...................................................................................................................................................... 3 Power train system diagram ........................................................................................................................... 4 Drive shaft....................................................................................................................................................... 6 HST hydraulic piping diagram......................................................................................................................... 7 HST pump....................................................................................................................................................... 8 HST motor..................................................................................................................................................... 16 Transfer......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential ..................................................................................................................................................... 36 Torque proportioning differential ................................................................................................................... 41 Limited slip differential .................................................................................................................................. 44 Final drive ..................................................................................................................................................... 48


10-200

1

SEN03924-01

10-200

2

200 Power train


200 Power train Power train

SEN03924-01

Power train

1

1. Engine 2. Damper 3. HST pump 4. 4-gear pump 5. High-pressure hose 6. HST motor 1 7. HST motor 2 8. Transfer 9. Front drive shaft 10. Front axle 11. Rear drive shaft 12. Rear axle


10-200

3

SEN03924-01

Power train system diagram

10-200

4

200 Power train Power train system diagram

1


200 Power train Power train system diagram

1. Engine 2. Damper 3. HST pump 4. Steering pump 5. Work equipment pump 6. Brake and cooling fan pump 7. Transfer lubrication pump 8. High-pressure hose 9. HST motor 1 10. HST motor 2 11. Emergency steering valve (if equipped) 12. Transfer 13. Transfer clutch 14. Parking brake 15. Front drive shaft 16. Front axle 17. Differential 18. Wet multiple disc type brake 19. Final drive 20. Front tire 21. Rear drive shaft 22. Rear axle 23. Differential 24. Wet multiple disc type brake 25. Final drive 26. Rear tire


SEN03924-01 Outline q The power from engine (1) is transmitted to HST pump (3) after its torsional vibrations have been reduced with damper (2) installed on the flywheel. q The power from engine (1) is also transmitted to HST pump (3) and the HST charge pump being built in HST pump (3) as well as steering pump (4), work equipment pump (5), brake and cooling fan pump (6) and transfer lubrication pump (7) being connected to HST pump (3). q The directional selector valve and servo piston installed on HST pump (3) continuously modify the oil discharge direction and discharged amount responding to inclination of the swash plate. q HST motors (9) and (10) are installed on transfer (12) and connected to HST pump (3) through high-pressure hose (8). q The hydraulic power from HST pump (3) changes the rotating direction and speed of HST m oto rs (9) and (1 0) to cont ro l th e machine forward and reverse travel and travel speed. q The power from HST motor 1 (9) is transmitted to the output shaft through transfer clutch (13) in transfer (12). The power from HST motor 2 (10) is transmitted to the output shaft through the gear in transfer (12). q As the parking brake lever is operated, parking brake (14) being contained in the rear side of transfer (12) activates the wet multiple disc type brake to stop the machine. q The power to the front side is transmitted to front axle (16) through front drive shaft (15). The power to the rear side is transmitted to rear axle (22) through rear drive shaft (21). q Speed of the power transmitted to axles (16) and (22) is reduced on the pinion gear of differentials (17) and (23), then transmitted to the sun gear through the sun gear shaft. q Speed of the power transmitted to the sun gear is reduced on the planetary mechanism of final drives (19) and (25), then transmitted to tires (20) and (26) through the axle shaft and wheel.

10-200

5

SEN03924-01

Drive shaft

1. Front axle 2. Front drive shaft 3. Transfer 4. Rear drive shaft 5. Rear axle

10-200

6

200 Power train Drive shaft

1

Outline q The power from the transfer output shaft is transmitted to front axle (1) and rear axle (5) through front drive shaft (2) and rear drive shaft (4). q When the machine is articulated or when it receives traveling impacts or working impacts, the distances between the transfer and the front and rear axles change. The drive shafts absorb fluctuations in the angle and length with the universal joints and slip joint so that the power will be transmitted without damaging the parts even when the machine is exposed to above impacts or changes in the component positions.


200 Power train HST hydraulic piping diagram

SEN03924-01

HST hydraulic piping diagram

1

1. Hydraulic tank 2. HST pump 3. Clutch solenoid valve 4. HST oil filter 5. HST motor 1 6. HST motor 2


10-200

7

SEN03924-01

200 Power train HST pump

HST pump

1

a

HST: Abbreviation for HydroStatic Transmission

1. Directional selector solenoid valve 2. High-pressure cutoff valve 3. Speed-related valve (DA valve) 4. Charge pump 5. Low-pressure relief valve 6. Servo cylinder 7. High-pressure relief valve 8. Control plate 9. Cylinder block 10. Piston 11. Swash plate

10-200

8

Specifications Model name

A4VG125DA

Type

Variable displacement swash plate type piston pump

Theoretical delivery (cc/rev) High-pressure relief valve set pressure (MPa {kg/cm2}) High-pressure cutoff valve set pressure (MPa {kg/cm2}) Low-pressure relief valve set pressure (MPa {kg/cm2})

0 – 110 44.1 {450} Effective differential pressure 41.2 {420} 2.94 {30}



SEN03924-01

Operation Flow of power

q q

q

q

q q

The HST pump is installed on the damper of the engine flywheel. The power from the engine is transmitted to the HST pump through the flywheel and damper. The HST pump is equipped with directional selector solenoid valve (1) and servo cylinder (6). Driving the machine forward or reverse activates directional selector solenoid valve (1), tilting swash plate (11) and, as a result, causing the switch between the oil suction and discharge ports. The HST pump is built-in cylinder block and 9 pistons (10) rotate along with drive shaft (12). Tips of piston (10) slides on the swash plate surface of swash plate (11) that does not rotate.


Flow of oil

q

q

q

q q

q

Inclination of swash plate (11) starts reciprocating movement of piston (10). The pumping action initiated by this reciprocating movement suctions or discharges the oil in cylinder block (9) continuously. The pumping action directs the oil flow in a certain definite direction so that it may flow to the HST motor. Reversing the inclination of swash plate (11) reverses the suction and discharge ports and, as a result, reversing the oil discharging direction, too. Piston (10) does not stroke when swash plate (11) is at neutral, thus the oil is not discharged. Increasing or decreasing the inclination (angle) of swash plate (11) changes the stroke of piston (10), allowing to control the travel speed. If the amount of the oil in the low-pressure circuit (the oil to be returned from the motor to the pump) becomes insufficient due to leakage of oil in the HST pump, HST motor and control valve, the charge pump supplies the oil through speed-related valve (3) and the check valve on high-pressure relief valve (7).

10-200

9

SEN03924-01

High-pressure relief valve

1. Nut 2. Locknut 3. Poppet spring 4. Check spring 5. Main piston 6. Valve seat 7. Pilot poppet 8. Adjustment screw

10-200

10


1

Function q This valve is installed on the HST pump. If the oil pressure on the high pressure circuit side across the HST pump and HST motor goes beyond the set pressure, it drains the pressure to the low pressure circuit side. This valve sets the maximum pressure of the HST circuit in this manner to protect the circuit. q If low level of the oil is detected in the circuit, the valve conducts oil from the HST charge pump in order to protect cavitation.



SEN03924-01

Operation

q

q q q

Port (A) is connected to the high pressure circuit side of the HST pump, and ports (C) and (D) are connected to the low pressure circuit side of the pump. Oil fills up chamber (B) after flowing through the orifice of main piston (5). Pilot poppet (7) is seated on valve seat (6). If oil pressure in port (A) and chamber (B) goes beyond the set pressure, pilot poppet (7) is pushed in the left direction. As a result, the oil pressure in chamber (B) is released to port (C) through chamber (D) and the oil pressure in chamber (B) is decreased.

q

q

q

q

q

q


As the oil pressure in chamber (B) goes lower, the orifice of main piston (5) is activated and differential pressure is generated in port (A) and chamber (B). The oil pressure in port (A) pushes main piston (5) in the left direction, relieving the abnormal pressure generated in port (A) to port (C). As the oil pressure in port (A) goes lower than that in port (C), check spring (4) pushes back main piston (5) in the right direction. The oil in port (C) is conducted to port (A) through chamber (D) so that the oil level in port (A) may not go low. Increasing or decreasing the repulsive force of poppet spring (3) allows adjusting the set pressure. When increasing the set pressure, remove the nut to loosen the locknut and screw the adjustment screw. When decreasing, loosen the adjustment screw.

10-200

11


SEN03924-01

Low-pressure relief valve

1

q

When increasing the set pressure, loosen locknut (1) and screw adjustment screw (2). When decreasing, loosen the adjustment screw.

1. Locknut 2. Adjustment screw 3. Piston 4. Spring Function q This valve is installed on the HST pump. If the oil pressure on the low pressure circuit side across the HST pump and HST motor goes beyond the set pressure, it drains the oil to the hydraulic tank. This valve sets the oil pressure of the HST pump charge circuit in this manner to protect the circuit. Operation

q

q q

q

Port (A) is connected to the HST pump charge circuit and port (B) is connected to the drain circuit. As long as port (A) is below the set pressure, oil does not flow to port (B). If oil pressure in port (A) goes beyond the set pressure, piston (3) is pushed in the right direction. As a result, the oil pressure in port (A) is released to port (B) and the oil pressure in port (A) is decreased. Increasing or decreasing the repulsive force of spring (4) allows adjusting the set pressure.

10-200

12



SEN03924-01

HST charge pump

1. Cover bolt 2. Pump gear 3. Key 4. Coupling 5. Drive shaft 6. Plate 7. Charge pump cover 8. Crescent separator plate Outline q This pump is installed on the HST pump. It, working in conjunction with the HST pump, supplies oil to the HST speed-related valve and the low-pressure relief valve on the HST pump.


1

Specifications Type

Gear pump (inscription type)

Theoretical delivery (cc/rev)

28.3

Function q This pump is connected to the HST pump drive shaft (5) with coupling (4). Pumping action is turned on as it is rotated. q It contains pump gear (2) and crescent separator plate (8) to suction or delivery oil continuously in the direction shown in the figure.

10-200

13

SEN03924-01

Speed-related valve (DA valve)


1

1. Locknut 2. Adjustment screw 3. Poppet spring 4. Spring seat 5. Pilot poppet Function q It diverges the oil from the HST charge pump into 2 parts. One part flows to the directional selector solenoid valve and other part flows to the low-pressure relief valve. Operation q Port (A), port (D) and port (C) are connected to the HST pump charge circuit, low-pressure relief valve circuit and directional selector solenoid valve circuit, respectively. q The oil from the HST charge pump constantly flows to the low-pressure relief valve circuit through port (A), orifice of pilot poppet (5), chamber (B) and port (D). q Orifice of pilot poppet (5) applies to the oil pressure from the HST charge pump. As the result, the differential pressure is generated in port (A) and chamber (B). q Oil pressure in port (A) pushes pilot poppet (5) in the left direction to flow the oil in chamber (B) to the directional selector solenoid valve circuit through port (C). q A set of pilot poppet (5) is consisted of poppet spring (3) and spring seat (4). q When decreasing the set pressure, loosen locknut (1) and screw adjustment screw (2). When increasing, loosen the adjustment screw.

10-200

14



SEN03924-01

High-pressure cutoff valve

1

1. Adjustment screw 2. Locknut 3. Spring 4. Spool 5. Piston 6. Barrel 7. Shuttle spool 8. Valve seat Function q This valve is installed on the HST pump. If the oil pressure on the high pressure circuit side across the HST pump and HST motor goes beyond the set pressure, it drains the oil in the servo cylinder circuit to the hydraulic tank. This valve sets the maximum pressure of the HST pump circuit in this manner to protect the circuit. Operation q Port (A), port (B), port (Pc) and port (T) are connected to the high pressure circuit in the reverse travel, high pressure circuit in the forward travel, speed-related valve circuit and drain circuit, respectively. q As oil pressure in (A) side goes high, shuttle spool (7) is pushed down and closes the port (B) side circuit. q Oil pressure on port (A) side pushes up piston (5) and, at the same time, pushes up spool (4), too, by compressing spring (3). q Port (Pc) and port (T) are opened, releasing abnormal pressure generated in port (Pc) to port (T). q As oil pressure in port (Pc) goes low, the swash plate angle of the HST pump is reduced. As a result, the pump delivery is reduced and the HST pump circuit is protected.


10-200

15

200 Power train HST motor

SEN03924-01

HST motor a

1

HST: Abbreviation for HydroStatic Transmission

HST motor 1

1. Drive shaft 2. Piston 3. Cylinder block 4. Port plate 5. EP servo valve

10-200

16

Specifications Model name Type

A6VM140EP Variable displacement bent axis type piston motor

Theoretical delivery 0 – 140 (cc/rev) High-pressure relief valve set pressure 44.1 {450} (MPa {kg/cm2}) High-pressure cutoff Effective differential pressure valve set pressure 40.7 {415} 2 (MPa {kg/cm }) Low-pressure relief valve set pressure 3.0 {31} (MPa {kg/cm2})



SEN03924-01

HST motor 2

1. Drive shaft 2. Piston 3. Cylinder block 4. Port plate 5. HA servo valve 6. Directional shuttle valve


Specifications Model name

A6VM140HA

Type

Variable displacement bent axis type piston motor

Theoretical delivery 59 – 128 (cc/rev) High-pressure relief valve set pressure 44.1 {450} (MPa {kg/cm2}) High-pressure cutoff Effective differential pressure valve set pressure 40.7 {415} (MPa {kg/cm2}) Low-pressure relief valve set pressure 3.0 {31} (MPa {kg/cm2})

10-200

17

SEN03924-01 Principle q It is assumed that the shaft of the disc is supported to enable free rotation of the disc. Force F being applied aslant to the disc is divided into force F1 orthogonal to the disc and force F2 that works in the circumferential direction of the disc. Force F1 pushes the disc in the axial direction and force F2 rotates the disc clockwise. q Also when force F' works on the disc instead of force F, it is likewise divided into force F1' and F2'. Force F2' rotates the disc counterclockwise.


Operation q Pressurized oil from the HST pump flows to the back side of piston (2) through the HST motor inlet port, and is activated by inclination of piston (2) and cylinder block (3) as the rotating force of drive shaft (1). q As the HST motor is rotated forward or reverse, the oil in the high pressure circuit side is conducted to the directional shuttle valve (6). q As a large load is applied to the motor being connected to servo valve (5), the pressure difference is generated between the high pressure circuit side and directional shuttle valve (6), allowing the servo cylinder to increase inclination of cylinder block (3).

Structure q 7 pistons (2) are installed on the disc portion of drive shaft (1) like spherical joints. They are housed in cylinder block (3) having a certain angle to drive shaft (1). q As external load to the HST motor is increased, servo valve (5) and directional shuttle valve (6) work to increase inclination of cylinder block (3) and piston (2), reducing the revolving speed and increasing the torque.

10-200

18



SEN03924-01

EP servo valve

1. Motor 1 solenoid valve 2. EP servo valve 3. Spring 4. Servo cylinder Function q This valve is installed on the rear side of HST motor 1. It controls the motor displacement depending on the current value given to motor 1 solenoid valve (1).


1

Operation q Suction force F1 of motor 1 solenoid valve (1) and force F2 of spring (3) are applied to EP servo valve (2). q When the current value given to motor 1 solenoid valve (1) is small (when F1 < F2), EP servo valve (2) conducts the oil pressure on the motor high pressure side circuit to the small diameter side (S) of servo cylinder (4) and releases the oil pressure on the large diameter side (L) to the tank (motor housing). As the result, the servo cylinder (4) is moved toward the min side. q When the current value given to motor 1 solenoid valve (1) is large (when F1 > F2), EP servo valve (2) conducts the oil pressure to the large diameter side (L) to move servo cylinder (4) toward the max side using the difference in area between the large diameter and small diameter side (S). q Magnitude of spring (3) force varies depending on the position of servo cylinder (4) (motor displacement). q The current value given to motor 1 solenoid valve (1) controls the motor displacement to the position where suction power F1 and spring force F2 balance.

10-200

19

SEN03924-01

HA servo valve

1. Motor 2 solenoid valve 2. HA servo valve 3. Servo cylinder Function q This valve is installed in the rear side of HST motor 2. In order to bring out the motor output corresponding to the external load to the motor, it controls the motor displacement using the oil pressure of the circuit being selected from the directional shuttle valve.

10-200

20


1

Operation q If the load to the motor is small, HA servo valve (2) conducts oil pressure to the small diameter side (S) through the directional shuttle valve and releases the oil pressure on the large diameter side (L) to the tank (motor housing). Servo cylinder (3) moves toward the min side, minimizing the motor displacement. q If a large load is applied to the motor during, for instance, uphill travel, HA servo valve (2) is switched to conduct the oil pressure from the directional shuttle valve to the large diameter side (L). As a result, the difference in area between the large diameter side (L) and small diameter side (S) moves servo cylinder (3) toward the max side. The motor displacement becomes the maximum and generates large torque. q As motor 2 solenoid valve (1) is energized, HA servo valve (2) conducts the oil pressure from the directional shuttle valve to the large diameter side (L) independent of the magnitude of the load to the motor to set the motor displacement to the maximum.



SEN03924-01

Directional shuttle valve

1

1. Directional selector solenoid valve 2. Directional shuttle valve Function q This valve is installed in the rear side of HST motor 2. It controls the destination of the oil pressure to work on the HA servo valve referencing the incoming signal, which corresponds to the directional signal of the directional selector solenoid valve on the HST pump. Above process reduces the decelerating impacts that results when the oil pressure is switched. Operation Directional selector solenoid valve (1) interlocks with the directional selector valve on the HST pump, since it has received the signal that is corresponding to the directional signal to be sent to the directional selector solenoid valve on the HST pump. q Directional shuttle valve (2) is activated by directional selector solenoid valve (1) and controls the destination of the oil pressure to work on the HA servo valve. q


10-200

21

SEN03924-01

Transfer

200 Power train Transfer

1

a: Clutch port b: Lubrication inlet port c: Lubrication suction port 1. HST motor 2 mounting section 2. HST motor 1 mounting section 3. Oil filler pipe 4. Transfer 5. Parking brake lever 6. Speed sensor

10-200

22



1. HST motor 1 2. Input shaft 3. Transfer clutch 4. Carrier 5. Ring gear (number of teeth: 86) 6. Planetary pinion (number of teeth: 24) 7. Planetary shaft 8. Motor 1 gear (number of teeth: 50)


SEN03924-01

9. Sun gear (number of teeth: 37) 10. Parking brake 11. Rear coupling 12. Output gear (number of teeth: 55) 13. Spacer 14. Output shaft 15. Front coupling

10-200

23


SEN03924-01 Input shaft

Unit: mm

No.

Check item

1

Clearance between input shaft and bearing (front)

Criteria Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

60

+0.012 –0.007

0 –0.012

–0.024 – 0.007

—

2

Clearance between input shaft bearing and cage (front)

95

0 –0.013

+0.016 –0.006

–0.006 – 0.029

—

3

Clearance between input shaft and bearing (middle)

50

+0.011 –0.005

0 –0.012

–0.023 – 0.005

—

4

Clearance between input shaft bearing and ring gear (middle)

80

0 –0.013

+0.013 –0.006

–0.006 – 0.026

—

5

Clearance between input shaft and bearing (rear)

50

+0.011 –0.005

0 –0.012

–0.023 – 0.005

—

6

Clearance between input shaft bearing and carrier (rear)

80

0 –0.013

+0.013 –0.006

–0.006 – 0.026

—

7

Clearance between press fitting shaft and bearing

55

+0.039 +0.020

0 –0.015

–0.054 – –0.020

—

8

Clearance between press fitting shaft bearing and motor 1 gear

100

0 –0.018

–0.016 –0.038

–0.038 – 0.002

—

9

Clearance between piston and spacer

177

–0.085 –0.125

+0.040 0

0.085 – 0.165

—

10 Clearance between piston and cage

222

–0.550 –0.650

+0.046 0

0.550 – 0.696

—

between clutch housing 11 Clearance and front case

200

+0.061 +0.015

+0.046 0

–0.061 – 0.031

—

10-200

24

Replace



SEN03924-01

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

1.7

±0.05

1.6

Strain on separator plate

—

0.05

0.15

Thickness of friction plate

2.2

±0.08

1.8

Strain on friction plate

—

0.02

0.25

1,147 N {117 kg}

±115 N {±11.7 kg}

918 N {94 kg}

Inside diameter of seal ring contact surface

25

+0.021 0

25.1

Width of seal ring groove

2.5

+0.15 +0.10

2.7

Width of seal ring

2.5

–0.01 –0.03

2.3

Thickness of seal ring

1.2

±0.1

1.05


90

+0.035 0

90.1


3

+0.15 +0.10

3.3

Width of seal ring

3

–0.01 –0.03

2.7

Thickness of seal ring

3.7

±0.12

3.55


120

+0.022 0

120.5


4.5

+0.1 0

5.0

Width of seal ring

4.36

0 –0.1

3.9

3

±0.1

2.7

Thickness of separator plate

12

13 of wave spring 14 Load (height: 2.2 mm)

15

16

17

Thickness of seal ring between motor 1 gear and 18 Backlash output gear clearance of planetary gear — Side (on both sides)


Replace

0.190 – 0.465 0.35 – 0.80

10-200

25

SEN03924-01


Output shaft

10-200

26



SEN03924-01

Unit: mm

No.

1

Check item Clearance between output shaft and bearing (front)


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

60

+0.030 +0.011

0 –0.015

–0.045 – –0.011

—

2

Clearance between output shaft bearing and cage (front)

110

0 –0.018

–0.015 –0.040

–0.040 – 0.003

—

3

Clearance between output shaft and bearing (rear)

65

+0.030 +0.011

0 –0.015

–0.045 – –0.011

—

4

Clearance between output shaft bearing and rear case (rear)

120

0 –0.018

–0.015 –0.040

–0.040 – 0.003

—

5

Clearance between oil seal and cage (front)

100

+0.170 +0.080

+0.054 0

–0.170 – –0.026

—

6

Clearance between dust seal and cage (front)

100

+0.400 +0.200

+0.054 0

–0.400 – –0.146

—

7

Clearance between oil seal and cage (rear)

100

+0.170 +0.080

+0.054 0

–0.170 – –0.026

—

8

Clearance between dust seal and cage (rear)

100

+0.400 +0.200

+0.054 0

–0.400 – –0.146

—

9

Clearance between output shaft and spacer

60

0 –0.030

+0.030 0

0– 0.060

—

diameter of coupling oil 10 Outside seal contact surface (front) diameter of coupling oil 11 Outside seal contact surface (rear) between cage and front 12 Clearance case rotational torque of output 13 Free shaft


Standard size

Tolerance

Repair limit

75

0 –0.074

74.8

75

0 –0.074

74.8

Standard size

Standard clearance

Clearance limit

0.7

0.1 – 1.3

—

Replace

Adjust with shims

3.9 – 5.9 Nm {0.4 – 0.6 kgm}

10-200

27

SEN03924-01

10-200

28




SEN03924-01

1. HST motor 2 2. Motor 2 gear (number of teeth: 50) 3. Strainer 4. Drain plug Unit: mm

No.

Check item

5

Clearance between input shaft and bearing

6

Clearance between input shaft bearing and cage

7

Backlash between motor 2 gear and output gear



Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

65

+0.035 +0.013

0 –0.015

–0.050 – –0.013

—

120

0 –0.015

+0.022 –0.013

–0.013 – 0.037

—

Replace

0.190 – 0.465

10-200

29


SEN03924-01 Outline q The transfer is equipped with 2 HST motors. It selects a gear speed out of 1st - 4th speed both in the forward and reverse travels and transmits it to the output shaft. It changes the gear speed by varying output and revolving direction of the HST motors and combinations of the transfer clutches.

Operation of clutch Clutch is "engaged" (fixed)

Relation between transfer clutch and transfer clutch pressure at respective speed ranges Speed range

Transfer clutch

Transfer clutch pressure

1st

Engaged

OFF

2nd

Engaged

OFF

3rd

Travel speed Travel speed Travel speed Travel speed 0 – A km/h A – 18.7 km/h 0 – A km/h A – 18.7 km/h

4th

Travel speed Travel speed Travel speed Travel speed 0 – A km/h A – 38 km/h 0 – A km/h A – 38 km/h

Engaged

Engaged

Disengaged

Disengaged

OFF

OFF

ON

ON

*1: The travel speeds listed above are the ones when the tires of the size 20.5-25 are worn. And value A varies depending on the opening ratio of the accelerator pedal.

Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation Transfer clutch

q

q

q

Clutch is "disengaged" (released)

Accelerator pedal angle (%) 0 – 65

65 – 90

90 – 100

Engaged o Disengaged (B)

8 km/h

8 – 10 km/h

10 km/h

Disengaged o Engaged (C)

7 km/h

7 – 9 km/h

9 km/h

q

q

q

10-200

30

As the oil from the clutch solenoid valve is cut off, piston (2) is pushed back in the right direction by the repulsive force of spring (1). Piston (2) compresses plates (3) and discs (4) and the rotation of discs (4) is stopped by the frictional force. As the internal teeth of disc (4) are meshed with the external teeth of ring gear (5), ring gear (5) is fixed.

The oil from the clutch solenoid valve is pressure-fed to the back side of piston (2), and pushes piston (2) in the left direction by compressing spring (1). Plates (3) and discs (4) are released from the frictional force, setting ring gear (5) to the neutral position. Wave spring (6) is assembled between plates (3) to accelerate return of piston (2) as the clutches are released. And at the same time, it helps smooth separation of plates (3) and discs (4) in order to prevent drag turning.



SEN03924-01

Power transmitting route Low speed mode

Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3). Power of HST motor 1 (2) O Input shaft (4) O Sun gear (5) O Planetary pinion (6) O Carrier (7) O Motor 1 gear (8) O Output gear (10) O Output shaft (11)

i


Power of HST motor 2 (3) O O O O O O O O O Motor 2 gear (9) O i

10-200

31

SEN03924-01


High speed mode

Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone. Power of HST motor 2 (3) O Motor 2 gear (9) O Output gear (10) O Output shaft (11)

10-200

32


200 Power train Clutch solenoid valve

SEN03924-01

Clutch solenoid valve

P: From HST charge pump A: To transfer clutch T: To drain 1. Clutch solenoid valve 2. Plunger 3. Coil 4. Push pin 5. Spring 6. Spool 7. Body


1

Operation q When the current value of input signal is large, the transfer clutch drains oil pressure. q As the current value of input signal becomes smaller, oil pressure of the transfer clutch goes higher inversely proportional to the current value. q If the current value of input signal is further lowered until the oil pressure of the transfer clutch reaches the oil pressure at which oil is pressure-fed from the HST charge pump, the oil pressure of the transfer clutch remains at this level even if the current value may be further decreased.

10-200

33

SEN03924-01

200 Power train Axle

Axle

1

Front axle

1

1. Differential 2. Final drive 3. Axle shaft 4. Axle housing 5. Wet multiple disc type brake 6. Coupling 7. Oil filler port and level plug 8. Drain plug 9. Brake oil port 10. Air bleeder 11. Oil temperature sensor

10-200

34


200 Power train Axle

SEN03924-01

Rear axle

1

1. Differential 2. Final drive 3. Axle shaft 4. Axle housing 5. Wet multiple disc type brake 6. Coupling 7. Oil filler port and level plug 8. Drain plug 9. Brake oil port 10. Air bleeder


10-200

35

SEN03924-01

200 Power train Differential

Differential

1

Front differential

1

1. Pinion (number of teeth: 9) 2. Shaft 3. Bevel gear (number of teeth: 42) 4. Sun gear shaft 5. Bevel pinion (number of teeth: 10) 6. Side gear (number of teeth: 12)

10-200

36



SEN03924-01

Unit: mm

No.

Check item

7

Starting torque of bevel gear

8

Thickness of pinion washer

9

Criteria

Remedy

6.3 – 21.1 Nm {0.64 – 2.15 kgm} (outside of bevel gear)

Adjust

Standard size

Tolerance

Repair limit

3

±0.08

2.8

4

±0.05

3.8

Thickness of side gear washer

of shim in differential 10 Thickness side bearing carrier (one side)

0.30 – 1.25

11 Backlash of bevel gear

0.20 – 0.33

Adjust

play of pinion 12 End (or starting torque)

0 – 0.165 (0 – 65 N {0 – 6.5 kg} (at cage bolt hole))

Replace

1.07 ± 0.33

Adjust

of shim in differential 13 Thickness housing and cage assembly Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

of differential 14 Clearance Outer race side bearing

120

0 –0.020

–0.041 –0.076

–0.076 – –0.021

—

Inner race

75

+0.051 +0.032

0 –0.015

–0.066 – –0.032

—

Outer race

140

0 –0.018

–0.054 –0.082

–0.082 – –0.036

—

Inner race

65

+0.039 +0.020

0 –0.015

–0.054 – –0.020

—

Clearance of bearing on Outer race 16 pinion shaft coupling side Inner race

120

0 –0.015

–0.041 –0.076

–0.076 – –0.026

—

55

+0.039 +0.020

0 –0.015

–0.054 – –0.020

—

28

–0.06 –0.11

+0.10 +0.05

0.11 – 0.21

—

268.5

–0.110 –0.191

+0.081 0

0.110 – 0.272

—

247

–0.100 –0.172

+0.072 0

0.100 – 0.244

—

Outer race

110

0 –0.015

0 –0.035

–0.035 – 0.015

—

Inner race

50

+0.021 +0.002

0 –0.012

–0.033 – –0.002

—

of bearing on 15 Clearance pinion shaft gear side

between pinion gear and 17 Clearance spider Clearance in installation position of

18 differential housing piston (between housing and piston) Clearance in installation position of

19 bearing carrier piston (between piston and carrier) Clearance between 20 drive shaft and cage bearing


Replace

Replace

10-200

37

SEN03924-01

Rear differential


1

1. Pinion (number of teeth: 9) 2. Shaft 3. Bevel gear (number of teeth: 42) 4. Sun gear shaft 5. Bevel pinion (number of teeth: 10) 6. Side gear (number of teeth: 12)

10-200

38



SEN03924-01

Unit: mm

No.

Check item

7

Starting torque of bevel gear

8

Thickness of pinion washer

9

Criteria

Remedy

6.3 – 21.1 Nm {0.64 – 2.15 kgm} (outside of bevel gear)

Adjust

Standard size

Tolerance

Repair limit

3

±0.08

2.8

4

±0.05

3.8

Thickness of side gear washer

of shim in differential 10 Thickness side bearing carrier (one side)

0.30 – 1.25

11 Backlash of bevel gear

0.20 – 0.33

Adjust

play of pinion 12 End (or starting torque)

0 – 0.165 (0 – 65 N {0 – 6.5 kg} (at cage bolt hole))

Replace

1.07 ± 0.33

Adjust

of shim in differential 13 Thickness housing and cage assembly Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

of differential 14 Clearance Outer race side bearing

120

0 –0.020

–0.041 –0.076

–0.076 – –0.021

—

Inner race

75

+0.051 +0.032

0 –0.015

–0.066 – –0.032

—

Outer race

140

0 –0.018

–0.048 –0.088

–0.088 – –0.030

—

Inner race

65

+0.039 +0.020

0 –0.015

–0.054 – –0.020

—

Clearance of bearing on Outer race 16 pinion shaft coupling side Inner race

120

0 –0.015

–0.041 –0.076

–0.076 – –0.026

—

55

+0.039 +0.020

0 –0.015

–0.054 – –0.020

—

28

–0.06 –0.11

+0.10 +0.05

0.11 – 0.21

—

268.5

–0.110 –0.191

+0.081 0

0.110 – 0.272

—

247

–0.100 –0.172

+0.072 0

0.100 – 0.244

—

of bearing on 15 Clearance pinion shaft gear side

between pinion gear and 17 Clearance spider Clearance in installation position of

18 differential housing piston (between housing and piston) Clearance in installation position of

19 bearing carrier piston (between piston and carrier)


Replace

Replace

10-200

39


SEN03924-01 Outline

q

q

q

While machine is traveling straight

The power from the engine is transmitted to the front and rear axles through the torque converter, transmission and drive shaft. In each axle, the direction of the power is changed by 90° and the speed is reduced by bevel pinion (1) and bevel gear (5). Then, the power is transmitted through pinion (4) to sun gear shafts (2). Speed of the power transmitted to the sun gear is further reduced by the final drive of the planetary gear type, and then transmitted to the axle shafts and wheels.

q

While machine is turning

q

10-200

40

While the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly, pinion (4) in the differential assembly does not rotate and the power of carrier (6) is transmitted through pinion (4) and side gear (3) to right and left sun gear shafts (2) evenly.

While the machine is turning, the right and left wheels rotate at different speeds. Accordingly, pinion (4) and side gear (3) in the differential rotate and transmit the power of carrier (6) to sun gear shafts (2), depending on the difference in rotation speed between the right and left wheels.


200 Power train Torque proportioning differential

SEN03924-01

Torque proportioning differential Outline

1

Operation Straight travel (When the road resistances under both tires are the same)

q

q

When the road resistances under the both tires are the same, distance (a) from pinion (4) to the meshing point of left side gear (7) and distance (b) to the meshing point of right side gear (3) are the same. Accordingly, left traction force (TL) and right traction force (TR) are balanced.

Travel on soft ground (When the road resistances under both tires are different)

q

q

A 4-wheel-drive wheel loader, as a construction machine, must naturally work on places where the ground condition is bad. If its tires slip in such places, its function lowers and the lives of the tires are shortened. To solve this problem, the torque proportioning differential is used. Pinion (4) of this differential has an odd number of teeth. The meshing points of pinion (4) and side gears (3) change according to the difference of the road resistance. Consequently, the traction forces of the tires on both sides change.

q

q


When the tires slip on soft ground, the side gear of the tire on the less road resistance side turns forward. As a result, the meshing points of pinion (4) and the side gears change. If left side gear (7) turns forward a little, distance (a) from the pinion to the meshing point of the left side gear becomes longer than distance (b) to the meshing point of the right side gear, and then (a) and (b) are balanced at a point where (a) x (TL) = (b) x (TR). The ratio of (a) : (b) changes up to 1 : 1.38, depending on the meshing condition.

10-200

41

SEN03924-01 q

q


Accordingly, the pinion does not run idle and the drive force is transmitted to both side gears and the tires do not slip until the ratio of (a) : (b) becomes 1 : 1.38, or the difference between the road resistances under both tires becomes 38%. The lives of the tires are lengthened 20 - 30% and the working capacity is increased by the above effect.

10-200

42




SEN03924-01

10-200

43

SEN03924-01

Limited slip differential

200 Power train Limited slip differential

1

(If equipped)

1. Plate 2. Disc 3. Pinion (number of teeth: 12) 4. Washer 5. Side gear (number of teeth: 24) 6. Bevel pinion 7. Shaft 8. Pressure ring 9. Bevel gear (number of teeth: 42) 10. Case

10-200

44



SEN03924-01

Unit: mm

No.

Check item


Remedy

Tolerance

Repair limit

±0.02

2.9

+0.04 –0.03

2.45

±0.05

1.8

3

11 Thickness of plate

3.1

12 Thickness of disc

2.5 2

13 Thicknesses of washer 2.1 between disc and plate 14 Clearance (total clearance on both sides) play of side gear in axial 15 End direction (one side)

0.13 – 0.35

16 Backlash of case and plate

0.1 – 0.6

17 Backlash of side gear and disc between spider and 18 Clearance differential pinion

0.13 – 0.36 Standard size 28


Replace

0.2 – 0.6

Tolerance Shaft

Hole

Standard clearance

Clearance limit

–0.11 –0.16

+0.05 0

0.11 – 0.21

—

10-200

45


SEN03924-01 Operation of limited slip differential q The power from the transmission is transmitted through bevel gear (9), case (10), pressure ring (8), shaft (7), pinion (3) and side gear (5), and then divided to the right and left shafts. q The brake unit consisting of disc (2) and plate (1) is installed to the back side of side gear (5). It generates braking torque in proportion to the torque transmitted from pressure ring (8) to shaft (7). q Since the brake torque restricts the rotation of side gears (5) and case (10), right and left side gears (5) cannot rotate freely. Thus, the operation of the differential is restricted.

While machine is traveling straight When the drive forces of the right and left wheels are balanced [When the road conditions (coefficient of friction) under both wheels and the wheel loads are even, and the center of load is at the center of the bucket]

Mechanism of generation of braking torque by right and left side gears (5)

q

q

q

Shaft (7) is supported on the cam surfaces being provided on the surfaces of pressure rings (8) that are facing each other. The power (= torque) transmitted from pressure rings (8) to shaft (7) is transmitted on the cam surfaces. Force (Fa) to separate pressure rings (8) from each other is generated by inclination of the cam surfaces in proportion to the transmitted torque. Separating load (Fa) acts on the brake on the back side of each side gear (5) to generate braking torque.

10-200

46

q

The power from the transmission is distributed evenly by the differential gears to the right and left. Under this condition, the slip limits of the right and left wheels are the same. Accordingly, even if the power from the transmission may exceed the slip limits, both wheels slip and the differential does not work. No load is applied to the brake on the back side of the side gear.



When the drive forces of the right and left wheels are unbalanced [When the road conditions (coefficient of friction) under both wheels and the wheel loads are uneven, and either wheel slips more easily] Example 1. When either wheel is on soft ground in digging work Example 2. When either wheel is on snow and the other one is on asphalt in snow removing work Example 3. When the right and left wheel loads are unbalanced in travel on a slope

SEN03924-01 Difference in wheel drive force by type of differentials when either wheel slipped Wheel drive force (drive force of slipping wheel is 1) Slipping wheel Locked wheel

Total (ratio)

Limited slip differential (if equipped)

1

2.64

3.64 (1.53)

Torque proportioning differential (standard)

1

1.38

2.38 (1)

Conventional differential

1

1

2 (0.84)

Torque proportioning differential q On a road where either wheel slips easily, the drive force of the limited slip differential increases to 1.53 times of the torque proportioning differential. Conventional differential (this is not applied with this machine.) q On a road where either wheel slips easily, the drive force of the limited slip differential increases to 1.82 times of the conventional differential. While machine is turning

q

q

The power from the transmission is evenly divided between the right and left by the differential gear. If, however, the divided drive force exceeds the wheel slip limit of the slip side, surplus of the driving force is transmitted to the opposite side (lock side) brake through the brake and case on the gear back side. Then the power is distributed to the lock side wheel. The differential starts working only as the surplus portion of the drive force has exceeded the braking force.


q

The same gears as that for the conventional differential are employed for the limited slip differential. Thus, they allow to smoothly generate a difference in rotation speed between the outer and inner wheels that is necessary for tuning.

10-200

47

SEN03924-01

200 Power train Final drive

Final drive

1

Front final drive

1

1. Planetary gear (number of teeth: 26) 2. Planetary carrier 3. Axle shaft 4. Ring gear (number of teeth: 69) 5. Sun gear shaft (number of teeth: 15)

10-200

48



SEN03924-01

Rear final drive

1

1. Planetary gear (number of teeth: 26) 2. Planetary carrier 3. Axle shaft 4. Ring gear (number of teeth: 69) 5. Sun gear shaft (number of teeth: 15)


10-200

49


SEN03924-01

Unit: mm

No.

6

Check item

Criteria

Clearance between planetary gear bearing and shaft

7

Clearance between axle housing and ring gear

8

Clearance between oil seal and housing

9

Press fitting part of axle shaft seal

Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

33.338

+0.025 +0.013

+0.013 0

–0.025 – 0

—

316

+0.10 +0.03

+0.10 +0.04

–0.06 – +0.07

—

Max. 0.2

Adjust

Housing

155

+0.4 +0.2

+0.063 0

–0.4 – –0.137

—

Shaft

115

0 –0.054

–0.2 –0.4

–0.4 – –0.146

—

Clearance of press 10 fitting part of axle housing bearing

Outer race

152.4

+0.025 0

–0.012 –0.052

–0.077 – –0.012

—

Inner race

92.075

+0.073 +0.051

+0.025 0

–0.073 – –0.026

—

Clearance of press 11 fitting part of axle housing bearing

Outer race

130

0 –0.025

–0.038 –0.078

–0.078 – –0.013

—

Inner race

85

+0.035 +0.013

0 –0.020

–0.055 – –0.013

—

12 End play of axle shaft 13 Clearance of guide pin

a

Replace

0 – 0.1 12

+0.025 +0.007

+0.207 +0.145

Replace

Adjust 0.120 – 0.200

—

Replace

Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and assembly.

10-200

50



SEN03924-01

Outline

a q

q q

The figure shows the front axle. The final drive finally reduces speed of the power from the engine to increase the drive force. Ring gear (4) is press fitted to the axle housing and fixed with the pin. Speed of the power being transmitted from the differential through sun gear shaft (5) is reduced by the planetary gear unit to increase the drive force. The increased drive force is transmitted through planetary carrier (2) and axle shaft (3) to the tire.


10-200

51

SEN03924-01



10-200

52

SEN03925-01





10

300 Steering system Steering piping diagram .................................................................................................................................. 3 Steering column .............................................................................................................................................. 4 Priority valve ................................................................................................................................................... 5 Orbit-roll valve................................................................................................................................................. 8 Cushion valve ............................................................................................................................................... 16 Steering cylinder ........................................................................................................................................... 17 Emergency steering piping diagram ............................................................................................................. 19 Emergency steering valve............................................................................................................................. 20 Steering relief valve....................................................................................................................................... 23


10-300

1

SEN03925-01

10-300

2

300 Steering system


300 Steering system Steering piping diagram

SEN03925-01

Steering piping diagram

1

1. Steering cylinder (right) 2. Orbit-roll valve 3. Hydraulic tank 4. Priority valve 5. Steering pump 6. Cushion valve 7. Steering cylinder (left)


10-300

3

300 Steering system Steering column

SEN03925-01

Steering column

1

1. Steering wheel 2. Steering column 3. Orbit-roll valve 4. Steering tilt lock lever Unit: mm

No. 5

Check item Clearance between steering shaft and column bushing

Criteria Standard size 19

10-300

4

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

0 –0.08

+0.15 +0.05

0.05 – 0.23

0.4

Replace


300 Steering system Priority valve

SEN03925-01

Priority valve

1

P: From steering pump CF: To Orbit-roll valve EF: To work equipment control valve

LS: From Orbit-roll valve T: To hydraulic tank

1. Relief valve body 2. Spring seat 3. Spring 4. Poppet 5. Seat 6. Screen

7. Plug 8. Valve body 9. Spool 10. Spring 11. Plug

Unit: mm

No.

Check item

Criteria

Remedy

Standard size Free length

Installed length

Installed load

Free length

Installed load

63.4

47.6

187 N {19.1 kg}

63.4 ± 1

187 ± 14.7 N {19.1 ± 1.5 kg}

31

26.9

146 N {14.9 kg}

—

146 ± 14.7 N {14.9 ± 1.5 kg}

12 Control spring

13 Relief spring


Repair limit

Replace

10-300

5


SEN03925-01 Outline q The priority valve is installed between the steering pump and Orbit-roll valve and work equipment control valve. It diverges the oil from the steering pump to the steering circuit or work equipment circuit. It is also used for controlling the oil pressure from the priority valve to the Orbit-roll valve in order to protect the circuit. Set pressure: 21.0 MPa {210 kg/cm2}

Operation When steering wheel is at "neutral" position

q

q

q

q

q

10-300

6

When the engine is stopped, spool (3) is pushed in the left direction by the repulsive force of spring (4). Thus, port (M) and port (N) are fully opened and port (M) and port (Q) are closed. Starting the engine starts the steering pump rotation, and the oil from the pump flows to port (A) of the Orbit-roll valve through port (M) and port (N). The oil that flew to chamber (P) through orifice (m) of spool (3) pushes spool (3) in the right direction by compressing spring (4). Port (M) and port (Q) are opened and port (M) and port (N) are almost closed to stabilize spool (3). Most of the oil from the pump flows to the work equipment circuit through port (Q).



When steering wheel is "turned left"

q

q

q

q

q

Turning the steering wheel left changes the angle between the sleeve and spool on the Orbit-roll valve, switching flow of the oil. (see "Orbit-roll valve".) Part of the oil from the pump that has flown to port (A) is then conducted to the R.H. steering cylinder through port (B) and Gerotor, and the remaining portion of the oil flows to chamber (R) through orifice (b) and port (J). Change in the angle between the sleeve and spool on the Orbit-roll valve generates a difference pressure between the oil pressure up to port (A) and that after port (B). Spool (3) stabilizes at a position where the difference pressure between that of up to port (A) and after port (B) [chamber (P) pressure chamber (R) pressure] is balanced with the repulsive force of spring (4). The ratio of diversion is determined by the displacement in angle between the spool and sleeve on the Orbit-roll valve, namely the opening ratio of port (A) and port (B). And changing the operating distance of the steering wheel enables its stepless adjustment.


SEN03925-01 When steering cylinder is at stroke end

q

q

q

q

q

Trying to continuously turn the steering wheel after the steering cylinder has reached the stroke end increases oil pressure in port (S). As the oil pressure in port (S) goes beyond the set pressure of relief valve (10), the relief valve (10) releases the oil pressure in port (S) to the hydraulic tank through port (T). It generates differential pressure before and after orifice (r), breaking down the balance between the difference pressure up to port (A) and after port (B) and the repulsive force of spring (4). As a result, oil pressure up to port (A) becomes relatively higher. As port (A) oil pressure is increased, oil in chamber (P) pushes spool (3) in the right direction by compressing spring (4). Port (M) and port (N) are almost closed, and port (M) and port (N) are nearly fully opened to stabilize spool (3).

10-300

7

300 Steering system Orbit-roll valve

SEN03925-01

Orbit-roll valve

1

P: From steering pump L: To steering cylinder R: To steering cylinder

LS: To priority valve T: To hydraulic tank

1. Gland 2. Valve body 3. Check valve 4. Gerotor 5. Spacer 6. Cover 7. Spacer

8. Drive shaft 9. Sleeve 10. Spool 11. Center pin 12. Centering spring 13. Anti-cavitation valve 14. Overload relief valve

10-300

8



Outline

q

q

The Orbit-roll valve is connected to the drive shaft of the steering column. It changes the oil flow from the steering pump to the right or left steering cylinder to decide the travel direction of the machine. The Orbit-roll valve is roughly divided into spool (9) and sleeve (8) that have rotary type direction selecting function and Gerotor (5) (combination of rotor (5a) and stator (5b)) that operates as a hydraulic motor during the normal steering operation and as a hand pump (the steering wheel's operating effort becomes too high to operate it actually) when the oil is not supplied because of a trouble of the steering pump or engine.


SEN03925-01 Structure

q

q

q

Top (A) of spool (9) is connected to the drive shaft of the steering column and further connected to sleeve (8) through center pin (7) (which is not in contact with spool (9) while the steering wheel is at "neutral") and centering spring (2). Top (B) of drive shaft (3) is engaged with center pin (7) and united with sleeve (8) and the bottom is engaged with the spline of rotor (5a) of the Gerotor (5). 4 ports are provided on valve body (4). Each port is respectively connected to the pump circuit, tank circuit, L.H. steering circuit and R.H. steering circuit. And the ports of the pump side and tank side are connected by the check valve in the body. If the pump or engine fails, the oil can be sucked through this check valve directly from the tank side.

10-300

9

SEN03925-01


Operation When steering wheel is at "neutral" position

10-300

10



q

q

q q q

SEN03925-01

When the steering wheel is at "neutral" position, centering spring (2) sets center pin (7) to the center of the oblong hole on spool (9) and movement of spool (9) and sleeve (8) is stopped. Port (A) from sleeve (8) pump, port (E) to the Gerotor, port (F) to the R.H. steering circuit and port (G) to the L.H. steering circuit cut off the vertical grooves (B), (C) and (D) on spool (9). Orifice (b) of port (J) to the priority valve is connected to vertical groove (B) on spool (9). Port (K) of sleeve (8) is connected to vertical groove (M) and port (L) on spool (9). Due to connection and disconnection of the ports and vertical grooves, the oil in the priority valve being set to the pilot pressure is conducted through port (J), orifice (b), vertical groove (M) and port (K), then drained from port (L) to the hydraulic tank.


10-300

11

SEN03925-01


When steering wheel is "turned left"

10-300

12



q

q

q

q

q

q

q

q

q

As the steering wheel is "turned left", spool (9) being connected to the drive shaft of the steering column is rotated counterclockwise. Since spool (9) and sleeve (8) are connected by centering spring(2), spool (9) compresses centering spring (2). An angular displacement corresponding to the amount of compression of centering spring (2) is generated between spool (9) and sleeve (8). Port (A) and vertical groove (B) are connected first being followed by the connection between vertical groove (B) and port (E), port (E) and vertical groove (C), and vertical groove (C) and port (G) to the L.H. steering circuit. Although the connection between vertical groove (B) and orifice (b) of port (J) to the priority valve is maintained, port (K) of sleeve (8) starts gradually closing vertical groove (M) and port (L). Port (F) of the R.H. steering circuit is connected to vertical groove (D) at the same time as port (A) and vertical groove (B) are connected. Due to connection and disconnection of the ports and vertical grooves, the oil from the pump flows from port (A) to vertical groove (B) then flows to port (E), starting rotation of the Gerotor. The oil discharged from the Gerotor flows to the L.H. steering cylinder head side through port (E), vertical groove (C) and port (G). Oil pressure of vertical groove (M) is transmitted to port (J) through orifice (b), then supplied from port (J) as the pilot pressure of the priority valve. The oil from the R.H. steering cylinder head is drained to the hydraulic tank through port (F), vertical groove (D) and port (H).


SEN03925-01 When steering wheel is at "stop" position q As operation of the steering wheel is stopped, angular displacement between spool (9) and sleeve (8) disappears and the steering wheel is returned to the neutral position by the repulsive force of centering spring (2).

10-300

13


SEN03925-01 Connection of hand pump and sleeve

q

q

q

Above figure shows the suction and discharge ports (P) of the Gerotor and connections with the sleeve ports. If the steering wheel is turned to the right, ports (a), (c), (e), (g), (i), and (k) will be connected to the pump side by the vertical grooves of the spool. Likewise, ports (b), (d), (f), (h), (j), and (l) are connected to the R.H. steering cylinder head side. Under the condition in Fig. 1, ports (1), (2) and (3) are in the discharge state of the Gerotor and connected to ports (l), (b), and (d) and the oil is sent to the steering cylinder. Ports (5), (6), and (7) are also connected and the oil form the pump flows in them. Fig. 2 shows the state that has resulted from turning the steering wheel by 90° continued for above condition. Under this state, ports (2), (3), and (4) are in the suction state and connected to ports (k), (a), and (c). Ports (5), (6), and (7) are in the discharge state and connected to ports (d), (f), and (h). As shown above, the ports in the discharge state of the Gerotor are connected to the ports being connected to the steering cylinder. The ports in the suction state are connected to the pump circuit.

10-300

14

q

The internal gear of the Gerotor advances by 1 tooth with every 1/7 turn of the steering wheel and discharges the oil from the pump according to the steering angle of the steering wheel. Accordingly, the discharge amount varies in proportion to the steering angle of the steering wheel.



SEN03925-01 Role of centering spring

q

q


Centering spring (2) is composed of 4 Xshaped leaf springs and 2 flat leaf springs and installed between spool (9) and sleeve (8) as shown in the figure. If the steering wheel is turned, spool (9) compresses centering spring (2) and angular displacement (a) is generated between spool (9) and sleeve (8). As a result, the ports of spool (9) and sleeve (8) are connected and the oil is sent to the steering cylinder. When the steering wheel stops turning, the Gerotor also stops turning. Then, the oil is not sent to the steering cylinder any more and its pressure rises. To prevent this, when the steering wheel stopped turning, Gerotor is turned by the reaction force of centering spring (2) by angular displacement (a) of spool (9) and sleeve (8) to return the steering wheel to the "neutral" position.

10-300

15

SEN03925-01

Cushion valve

A: From steering cylinder left turning port AS: From steering cylinder left turning port B: From steering cylinder right turning port BS: From steering cylinder right turning port 1. Valve seat 2. Valve body 3. Spring 4. Poppet 5. Orifice 6. Plug 7. Spring 8. Spool 9. Plug 10. Spring 11. Poppet

10-300

16

300 Steering system Cushion valve

1

Outline q If sudden increase or bouncing occurs in oil pressure of the steering cylinder circuit, this valve mitigates the impacts by releasing the highly pressurized oil to instantly to other line. Function q As highly pressurized oil rushed into port (A), it compresses spring (3) and opens poppet (4) of port (A) side, then flows through the center groove of spool (8) up to port (B) opening poppet (11) of port (B) side. q At the same time, the highly pressurized oil flows to the pressure chamber of plug (6) through orifice (5) of port (A) side. Then overcoming the port (B) side pressure and repulsive force of spring (7), it pushes spool (8) in the right direction, cutting off the flow of oil from port (A) to port (B). q Temporary flow of oil to the cushion valve works as cushioning effects in mitigating the steering impacts. After the operation of the cushion valve is completed, the steering functions as usual. q If the pressure change on the steering cylinder circuit is gradual, spool (8) cuts off the circuit before poppet (4) opens. Thus, the cushion valve remains inactivated.


300 Steering system Steering cylinder

SEN03925-01

Steering cylinder

1

Unit: mm

No.

1

Check item Clearance between bushing in cylinder rod frame connecting part and mounting pin

2

Clearance between bushing in cylinder bottom frame connecting part and mounting pin

3

Connecting part of steering cylinder and front frame

4

Connecting part of steering cylinder and rear frame



Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

40

0 –0.025

+0.180 +0.042

0.042 – 0.205

—

40

0 –0.025

+0.180 +0.042

0.042 – 0.205

—

Width of boss

Width of hinge

Standard (a + b) clearance

50

53

Max. 0.5 (after shim is adjusted)

50

53

Max. 0.5 (after shim is adjusted)

Replace

10-300

17

300 Steering system Steering cylinder

SEN03925-01

Unit: mm

No.

Check item

Criteria

Remedy

Shaft

Hole

Standard clearance

Clearance limit

40

–0.025 –0.064

+0.121 –0.005

0.020 – 0.185

0.485

2

Clearance between piston rod supporting shaft and bushing

40

0 –0.025

+0.180 +0.042

0.042 – 0.205

1.0

3

Clearance between cylinder bottom supporting shaft and bushing

40

0 –0.025

+0.180 +0.042

0.042 – 0.205

1.0

1

Clearance between piston rod and bushing

10-300

18

Standard size

Tolerance

Replace pin and bushing


300 Steering system Emergency steering piping diagram

SEN03925-01

Emergency steering piping diagram

1

(If equipped)

1. Steering pump 2. Priority valve 3. Orbit-roll valve 4. Check valve 5. Emergency steering valve 6. HST motor 2 7. Pressure switch (for detecting emergency steering operation) 8. Steering relief valve 9. Pressure switch (for detecting low oil pressure on steering)


10-300

19

300 Steering system Emergency steering valve

SEN03925-01

Emergency steering valve

1

(If equipped)

PP: From steering pump A: To HST motor 2 port A B: To HST motor 2 port B Y: To Orbit-roll valve S: From hydraulic tank G: To pressure switch

10-300

20

1. Check valve body 2. Check valve 3. Valve body 4. Pressure reducing valve 5. Selector valve



SEN03925-01

Operation When engine and steering pump are normal

q

q

As long as the engine and steering pump are operating normally, the oil being pressure-fed from the steering pump flows to the Orbit-roll valve, enabling the steering. The oil from the steering pump flows to port (PP), pushes spool (1) in the left direction, then cuts off the circuit from the HST motor to the Orbit-roll valve.


10-300

21

SEN03925-01


When engine or steering pump is abnormal

q

q

q q

a

If, during travel, the steering pump fails to supply sufficient amount of oil to the Orbit-roll valve due to a trouble on the engine or steering pump, discharge pressure of the steering pump goes low. As a result, spool (1) is pushed back in the right direction by the repulsive force of spring (2). The high pressure side is selected for the oil from the HST pump at check valves (3) and (4), and the oil pressure is decreased to an appropriate level at pressure reducing valve (5). De-pressurized oil flows through port (Y) to the Orbit-roll valve, enabling the steering. If the oil in the HST circuit goes low because of flowing out to the steering circuit, oil is supplied to the HST circuit by check valves (6) and (7). Thanks to the function of check valves (3) and (4), the emergency steering system is operable both in the forward and reverse travel.

10-300

22


300 Steering system Steering relief valve

SEN03925-01

Steering relief valve

1

(If equipped)

P1: From steering pump P2: From emergency steering pump T: Drain S1: Steering pump oil pressure switch S3: Emergency steering oil pressure switch

Outline q The steering relief valve is installed to the right side of the transmission and used to hold the steering oil pressure to the set pressure. Set pressure: 1.96 MPa {20 kg/cm2} (cracking pressure at 0.5 l/min)

1. Block 2. Relief valve 3. Orifice


10-300

23

SEN03925-01



10-300

24

SEN03926-00





10

400 Brake system Brake piping diagram ...................................................................................................................................... 3 Charge valve................................................................................................................................................... 4 Brake valve ..................................................................................................................................................... 8 Inching valve ................................................................................................................................................. 12 Accumulator (for brake) ................................................................................................................................ 13 Slack adjuster ............................................................................................................................................... 14 Brake............................................................................................................................................................. 16 Parking brake control .................................................................................................................................... 21 Parking brake................................................................................................................................................ 22


10-400

1

SEN03926-00

10-400

2

400 Brake system


400 Brake system Brake piping diagram

SEN03926-00

Brake piping diagram

1. Hydraulic tank 2. Brake valve 3. Brake and cooling fan pump 4. Rear brake 5. Accumulator (for front side) 6. Accumulator (for rear side) 7. Charge valve


1

8. Strainer 9. Slack adjuster (for front left side) 10. Front brake 11. Slack adjuster (for front right side) 12. Slack adjuster (for rear right side) 13. Slack adjuster (for rear left side)

10-400

3

SEN03926-00

Charge valve

10-400

4

400 Brake system Charge valve

1



SEN03926-00

P: From brake and cooling fan pump T: To hydraulic tank A: To cooling fan motor ACC1: To accumulator (rear side) ACC2: To accumulator (front side) S: Brake operation sensor port G: Gauge port 1. Valve body 2. Inverse shuttle valve 3. Plunger 4. Unload relief valve 5. Unload valve 6. Relief valve Unit: mm

No.

Check item

7

Clearance between inverse shuttle valve and body


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

12

–0.006 –0.014

+0.011 0

0.006 – 0.025

0.029

8

Clearance between plunger and body

8

–0.005 –0.012

+0.009 0

0.005 – 0.021

0.024

9

Clearance between unload valve and body

18

–0.006 –0.017

+0.011 0

0.006 – 0.028

0.032

Standard size

Repair limit

Installed length

Installed load

21.6 relief valve return spring 11 Unload (inside)

Free length

Installed load

18.3

9.8 N {1.0 kg}

—

8.3 N {0.85 kg}

35.9

30.0

188 N {19.2 kg}

—

160 N {16.3 kg}

relief valve return spring 12 Unload (outside)

39.8

27.5

137 N {14.0 kg}

—

116 N {11.8 kg}

13 Unload valve return spring

51.6

45.0

49 N {5.0 kg}

—

42 N {4.3 kg}

14 Check valve return spring

11.5

9.0

4.9 N {0.5 kg}

—

4.2 N {0.43 kg}

10 Inverse shuttle valve return spring

Free length

Replace

Function q The charge valve maintains the oil pressure from the pump to the set pressure and accumulates it in the accumulator. q If the oil pressure from the pump goes beyond the relief valve s et pres sur e, this valve releases the oil pressure to the drain circuit in order to reduce the load to the pump.


10-400

5


SEN03926-00 Operation When oil is not supplied to accumulator (cut-out state)

q

q

q

q

Plunger (1) is moved in the left direction by the accumulator pressure, and maintains unload relief valve (2) being pushed open. The oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through port (F), unload relief valve (2) and port (T). Since oil pressure in port (F) is decreased, unload valve (3) moves in the left direction being subjected to the action of the oil from chamber (B). Port (C) and port (D) are opened, supplying most of the oil from the pump to the cooling fan motor through port (P), ports (C) and (D), and port (A).

When oil is supplied to accumulator 1. Cut-in state

q

q

q q

q

q

10-400

6

As the accumulator pressure goes low, pressure on port (E) goes low, allowing plunger (1) to move in the right direction and unload relief valve (2) to close the drain circuit. Since the oil pressure in port (F) and the spring chamber of unload valve (3) increases, unload valve (3) moves in the right direction. Port (C) and port (B) are opened, conducting the oil from the pump to port (B). As oil pressure in port (B) increases beyond the set pressure of check valve (4), check valve opens, allowing the oil to be supplied to the accumulator through port (E). The pressure for supplying oil to the accumulator depends on the set pressure of check valve (4). Amount of oil supplied to the accumulator is constant independent of the engine speed, thus surplus of the oil flows to the cooling fan motor through port (A). Inverse shuttle valve (5) supplies precedence to the accumulator of lower pressure when supplying oil.



2.

When pressure reaches cut-out pressure

q

As pressure in port (F) reaches the set pressure (cut-out pressure of unload relief valve (2)), oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through port (F), unload relief valve (2) and port (T). Plunger (1) is moved in the left direction by the accumulator pressure, and maintains unload relief valve (2) being pushed open. Since oil pressure in port (F) is decreased, unload valve (3) moves in the left direction being subjected to the action of the oil from chamber (B). Port (C) and port (D) are opened, supplying most of the oil from the pump to the cooling fan motor through port (P), ports (C) and (D), and port (A).

q

q

q


SEN03926-00 When the oil pressure from the pump went beyond the set pressure

q

As oil pressure in chamber (B) reaches the set pressure of relief valve (6), relief valve (6) is opened to drain the oil from the pump to the hydraulic tank through port (T). Above process protects the brake circuit by restricting its maximum pressure.

10-400

7

400 Brake system Brake valve

SEN03926-00

Brake valve

1

P1: From HST pump T1: To hydraulic tank T2: To steering pump (suction side) PA: From accumulator (rear side)

A: To Rear brake PB: From accumulator (front side) B: To front brake

1. Rod 2. Inching valve spool 3. Inching valve body 4. Brake valve spool (for rear)

5. Brake valve body (for rear) 6. Brake valve spool (for front) 7. Brake valve body (for front)

Unit: mm

No. 8

9

Check item Clearance between inching valve spool and body Clearance between inching valve guide and body

between inching valve 10 Clearance spool and guide


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

22.4

–0.022 –0.053

+0.033 0

0.020 – 0.086

0.096

22.4

–0.022 –0.053

+0.033 0

0.020 – 0.086

0.096

12

–0.050 –0.093

+0.050 0

0.050 – 0.143

0.157

Standard size

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

34.7

16.7

24.5 N {2.5 kg}

—

20.8 N {2.1 kg}

12 Brake valve control spring

35.6

24.0

113 N {11.5 kg}

—

96 N {9.8 kg}

13 Inching valve return spring

50.0

49.5

19.6 N {2.0 kg}

—

16.7 N {1.7 kg}

14 Brake valve return spring

114.9

52.4

147 N {15.0 kg}

—

125 N {12.7 kg}

11 Inching valve control spring

10-400

8

Replace



SEN03926-00

Outline q The brake valve is installed in the lower front side of the operator's seat. Pressing the brake pedal conducts oil to the brake piston, operating the brake. q The left side and right side brake pedals are mechanically interlocked. Pressing one of the pedals operates another pedal at the same time. q The brake valve contains the inching valve to regulate the control pressure of the HST pump. Operation When the brake pedal is pressed down

q

q

q

Brake pedal (1) pressing effort is transmitted to spool (5) through rod (2), spool (3) and spring (4). As spool (5) is pushed in the right direction, port (Ta) is closed and the oil from the pump activates the rear brake after being conducted through the accumulator, port (PA), port (A) and rear brake piston. As spool (5) is pushed in the right direction, spool (6) is also pushed in the right direction, closing port (Tb). The oil from the pump flows through the accumulator, port (PB) and port (B) to the front brake piston to activate the front brake.


When brake of one side is operated (when the other brake failed) q Even when only one side of the brakes remains operable due to, for instance, oil leak on the front or rear brake system, brake pedal (1) pressing effort moves in the right direction after being transmitted mechanically through spool (5) and spool (6). q Oil from the pump is conducted normally to the brake piston of the healthy system to enable stopping the machine as needed in order to ensure safety.

10-400

9

SEN03926-00


Balancing operation

q

q

q

q

q

q

q

As the rear brake piston is filled with oil and the oil pressure rises between port (PA) and port (A), the oil being conducted to chamber (E) through orifice (c) of spool (5) pushes spool (5) in the left direction resisting repulsive force of spring (4). As the result, port (PA) and port (A) are disconnected. Since port (Ta) remains closed, the oil conducted to the brake piston is retained and the brake remains operable. At the same time as spool (5) is moved to the left, the front brake piston is filled up with oil, increasing the oil pressure between port (PB) and port (B). Thus, the oil conducted to chamber (F) through orifice (d) of spool (6) pushes back spool (6) in the left direction by the move distance of spool (5). As the result, port (PB) and port (B) are disconnected. Since port (Tb) remains closed, the oil conducted to the brake piston is retained and the brake remains operable. The oil pressure of the rear brake circuit [port (A) side] is balanced with the brake pedal pressing effort, and the oil pressure of the front brake circuit [port (B) side] is balanced with the oil pressure of the rear brake circuit [port (A) side]. As spools (5) and (6) are moved in the right direction to the stroke end, port (PA) and port (A) as well as port (PB) and port (B) are fully connected. As a result, oil pressure of the rear brake cir cuit and the front br ake circuit becomes equal to that from the pump. Braking force is adjustable by adjusting the brake pedal pressing effort until spools (5) and (6) are driven in the right direction to the stroke end.

10-400

10



SEN03926-00

When brake pedal is released

q q

q

q

q

Releasing brake pedal (1) releases the pedal pressing effort being applied to spool (5). Spool (5) is pushed back in the left direction by the back pressure of the rear brake piston and repulsive force of spring (7), and port (PA) and port (A) are closed. At the same time, oil in the rear brake piston is drained to the hydraulic tank through port (A) and port (Ta), releasing the rear brake. At the same time as spool (5) is moved in the left direction, spool (6) is also pushed back in the left direction by the back pressure of the front brake piston and repulsive force of spring (7). As the result, port (PB) and port (B) are closed. Oil in the front brake piston is drained to the hydraulic tank through port (B) and port (Tb), releasing the front brake.


10-400

11

SEN03926-00

Inching valve

P1: From HST pump port Y T2: To steering pump (suction side) 1. Brake pedal 2. Brake valve 3. Spool 4. Body

10-400

12

400 Brake system Inching valve

1

Outline q The inching valve, which is contained in brake valve (2), reduces the control oil pressure of the HST circuit responding to stroke (S) of spool (3) in order to reduce the capacity of the HST pump.


400 Brake system Accumulator (for brake)

SEN03926-00

Accumulator (for brake)

1

1. Cylinder 2. Free piston Function q The accumulator is installed between the charge valve and brake valve. The space between cylinder (1) and free piston (2) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulses generated by the hydraulic pump and secures the braking force and operability when the engine is stopped by utilizing its compressibility. Specifications Gas used


Nitrogen gas

Amount of gas (cc)

500

Charge pressure (MPa {kg/cm2})

3.5 ± 0.1 {35.7 ± 1} (at 20°C)

Max. pressure used (MPa {kg/cm2})

10 {102}

10-400

13

400 Brake system Slack adjuster

SEN03926-00

Slack adjuster

1

A: From brake valve B: To brake piston 1. Body 2. Check valve 3. Piston Unit: mm

No. 4

5

Check item Clearance between piston and body Clearance between check valve and body


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

30

–0.065 –0.098

+0.052 0

0.065 – 0.150

0.163

10

–0.013 –0.028

+0.015 0

0.013 – 0.043

0.048

Standard size

6

7

Piston return spring

Check valve return spring

10-400

14

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

87.5

48.2

11.8 N {1.2 kg}

—

9.8 N {1.0 kg}

21.7

19.25

53.9 N {5.5 kg}

—

46.1 N {4.7 kg}

Replace


400 Brake system Slack adjuster

SEN03926-00

Function q The slack adjuster is installed between the brake valve and brake piston. It maintains the time lag up to activation of the brake constant. Operation When brake is applied

q

q

q

The oil from the brake valve flows to port (A) and moves piston (1) in the right direction to activate the brake using the oil being amassed between piston (1) and the brake piston. The slack adjuster maintains the time lag up to activation of the brake constant by operating t he b r a k e u s i n g th e o i l b e i ng a m a s s e d between piston (1) and the brake piston. If the oil between piston (1) and brake piston goes low due to wear on the brake disc and like, it pushes open check valve (2) to make up the deficit.


When brake is released

q

The oil being stopped between piston (1) and brake piston pushes back piston (1) in the left direction, allowing the oil, equivalent in the volume to piston (1) move distance, to return to the brake valve through port (A) then is drained to the hydraulic tank.

10-400

15

SEN03926-00

400 Brake system Brake

Brake

1

Front brake

1

1. Differential housing 2. Bearing carrier 3. Piston 4. Spring 5. Inner ring (2 pieces) 6. Sun gear shaft 7. Axle housing 8. Outer ring 9. Disc (2 pieces)

10-400

16



SEN03926-00

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

6.5

±0.1

6.0

8.7

±0.15

7.9

11 Depth of lining groove

0.8

±0.2

0.4

Thickness of lining

1.0

0.8 (min.)

—

Standard size

Tolerance

Wear limit

20.1

±0.1

0.3

Installed height

Installed load

Installed load

7.6

912 N {93 kg}

730 N {74 kg}

10 Thickness of plate Thickness of brake disc

of disc contact surface of 12 Wear brake outer ring

Standard size of spring 13 Load (when 2 pieces are piled)

Replace

Repair limit

Outline q The front brake is a wet multiple disc type brake, which consists of piston (3), inner ring (5), disc (9), outer ring (8), and spring (4). q The brake cylinder consists of differential housing (1) and bearing carrier (2). And piston (3) is assembled to them. Inner ring (5) and outer ring (8) are coupled with the spline of differential housing (1). q Disc (9) has linings stuck to its both sides and is installed between inner ring (5) and outer ring (8), and they are coupled together by the spline of sun gear shaft (6).


10-400

17

SEN03926-00

Rear brake


1

1. Differential housing 2. Bearing carrier 3. Piston 4. Spring 5. Inner ring (2 pieces) 6. Sun gear shaft 7. Axle housing 8. Outer ring 9. Disc (2 pieces)

10-400

18



SEN03926-00

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

6.5

±0.1

6.0

8.7

±0.15

7.9

11 Depth of lining groove

0.8

±0.2

0.4

Thickness of lining

1.0

0.8 (min.)

—

Standard size

Tolerance

Wear limit

20.1

±0.1

0.3

Installed height

Installed load

Installed load

7.6

912 N {93 kg}

730 N {74 kg}

10 Thickness of plate Thickness of brake disc

of disc contact surface of 12 Wear brake outer ring

Standard size of spring 13 Load (when 2 pieces are piled)

Replace

Repair limit

Outline q The rear brake is a wet multiple disc type brake, which consists of piston (3), inner ring (5), disc (9), outer ring (8), and spring (4). q The brake cylinder consists of differential housing (1) and bearing carrier (2). And piston (3) is assembled to them. Inner ring (5) and outer ring (8) are coupled with the spline of differential housing (1). q Disc (9) has linings stuck to its both sides and is installed between inner ring (5) and outer ring (8), and they are coupled together by the spline of sun gear shaft (6).


10-400

19

SEN03926-00


Operation When brake is operated

q

As the brake pedal is pressed, oil pressure (P) being supplied through the hydraulic tank, pump and brake charge valve to the brake cylinder acts on piston (2) in the brake cylinder to move the piston. Accordingly, disc (4) between piston (2), inner ring (3), and outer ring (5) is stopped and the brake is applied to the machine.

When brake is released

q

If the oil pressure is released, piston (2) is returned to the original position by the returning force of spring (8) and clearance is made between inner ring (3) and outer ring (5), and disc (4) becomes free. The linings stuck to disc (4) have cross grooves on them. While disc (4) is rotating, oil flows in those grooves to cool the linings.

10-400

20


400 Brake system Parking brake control

SEN03926-00

Parking brake control

1. Parking brake lever 2. Parking brake lever bottom switch 3. Parking brake lever intermediate switch

1

4. Control cable 5. Transfer 6. Multi-disc brake lever

Outline q The parking brake is built in transfer (5). On this mechanical parking brake, operating the multi-disc brake lever (6) from parking brake lever (1) allows "applying" or "releasing" the parking brake. q Pulling parking brake lever (1) on the operator's seat pulls up the multi-disc brake lever (6), which is connected with control cable (4), "applying" the parking brake. q Returning parking brake lever (1) to its original position pushes down the multi-disc brake lever (6), which is connected with control cable (4), "releasing" the parking brake. q As long as the parking brake is "applied", current to the directional solenoid valve on the HST pump is cut off and the swash plate of the HST pump is maintained at the neutral position.


10-400

21

400 Brake system Parking brake

SEN03926-00

Parking brake

1

1. Lever 2. Housing 3. Ball 4. Piston

5. Plate 6. Disc 7. Wave spring 8. Output shaft Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

2.6

±0.06

2.5

Strain on plate

—

0.05

0.1

Thickness of brake disc

2.2

±0.08

2.05

Strain on brake disc

—

0.02

0.25

1,010 N {103 kg}

±101 N {±10.3 kg}

858 N {87.6 kg}

Thickness of plate

9

Replace

10 of wave spring 11 Load (height: 2.2 mm)

Outline q This parking brake is a wet multiple disc type brake being operated mechanically to apply braking to output shaft (8). q Lever (1) is connected to the control cable. Ball (3) provided between piston (4) and housing (2), that are connected to lever (1), moves on the slope of the piston groove responding to the pulling distance of the parking brake lever. By this move of the ball, piston (4) compresses plate (5) and disc (6) to each other, thereby applying brake to output shaft (8).

10-400

22


400 Brake system Parking brake


SEN03926-00

10-400

23

SEN03926-00



10-400

24

SEN03927-00





1

500 Undercarriage and frame Axle mount and center hinge pin .................................................................................................................... 2 Tires ................................................................................................................................................................ 7


10-500

1

SEN03927-00

Axle mount and center hinge pin a

500 Undercarriage and frame Axle mount and center hinge pin

1

The following drawing shows WA320-6.

10-500

2



1. 2. 3. 4. 5. 6. 7. 8. 9.

Front axle Tension bolt Rear axle Frame lock bar Front frame Center hinge pin Rear frame Additional counterweight Counterweight


SEN03927-00 Outline q Front axle (1) receives the force during work directly. Thus, it is fixed directly to front fame (5) with tension bolt (2). q Rear axle (3) is designed to sway at the center of rear frame (7) so that each tire may contact the ground surface even when the machine is traveling on soft ground. q Front frame (5) and rear frame (7) are coupled by the center hinge pin (6) with the bearing between them. The right and left steering cylinders connect the front frame (5) and rear frame (7). They adjust the bending angle or the turning radius of the frame according to move of the cylinder.

10-500

3

SEN03927-00

10-500

4




SEN03927-00

Unit: mm

No. 1

Check item Clearance between upper hinge pin and rear frame

Criteria Tolerance

Standard size

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

–0.030 –0.076

+0.046 0

0.030 – 0.122

—

2

Clearance between upper hinge pin and spacer (small)

75

–0.030 –0.076

+0.250 0

0.030 – 0.326

—

3

Clearance between upper hinge pin and bearing

75

–0.030 –0.076

0 –0.015

0.015 – 0.076

—

4

Clearance between upper hinge pin and spacer (large)

75

–0.030 –0.076

+0.026 –0.020

0.010 – 0.102

—

5

Clearance between rear frame and spacer (large)

90

–0.010 –0.040

+0.054 0

0.010 – 0.094

—

6

Clearance between front frame and upper hinge bearing

120

0 –0.020

–0.030 –0.076

–0.076 – –0.010

—

7

Clearance between lower hinge pin and rear frame bushing

75

–0.030 –0.076

+0.067 +0.027

0.057 – 0.143

—

8

Clearance between lower hinge pin and bearing

75

–0.030 –0.076

0 –0.015

0.015 – 0.076

—

9

Clearance between front frame and lower hinge bearing

115

0 –0.015

–0.041 –0.076

–0.076 – –0.026

—

between rear frame and 10 Clearance bushing

85

+0.089 +0.059

+0.054 0

–0.089 – –0.005

—

of press fitting part of 11 Clearance lower hinge pin seal

90

+0.280 +0.180

+0.054 0

–0.280 – –0.126

—

of upper hinge spacer 12 Height (small)

13 Height of upper hinge spacer (large)

Standard size

Tolerance

Repair limit

24.5

±0.1

—

64.0

±0.1

—

thickness of shim 14 Standard between upper hinge and retainer

2.0

thickness of shim 15 Standard between upper hinge and retainer

1.0

thickness of shim 16 Standard between lower hinge and retainer

1.0

torque of upper hinge 17 Tightening retainer mounting bolt

torque of lower hinge 18 Tightening retainer mounting bolt


19.6 ± 2.0 Nm {2.0 ± 0.2 kgm} (when shim is adjusted)

Replace

Adjust

98 – 123 Nm {10.0 – 12.5 kgm} (final value) 19.6 ± 2.0 Nm {2.0 ± 0.2 kgm} (when shim is adjusted) 98 – 123 Nm {10.0 – 12.5 kgm} (final value)

10-500

5


SEN03927-00

Unit: mm

No.

Check item

1

Thickness of thrust plate

2

Thickness of thrust washer

3

Clearance between shaft and hole on front support side

4

Clearance between shaft and hole on rear support side

10-500

6

Criteria

Remedy

Standard size

Tolerance

Repair limit

22

±0.5

—

5

+0.3 –0.1

—

Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

190

–0.050 –0.122

+0.472 0

0.050 – 0.594

—

170

–0.005 –0.124

+0.522 +0.050

0.055 – 0.646

—

Replace


500 Undercarriage and frame Tires

SEN03927-00

Tires

1

The radial tires (if equipped) of this machine have the following features. q High gripping force q Low fuel consumption q High operator comfort q Long life q Less frequency of burst q Less damages of machine q Less uneven wear q Less generation of heat Comparison of structures and characteristics of tires Radial tire

Bias tire

Structure The cords of carcass (1) are arranged at right angles to the center line of tread (T) (radially). q Tread (T) is stabilized and protected by several strong belts (2). q Side wall (W) and tread (T) are independent from each other.

Structure q The cords of carcass (1) are arranged bias from the center line of tread (T). q Side wall (W) and tread (T) are integral.

Ground contact characteristics q Even if the tire is deformed by a load, it does not move uselessly in ground contact and uniform ground contact surface is secured stably.

Ground contact characteristics q If the tire is deformed by a load, the ground contact surface is also deformed, leading to wasteful moves. As a result, the ground contact surface becomes unstable.

q

Deformation characteristics Only side wall (W) is deformed as load is applied and tread (T) made of strong belts (2) keeps stability independently.

q


Deformation characteristics Side wall (W) which receives loads and tread (T) move as one unit.

q

10-500

7

SEN03927-00



10-500

8

SEN03928-00





10

600 Hydraulic system Work equipment hydraulic piping diagram ...................................................................................................... 2 Work equipment control lever linkage ............................................................................................................. 6 Hydraulic tank ............................................................................................................................................... 10 4-gear pump.................................................................................................................................................. 12 Work equipment control valve....................................................................................................................... 14 Cut-off valve .................................................................................................................................................. 40 PPC valve ..................................................................................................................................................... 43 Lock valve ..................................................................................................................................................... 58 Accumulator (for PPC circuit)........................................................................................................................ 59 ECSS valve................................................................................................................................................... 61 Accumulator (for ECSS)................................................................................................................................ 63


10-600

1

SEN03928-00

Work equipment hydraulic piping diagram

600 Hydraulic system Work equipment hydraulic piping diagram

1

WA320-6

10-600

2



1. 2. 3. 4. 5. 6. 7. 8.

Work equipment control valve Bucket cylinder Hydraulic tank Work equipment PPC valve Lock valve Oil cooler Check valve 4-gear pump • Steering pump • Work equipment pump • Brake and cooling fan pump • Transfer lubrication pump 9. Cut off valve 10. Accumulator (for ECSS) (if equipped) 11. Lift cylinder 12. ECSS valve (if equipped) 13. Accumulator (for PPC circuit)


SEN03928-00 Outline q The hydraulic system is consisted of the HST, steering, work equipment, brake, cooling fan and transfer lubrication circuit. The work equipment circuit controls move of the lift arm and bucket. q The oil in hydraulic tank (3) is supplied to work equipment control valve (1) by work equipment pump of 4-gear pump (8). When each spool of the lift arm and bucket of work equipment control valve (1) is at the Hold position, the oil flows the drain circuit of work equipment control valve (1), is filtered on the return filter on hydraulic tank (3), then is returned to hydraulic tank (3). q Operating the work equipment lever operates the lift arm spool or bucket spool of work equipment PPC valve (4). The oil from work equipment PPC valve (4) operates respective spools of work equipment valve (1) with its oil pressure, then sends the oil pressure to lift cylinder (11) or bucket cylinder (2) to operate the lift arm or bucket. q The maximum pressure in the hydraulic circuit is controlled with the relief valve in work equipment control valve (1). The bucket cylinder circuit is equipped with the safety-suction valve for protection of the circuit. q Accumulator (for PPC circuit) (13) is installed on the PPC pilot circuit so that the work equipment can be lowered to the ground even while the engine is stopped. q Hydraulic tank (3) is pressurized, enclosed, and equipped with the breather having the relief valve, which doubles the oil filler cap function. The breather applies pressure to the tank and, at the same time, prevents generation of negative pressure in the tank to prevent cavitation in the pump.

10-600

3

SEN03928-00


WA320PZ-6

10-600

4



1. Work equipment control valve 2. Quick coupler solenoid valve 3. Bucket cylinder 4. Hydraulic tank 5. Attachment PPC valve 6. Work equipment PPC valve 7. Lock valve 8. Oil cooler 9. Check valve 10. 4-gear pump • Steering pump • Work equipment pump • Brake and cooling fan pump • Transfer lubrication pump 11. Cut off valve 12. ECSS valve (if equipped) 13. Accumulator (for ECSS) (if equipped) 14. Lift cylinder 15. Coupler plunger 16. Accumulator (for PPC circuit)


SEN03928-00 Outline q The hydraulic system is consisted of the HST, steering, work equipment, brake, cooling fan and transfer lubrication circuit. The work equipment circuit controls move of the lift arm, bucket and attachment. q The oil in hydraulic tank (4) is supplied to work equipment control valve (1) by work equipment pump of 4-gear pump (10). When each spool of the lift arm, bucket and attachment of work equipment control valve (1) is at the Hold position, the oil flows the drain circuit of work equipment control valve (1), is filtered on the return filter on hydraulic tank (4), then is returned to hydraulic tank (4). q Operating the work equipment control lever operates the lift arm spool or bucket spool of work equipment PPC valve (6). If operating the auxiliary control lever operates the spool of attachment PPC valve (5). The oil from work equipment PPC valve (6) or attachment PPC valve (5) operates respective spools of work equipment control valve (1) with its oil pressure, then sends the oil pressure to lift cylinder (14), bucket cylinder (3) or coupler plunger (15) to operate the lift arm, bucket or attachment. q The maximum pressure in the hydraulic circuit is controlled with the relief valve in work equipment control valve (1). The bucket cylinder circuit is equipped with the safety-suction valve for protection of the circuit. q Accumulator (for PPC circuit) (16) is installed on the PPC pilot circuit so that the work equipment can be lowered to the ground even while the engine is stopped. q Hydraulic tank (4) is pressurized, enclosed, and equipped with the breather having the relief valve, which doubles the oil filler cap function. The breather applies pressure to the tank and, at the same time, prevents generation of negative pressure in the tank to prevent cavitation in the pump.

10-600

5

SEN03928-00

Work equipment control lever linkage

600 Hydraulic system Work equipment control lever linkage

1

WA320-6 Multi-function mono-lever type

1. Work equipment control lever 2. Directional selector switch 3. Wrist rest 4. Lock valve 5. Work equipment lock lever 6. Work equipment PPC valve 7. Wrist rest height adjustment lock lever

10-600

6



SEN03928-00

WA320-6 2-lever type (If equipped)

1. Lift arm control lever 2. Bucket control lever 3. Wrist rest 4. Lock valve 5. Work equipment lock lever 6. Work equipment PPC valve 7. Wrist rest height adjustment lock lever


10-600

7

SEN03928-00


WA320PZ-6 Multi-function mono-lever type

1. Work equipment control lever 2. Auxiliary control lever 3. Directional selector switch 4. Wrist rest 5. Lock valve 6. Work equipment lock lever 7. Work equipment PPC valve 8. Attachment PPC valve 9. Wrist rest height adjustment lock lever

10-600

8



SEN03928-00

WA320PZ-6 2-lever type (If equipped)

1. Lift arm control lever 2. Bucket control lever 3. Auxiliary control lever 4. Wrist rest 5. Lock valve 6. Work equipment lock lever 7. Attachment PPC valve 8. Work equipment PPC valve 9. Wrist rest height adjustment lock lever


10-600

9

600 Hydraulic system Hydraulic tank

SEN03928-00

Hydraulic tank

1. Oil filler cap and breather 2. Return filter 3. Hydraulic tank 4. Drain plug 5. Sight gauge 6. Return filter bypass valve 7. Check valve

10-600

10

1

Specifications Capacity of hydraulic tank (l)

124

Quantity of oil in hydraulic tank (l)

89

Set pressure of bypass valve (MPa {kg/cm2}) Cracking pressure of check valve (MPa {kg/cm2})

0.2 {2.04} 0.2 ± 0.03 {1.96 ± 0.29}


600 Hydraulic system Hydraulic tank

Breather

SEN03928-00

1

1. Oil filler cap 2. Case 3. Lock-resetting knob 4. Sleeve 5. Poppet 6. Filter element

Prevention of negative pressure in tank q Since the tank is pressurized and enclosed, if the oil level in it lowers, negative pressure is generated. At this time, sleeve (4) is opened by the differential pressure between the tank pressure and the atmospheric pressure to prevent generation of the negative pressure. (set pressure of air intake valve: 3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2}) Prevention of pressure rise in tank While the hydraulic circuit is in operation, the oil level in the tank rises as the hydraulic cylinders operate, and the temperature rises. Consequently, the pressure in the tank rises, too. If the pressure in the tank rises beyond the set level, poppet (5) is activated to release the pressure in the tank to prevent rise of pressure in the tank. (set pressure of exhaust valve: 0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})

q


10-600

11

600 Hydraulic system 4-gear pump

SEN03928-00

4-gear pump

1

(steering, work equipment, brake, cooling fan and transfer lubrication) Type: SAR(3)90 + (2)32 + SB(1)18 + 12

1. Steering pump 2. Work equipment pump 3. Brake and cooling fan pump 4. Transfer lubrication pump

10-600

12

Outline q The 4-gear pump is installed on the HST pump. The axial rotation drives this gear to supply pressurized oil to the steering, work equipment, brake, cooling fan and transfer.


600 Hydraulic system 4-gear pump

SEN03928-00

Unit: mm

No.

Check item

Criteria Type

Remedy

Standard clearance

Clearance limit

0.10 – 0.15

0.19

SAR(3)90

5

Side clearance

SAR(2)32 SBR(1)18 SBR(1)12

6

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

SAR(3)90

0.083 – 0.144

SAR(2)32

0.071 – 0.121

SBR(1)18 SBR(1)12

7

Pin driven depth

Type

Standard size

SAR(3)90

13

SAR(2)32

12

SBR(1)18

10

SBR(1)12

8

Torque of spline rotating shaft

Delivery Oil temperature: 45 – 55°C

Allowance 0 –0.5

Repair limit

—

+0.5 0

7

Speed (rpm)

Discharge pressure (MPa {kg/cm2})

SAR(3)90 SAR(2)32 SBR(1)18 SBR(1)12


Replace

13.8 – 28.5 Nm {1.4 – 2.9 kgm} Type

— Oil: SAE10WCD

0.20

0.068 – 0.115

2,500

20.6 {210} 2.9 {30}

Standard delivery (l/min)

Allowable delivery (l/min)

208

192

72

65

40

35

27

24

—

10-600

13

SEN03928-00

Work equipment control valve

600 Hydraulic system Work equipment control valve

1

WA320-6

2-spool type

10-600

14



SEN03928-00

A1: To bucket cylinder head A2: To lift arm cylinder head B1: To bucket cylinder bottom B2: To lift arm cylinder bottom P1: From steering pump P1A: From PPC valve P1 port P2A: From PPC valve P2 port P1B: From PPC valve P3 port P2B: From PPC valve P4 port T: Drain port (To tank)


10-600

15

SEN03928-00

10-600

16




SEN03928-00

1. Bucket spool 2. Lift arm spool 3. Suction valve 4. Suction safety valve 5. Check valve 6. Main relief valve Unit: mm

No.

Item

Criteria

Remedy

Standard size

7

Spool return spring (for bucket)

Repair limit


Installed length

Installed load

Free length

Installed load

54.8 x 34

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

8

Spool return spring (for bucket and lift arm)

54.8 x 33.7

52.5

207.9 N {21.2 kg}

—

167 N {17 kg}

9


30.7 x 32.5

26.5

255 N {26 kg}

—

204 N {20.8 kg}

return spring 10 Spool (for lift arm)

51.9 x 16.9

40

182.4 N {18.6 kg}

—

146 N {14.9 kg}


87.6 x 34.7

83.5

229.5 N {23.4 kg}

—

183 N {18.7 kg}

12 Check valve spring

32.6 x 10.9

24.5

44.1 N {4.5 kg}

—

35.3 N {3.6 kg}

13 Suction valve spring

64.9 x 12.5

56

6.4 N {0.65 kg}

—

5.1 N {0.52 kg}



10-600

17

SEN03928-00


WA320-6

3-spool type

10-600

18



SEN03928-00

A1: To attachment cylinder A2: To bucket cylinder head A3: To lift arm cylinder head B1: To attachment cylinder B2: To bucket cylinder bottom B3: To lift arm cylinder bottom P1: From steering pump P1A: From attachment PPC valve P1B: From attachment PPC valve P2A: From PPC valve P1 port P2B: From PPC valve P3 port P3A: From PPC valve P2 port P3B: From PPC valve P4 port T: Drain port (to tank)


10-600

19

SEN03928-00

10-600

20




SEN03928-00

1. Attachment spool 2. Bucket spool 3. Lift arm spool 4. Suction valve 5. Safety-suction valve 6. Check valve 7. Main relief valve Unit: mm

No.

Item

Criteria

Remedy

Standard size

Repair limit


Installed length

Installed load

Free length

Installed load

54.8 x 34

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}


54.8 x 33.7

52.5

207.9 N {21.2 kg}

—

167 N {17 kg}

return spring 10 Spool (for bucket and lift arm)

30.7 x 32.5

26.5

255 N {26 kg}

—

204 N {20.8 kg}


51.9 x 16.9

40

182.4 N {18.6 kg}

—

146 N {14.9 kg}


87.6 x 34.7

83.5

229.5 N {23.4 kg}

—

183 N {18.7 kg}


32.6 x 10.9

24.5

44.1 N {4.5 kg}

—

35.3 N {3.6 kg}


64.9 x 12.5

56

6.4 N {0.65 kg}

—

5.1 N {0.52 kg}

8

9

Spool return spring (for bucket and attachment)



10-600

21

SEN03928-00


WA320PZ-6

2-spool type

10-600

22



SEN03928-00

A1: To bucket cylinder head A2: To lift arm cylinder head B1: To bucket cylinder bottom B2: To lift arm cylinder bottom P1: From steering pump P1A: From PPC valve P1 port P2A: From PPC valve P2 port P1B: From PPC valve P3 port P2B: From PPC valve P4 port T: Drain port (To tank)


10-600

23

SEN03928-00

10-600

24




SEN03928-00

1. Bucket spool 2. Lift arm spool 3. Suction valve 4. Suction safety valve 5. Check valve 6. Main relief valve Unit: mm

No.

Item

Criteria

Remedy

Standard size

7

Spool return spring (for bucket)

Repair limit


Installed length

Installed load

Free length

Installed load

54.8 x 34

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

8


54.8 x 33.7

52.5

207.9 N {21.2 kg}

—

167 N {17 kg}

9


30.7 x 32.5

26.5

255 N {26 kg}

—

204 N {20.8 kg}


51.9 x 16.9

40

182.4 N {18.6 kg}

—

146 N {14.9 kg}


87.6 x 34.7

83.5

229.5 N {23.4 kg}

—

183 N {18.7 kg}


32.6 x 10.9

24.5

44.1 N {4.5 kg}

—

35.3 N {3.6 kg}


27.7 x 10.4

25

380 N {38.8 kg}

—

304 N {31 kg}



10-600

25

SEN03928-00


WA320PZ-6

3-spool type

10-600

26



SEN03928-00

A1: To attachment cylinder A2: To bucket cylinder head A3: To lift arm cylinder head B1: To attachment cylinder B2: To bucket cylinder bottom B3: To lift arm cylinder bottom P1: From steering pump P1A: From attachment PPC valve P1B: From attachment PPC valve P2A: From PPC valve P1 port P2B: From PPC valve P3 port P3A: From PPC valve P2 port P3B: From PPC valve P4 port T: Drain port (to tank)


10-600

27

SEN03928-00

10-600

28




SEN03928-00

1. Attachment spool 2. Bucket spool 3. Lift arm spool 4. Suction valve 5. Safety-suction valve 6. Check valve 7. Main relief valve Unit: mm

No.

Item

Criteria

Remedy

Standard size

Repair limit


Installed length

Installed load

Free length

Installed load

54.8 x 34

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}


54.8 x 33.7

52.5

207.9 N {21.2 kg}

—

167 N {17 kg}

return spring 10 Spool (for bucket and lift arm)

30.7 x 32.5

26.5

255 N {26 kg}

—

204 N {20.8 kg}


51.9 x 16.9

40

182.4 N {18.6 kg}

—

146 N {14.9 kg}


87.6 x 34.7

83.5

229.5 N {23.4 kg}

—

183 N {18.7 kg}


32.6 x 10.9

24.5

44.1 N {4.5 kg}

—

35.3 N {3.6 kg}


27.7 x 10.4

25

376 N {38.3 kg}

—

300 N {30.6 kg}

8

9

Spool return spring (for bucket and attachment)



10-600

29


SEN03928-00

Relief valve q

q q

If the oil pressure in ports (A) and (B) reaches the set pressure of pilot poppet spring (4), pilot poppet (3) opens. The oil in port (A) flows through orifice (E) to ports (B), (D), and (C). As a result, differential pressure is made between ports (A) and (B).

1. Main valve 2. Poppet seat 3. Pilot poppet 4. Spring 5. Adjustment screw Function q This valve is installed in the inlet of the work equipment control valve. When the oil pressure increases beyond the specified level, it drains the oil to the hydraulic tank. Above process protects the work equipment circuit by restricting the maximum pressure. Operation q Port (A) is connected to the pump circuit and port (C) is connected to the drain circuit. Oil flows through the orifice of main valve (1) and fills port (B). Pilot poppet (3) is in contact with (seated on) poppet seat (2).

10-600

30

q

q

q

The differential pressure between ports (A) and (B) pushes main valve (1) open, then the oil in port (A) flows through port (C) to the drain circuit to let the abnormal pressure escape. The set pressure can be changed by increasing or decreasing the tension of pilot poppet spring (4). To change the set pressure, loosen the locknut. Then, tighten or loosen adjustment screw (5) to heighten or lower the set pressure.



SEN03928-00

Safety-suction valve

1. Suction valve 2. Main valve 3. Main valve spring 4. Pilot piston 5. Suction valve spring 6. Valve body Function q The safety-suction valve is installed to the bucket cylinder circuit in the work equipment control valve. When an impact is applied to the bucket cylinder and abnormal pressure is generated while the bucket control lever is in neutral, the safety-suction valve releases the abnormal pressure to protect the cylinder. q And if negative pressure is generated in the cylinder circuit, this valve works as a suction valve.

q

q

If abnormal pressure is generated in port (A), suction valve (1) does not operate since (d2) > (d1). At this time, however, main valve (2) receives oil pressure for the differential area between (d3) and (d4) since (d3) of port (A) > (d4) of port (C). If the abnormal pressure reaches the set pressure of main valve spring (3), main valve (2) operates and the oil in port (A) flows to port (B).

Operation

1. Operation as safety valve q q

q

Port (A) and port (B) are connected to the cylinder circuit and drain circuit, respectively. The hydraulic oil in port (A) flows through the hole of pilot piston (4) to port (D). It also flows through the orifice consisting of main valve (2) and pilot piston (4) to port (C). Pilot piston (4) is fixed to the safety valve and the order of the diameters (areas) of the sections is (d2) > (d1) > (d3) > (d4).


10-600

31


SEN03928-00 2. Operation as suction valve q

q

q

q

q

When negative pressure is generated in port (A), the pressure in port (D) which is connected to port (A) becomes negative. Since the tank pressure of port (B) is applied to port (E), the safety valve receives oil pressure (e) for the differential area between (d2) and (d1). Accordingly, oil pressure (e) is applied in the opening direction of the valve and oil pressure (a) is applied in the closing direction of suction valve (1). When the pressure in port (A) lowers and becomes almost negative, it is lower than oil pressure (e). When oil pressure (e) > oil pressure (a) + force of valve spring (5), suction valve (1) opens and the oil flows through port (B) to port (A), thus the pressure in port (A) does not become negative.

Suction valve

1. Main poppet 2. Sleeve 3. Spring Function q This valve prevents to generate negative pressure on the circuit. Operation If negative pressure is generated in port (A) (lift arm cylinder head) [if a pressure lower than that in the tank circuit port (B) is generated], main poppet (1) is opened by the difference in area between (d1) and (d2), and the pressurized oil flows to cylinder port (A) from tank port (B).

q

10-600

32



SEN03928-00

Operation of work equipment control valve 1. When lift arm and bucket spool are at the neutral position

Operation q The oil flows from the pump to port (A) and its maximum pressure is limited by relief valve (1). q The bypass circuit of bucket spool (2) is opened to hold the lift arm. As a result, the oil in port (A) flows around the spool into port (B). q Since lift arm spool (3) is in neutral, its bypass circuit is open. Accordingly, the oil in port (B) flows around the spool into the drain circuit and then returns to the tank.


q

The oil from the PPC pump flows in port (L) of the PPC valve. Since the lift arm and bucket control levers are in the hold positions, however, the oil returns through the PPC relief valve to the hydraulic tank.

10-600

33


SEN03928-00 2. When lift arm spool is at raise position

Operation q If the lift arm control lever is pulled, the oil flows from port (L) of the PPC valve through port (N) to port (S) of the work equipment control valve. q The oil in port (T) flows through port (M) to the drain circuit. The oil in port (S) pushes lift arm spool (3) to set it in the raise position. q The oil from the pump flows through the bypass circuit of bucket spool (2) to the bypass circuit of spool (3). q Since the bypass circuit is closed by spool (3), the oil pushes check valve (5) open. q Then, the oil flows through port (D) to the cylinder bottom.

10-600

34

q

The oil in the cylinder head flows through port (E) into drain port (F) and then returns to the tank. Accordingly, the lift arm is raised.



SEN03928-00

3. When lift arm spool is at lower position

Operation q If the lift arm control lever is pushed, the oil flows from port (L) of the PPC valve through port (M) to port (T) of work equipment control valve. q The oil in port (S) flows to the drain circuit. The oil in port (T) pushes lift arm spool (3) to set it in the lower position. q The oil from the pump flows through the bypass circuit of bucket spool (2) to the bypass circuit of spool (3). q Since the bypass circuit is closed by spool (3), the oil pushes check valve (5) open. q The oil flows through port (E) to the cylinder head.


q

The oil in the cylinder bottom flows through port (D) into drain port (F) and then returns to the tank. Accordingly, the lift arm is lowered.

10-600

35


SEN03928-00 4. When lift arm spool is at float position

Operation q If the lift arm control lever is pushed to the float position, lift arm spool (3) moves over the lower position to the float position. q The oil from the pump flows through the bypass circuit of bucket spool (2) to the bypass circuit of lift arm spool (3). q The oil in the bypass circuit flows through spool (3) to the drain circuit and cannot push check valve (5) open. q In addition, the lift arm descends by its own weight since both the raise circuit (D) and lower circuit (E) of the lift arm cylinder are connected to the drain circuit.

10-600

36

q

While the bucket is in contact with the ground, it can move up and down according to the unevenness of the ground.



SEN03928-00

5. When bucket spool is at dump position

Operation q If the bucket control lever is pushed, the oil in port (L) of the PPC valve flows through port (Q) to port (V) of the work equipment control valve. q The oil in port (R) flows to the drain circuit. The oil in port (V) sets bucket spool (2) in the dump position. q Since the oil from the pump is stopped by spool (2), the oil from port (A) pushes check valve (7) open. q The oil from check valve (7) flows through port (H) to the bucket cylinder head. q The oil in the bucket cylinder bottom flows through port (G) into drain port (F) and then returns to the tank. Accordingly, the bucket is dumped. WA320, 320PZ-6 (KA SPEC.)

10-600

37

SEN03928-00


6. When bucket spool is at tilt position

Operation q If the bucket control lever is pulled, the oil in port (L) of the PPC valve flows through port (P) to port (R) of the work equipment control valve. q The oil in port (V) flows to the drain circuit. The oil in port (R) sets bucket spool (2) in the tilt position. q Since the oil from the pump is stopped by spool (2), the oil from port (A) pushes check valve (7) open. q The oil from check valve (7) flows through port (G) to the bucket cylinder bottom. q The oil in the bucket cylinder head flows through port (H) into drain port (F) and then returns to the tank. Accordingly, the bucket is tilted. 10-600

38




SEN03928-00

10-600

39

SEN03928-00

Cut-off valve a

600 Hydraulic system Cut-off valve

1

Do not disassemble. If it is disassembled, its set pressure must be adjusted.

10-600

40



SEN03928-00

C1: To work equipment control valve C2: From work equipment control valve DA: DA port pressure

T1: To tank T2: To tank P: From work equipment pump

1. Unload valve 2. Check valve

3. Cut-off relief valve 4. Screen Unit: mm

No.

Check item

Criteria

Remedy

Standard size

5

6

Unload valve spring

Check valve spring

Repair limit


Installed length

Installed load

Free length

Installed load

36.95 x 12.6

30

35.3 N {3.6 kg}

—

28.4 N {2.9 kg}

33 x 13.8

20

1.7 N {0.17 kg}

—

1.4 N {0.14 kg}


Function q The cut-off valve is installed between the work equipment pump and work equipment control valve. It sends the oil from the work equipment pump to the work equipment control valve or drains it to control the work equipment speed according to the working condition. Operating condition of cut-off valve q

While the engine speed is in the low range, the cut-off valve operates at low pressure.


10-600

41

SEN03928-00 1. When work equipment pump pressure is lower than cut-off pressure q Similarly to the state where the work equipment is held, the oil of the work equipment pump pushes up check valve (1) and merges with the oil from the steering pump and then flows into the work equipment control valve.

10-600

42


2. When work equipment pump pressure is higher than cut-off pressure q If the work equipment pump pressure reaches the cut-off pressure, cut-off valve (2) is opened by the oil pressure in chamber (a) and then the oil in chamber (b) of unload valve (3) is drained through chamber (c) of cut-off valve (2). q Since the oil in chamber (d) of unload valve (3) flows through orifices (e) and (f) to chamber (b), the oil pressure in chamber (d) lowers and unload valve (3) opens. q Accordingly, the oil from the work equipment pump is drained.


600 Hydraulic system PPC valve

SEN03928-00

PPC valve a

1

PPC: Abbreviation for Proportional Pressure Control

Work equipment PPC valve Mono-lever type

P: From HST charge pump P1: To bucket valve (tilt) P2: To bucket valve (dump)


P3: To lift arm valve (raise) P4: To lift arm valve (lower, float) T: To hydraulic tank

10-600

43


SEN03928-00

1. Spool 2. Metering spring 3. Centering spring 4. Rod 5. Disc 6. Nut (for connecting lever)

10-600

44

7. Joint 8. Plate 9. Piston 10. Retainer 11. Body 12. Filter



SEN03928-00

Operation When in neutral 1) Bucket PPC valve q Ports (PA) and (PB) of the control valve (bucket valve) and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).


2) Lift arm PPC valve q Ports (PA) and (PB) of the control valve (lift arm valve) and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

10-600

45

SEN03928-00


When in fine control (Neutral o fine control) q If rod (4) and piston (9) are pushed by disc (5), retainer (10) is pushed and spool (1) is also pushed downward through metering spring (2). q When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). q The pilot pressurized oil from the HST charge pump flows through fine control hole (f) and port (P1) to port (PB). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). q As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1). q The positional relationship between spool (1) and body (11) (where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)) does not change until retainer (10) comes in contact with spool (1). q Metering spring (2) contracts in proportion to the stroke of the control lever. q Pressure at port (P1) also rises in proportion to the stroke of the control lever. q The control valve spool moves to a position where the pressure in chamber (PB) (equal to the pressure in port (P1)) is balanced with the force of the control valve spool return spring.

10-600

46



When in fine control mode (when control lever is returned) q When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). q Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). q Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. q When the control valve spool returns, the pressurized oil in drain chamber (D) flows in through fine control hole (f') of the valve which is not in operation and flows through port (P2) into chamber (PA).


SEN03928-00 When lever is operated to stroke end q Disc (5) and rod (4) push down piston (9) and retainer (10) pushes down spool (1). q Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). q The pilot pressure oil from the HST charge pump flows through fine control hole (f) and port (P1) into chamber (PB) to push the control valve spool. q The oil returning from chamber (PA) flows through port (P2) and fine control hole (f') into drain chamber (D).

10-600

47

SEN03928-00


When lift arm is "float" q If disc (5) pushes down rod (4) and piston (9) on port (P4) "lower" side, the detent starts operation before the stroke end. (the operating effort of the lever becomes heavy.) q If rod (4) is pushed down further, the detent operates to keep the lift arm in "float" state even if the lever is released. q At the same time, the control valve is also moved to the "float" position to keep the lift arm in float condition.

When "float" state of lift arm is reset When returning disc (5) from the "float" position, the rod is pushed down with a force larger than absorptive power of the solenoid. q The "float" state also can be reset and the lever can be returned to the "neutral" position by turning off the current in the solenoid (deenergizing the solenoid). q

q

The lift arm raise and bucket tilt operations are carried out similarly to the above.

10-600

48



SEN03928-00

2-lever type

P: From HST charge pump P1: To bucket tilt valve P2: To lift arm LOWER (FLOAT) valve P3: To lift arm RAISE valve P4: To bucket DUMP valve T: To hydraulic tank


10-600

49


SEN03928-00

1. Spool 2. Metering spring 3. Centering spring 4. Rod 5. Lever 6. Ring

10-600

50

7. Plate 8. Piston 9. Retainer 10. Body 11. Filter



SEN03928-00

Operation When in neutral 1) Bucket PPC valve q Ports (PA) and (PB) of the control valve (bucket valve) and ports (P1) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).


2) Lift arm PPC valve q Ports (PA) and (PB) of the control valve (lift arm valve) and ports (P2) and (P3) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

10-600

51

SEN03928-00


When in fine control (Neutral o fine control) q If rod (4) and piston (8) are pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed downward through metering spring (2). q When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). q The pilot pressurized oil from the HST charge pump flows through fine control hole (f) and port (P1) to port (PB). q If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). q As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1). q The positional relationship between spool (1) and body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). q Metering spring (2) contracts in proportion to the stroke of the control lever. q Pressure at port (P1) also rises in proportion to the stroke of the control lever. q The control valve spool moves to a position where the pressure in chamber (PB) (equal to the pressure in port (P1)) is balanced with the force of the control valve spool return spring.

10-600

52



When in fine control mode (when control lever is returned) q If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). q Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). q Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. q When the control valve spool returns, the pressurized oil in drain chamber (D) flows in through fine control hole (f') of the valve which is not in operation and then flows through port (P4) into chamber (PA).


SEN03928-00 When lever is operated to stroke end q Lever (5) and rod (4) push down piston (8) and retainer (9) pushes down spool (1). q Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). q The pilot pressure oil from the HST charge pump flows through fine control hole (f) and port (P1) into chamber (PB) to push the control valve spool. q The oil returning from chamber (PA) flows through port (P4) and fine control hole (f') into drain chamber (D).

10-600

53

SEN03928-00


When lift arm is "float" q As lever (5) pushes down rod (4) and piston (8) on port (P3) "lower" side, the detent starts operation before the stroke end. (the operating effort of the lever becomes heavy.) q If rod (4) is pushed down further, the detent operates to keep the lift arm in "float" state even if the lever is released. q At the same time, the control valve is also moved to the "float" position to keep the lift arm in float condition.

When "float" state of lift arm is reset When returning lever (5) from the "float" position, the rod is pushed down with a force larger than absorptive power of the solenoid. q The "float" state also can be reset and the lever can be returned to the "neutral" position by turning off the current in the solenoid (deenergizing the solenoid). q

q

The lift arm raise and bucket tilt operations are carried out similarly to the above.

10-600

54




SEN03928-00

10-600

55


SEN03928-00 Attachment PPC valve

a

For the details of operation, see the paragraph of "Work equipment PPC valve".

10-600

56



SEN03928-00

P: From HST charge pump P1: To attachment valve P2: To attachment valve T: To tank 1. Spool 2. Piston 3. Lever 4. Plate 5. Retainer 6. Body 7. Filter Unit: mm

No.

Item

Criteria

Remedy

Standard size

8

9

Centering spring

Metering spring


Repair limit


Installed length

Installed load

Free length

Installed load

41.1 x 15.5

29

36.3 N {3.7 kg}

—

29.0 N {2.96 kg}

22.73 x 8.1

22

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}


10-600

57

600 Hydraulic system Lock valve

SEN03928-00

Lock valve

1

1. Lever 2. End cap 3. Ball 4. Seat 5. Body Outline q The lock valve is installed between the HST charge pump and work equipment PPC valve. As the work equipment lock lever is set to the "Lock" position, this valve, in conjunction with the work equipment lock lever, cuts off the oil of the PPC circuit to disable the work equipment operation.

10-600

58


600 Hydraulic system Accumulator (for PPC circuit)

SEN03928-00

Accumulator (for PPC circuit)

1

1. Gas plug 2. Poppet 3. Holder 4. Bladder 5. Film 6. Shell 7. Oil port Outline q This accumulator is installed between the charge valve and work equipment PPC valve. Even if the engine stops with the work equipment raised, the pressure of the compressed nitrogen gas in the accumulator applies the pilot oil pressure to the work equipment control valve so that the work equipment will lower by its weight. Specifications


Gas used

Nitrogen gas

Amount of gas (cc)

500

Charged pressure (MPa {kg/cm2})

1.18(+0.2/0) {12(+2/0)} (at 80°C)


3.92 {40}

10-600

59

SEN03928-00

Quick coupler solenoid valve

600 Hydraulic system Quick coupler solenoid valve

1

WA320PZ-6

P: From work equipment control valve port B2 T: To work equipment control valve port A2 A: To coupler plunger head side B: To coupler plunger bottom side 1. Body 2. Solenoid 3. Check valve 1 4. Check valve 2

10-600

60

Outline q When an attachment is installed or removed, the quick coupler solenoid valve changes the oil flow for the coupler plunger electrically to extract or retract the coupler plunger and connect or disconnect the attachment and quick coupler.


600 Hydraulic system ECSS valve

SEN03928-00

ECSS valve

1

(If equipped) a

ECSS: Abbreviation for Electronically Controlled Suspension System

P: From work equipment pump T: To hydraulic tank A: From lift cylinder bottom B: From lift cylinder head SP: To accumulator (for ECSS)


10-600

61

SEN03928-00

600 Hydraulic system ECSS valve

1. Main spool 2. Solenoid valve 3. Flow control valve 4. Shuttle valve 5. Charge valve

10-600

62


600 Hydraulic system Accumulator (for ECSS)

SEN03928-00

Accumulator (for ECSS)

1

(If equipped) 1. Valve 2. Top cover 3. Cylinder 4. Free piston Function q This accumulator is installed to the lift cylinder bottom circuit. The space between cylinder (3) and free piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the oil pressure pulses generated on the lift cylinder bottom side during travel for higher travel performance and operating performance by utilizing its compressibility. Specifications


Gas used

Nitrogen gas

Amount of gas (cc)

3,000

Charged pressure (MPa {kg/cm2})

2.0 ± 0.1 {20 ± 1} (at 20°C)


20.6 {210}

10-600

63

SEN03928-00



10-600

64

SEN03929-01





10

700 Work equipment Work equipment linkage ................................................................................................................................. 2 Bucket ............................................................................................................................................................. 6 Bucket positioner and boom kick-out ............................................................................................................ 10 Work equipment cylinder .............................................................................................................................. 22


10-700

1

SEN03929-01

Work equipment linkage

700 Work equipment Work equipment linkage

1

WA320-6

10-700

2



SEN03929-01

1. Bucket 2. Bell crank 3. Bucket cylinder 4. Lift cylinder 5. Lift arm 6. Bucket link Unit: mm

No. 7

Check item Clearance between bushing and pin at each end of bucket link

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

–0.030 –0.076

+0.174 +0.100

0.130 – 0.250

1.0

Standard size

8

Clearance between bushing and pin connecting lift arm and bucket

75

–0.030 –0.076

+0.174 +0.100

0.130 – 0.250

1.0

9

Clearance between bushing and pin connecting lift arm and frame

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

95

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

95

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

Clearance between bushing and pin

10 connecting bucket cylinder bottom and frame Clearance between bushing and pin

11 connecting bucket cylinder rod and bell crank between bushing and pin 12 Clearance connecting bell crank and lift arm Clearance between bushing and pin

13 connecting lift cylinder rod and lift arm Clearance between bushing and pin

14 connecting lift cylinder bottom and frame

Width of boss

Width of hinge

Tolerance

Standard size

Tolerance

Standard clearance

90

0 –0.5

93

±1.5

1.5 – 5.0

part of lift arm and 16 Connecting frame

105

—

109

±1.5

2.5 – 5.5

part of lift arm and 17 Connecting bucket

105

—

108

+1.5 0

3.0 – 4.5

part of bucket link and 18 Connecting bucket

104

+2.8 –0.5

109

+1.5 0

2.2 – 7.0

part of lift cylinder and 19 Connecting frame

85

0 –0.5

89

±1.5

2.5 – 6.0

part of bell crank and 20 Connecting bucket link

104

+2.8 –0.5

109

±1.5

0.7 – 7.0

part of bell crank and lift 21 Connecting arm

194

±0.5

197

±0.5

2.0 – 4.0

part of bucket cylinder 22 Connecting and bell crank

90

0 –0.5

93

±1.5

1.5 – 5.0

part of lift arm and lift 23 Connecting cylinder

85

—

88

±1.5

1.5 – 4.5

part of bucket cylinder 15 Connecting and frame


Standard size

Replace (Replace pin when it has scuff marks, too.)

Adjust shim so that clearance will be below 1.5 mm on each side

Replace


10-700

3

SEN03929-01


WA320PZ-6

10-700

4



SEN03929-01

1. Bucket 2. Bell crank 3. Bucket cylinder 4. Lift cylinder 5. Lift arm 6. Bucket link 7. Quick coupler Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

Clearance between bushing and pin connecting lift arm and quick coupler

75

–0.030 –0.076

+0.174 +0.100

0.130 – 0.250

1.0

between bushing and pin 10 Clearance connecting lift arm and frame

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

110

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

85

–0.036 –0.090

+0.207 +0.120

0.156 – 0.297

1.0

8

9

Clearance between bushing and pin at each end of bucket link

Standard size

Clearance between bushing and pin

11 connecting bucket cylinder bottom and frame Clearance between bushing and pin

12 connecting bucket cylinder rod and bell crank between bushing and pin 13 Clearance connecting bell crank and lift arm Clearance between bushing and pin

14 connecting lift cylinder rod and lift arm Clearance between bushing and pin

15 connecting lift cylinder bottom and frame

Width of boss part of bucket cylinder 16 Connecting and frame

part of lift arm and 17 Connecting frame

Width of hinge

Tolerance

Standard size

Tolerance

Standard clearance

110

0 –0.5

114

±1.5

2.5 – 6.0

105

—

109

±1.5

2.5 – 5.5 3.0 – 4.5

Standard size

Replace (Replace pin when it has scuff marks, too.)


part of lift arm and quick 18 Connecting coupler

105

—

108

+1.5 0

part of bucket link and 19 Connecting quick coupler

108

±1.0

112

+1.5 0

3.0 – 6.5

part of lift cylinder and 20 Connecting frame

85

0 –0.5

89

±1.5

2.5 – 6.0

part of bell crank and 21 Connecting bucket link

108

±1.0

112

±1.5

1.5 – 6.5

part of bell crank and lift 22 Connecting arm

194

—

196

+1.5 –0.5

1.5 – 3.5

Replace

part of bucket cylinder 23 Connecting and bell crank

110

0 –0.5

112

±1.5

0.5 – 4.0

part of lift arm and lift 24 Connecting cylinder

84

—

88

±1.5

2.5 – 5.5



10-700

5

700 Work equipment Bucket

SEN03929-01

Bucket

1

WA320-6

1. Bucket 2. Wear plate 3. Bolt-on cutting edge

10-700

6

4. Bucket teeth (if equipped) 5. Adapter



SEN03929-01

Unit: mm

No. 6

Check item

Criteria Repair limit

31.8

19

90

5

Tooth

46

21

Tip tooth

48

36

Max. 0.5

—

Wear of cutting edge (thickness)

7

Wear of cutting edge (length)

8

Wear of bucket teeth

9

Remedy

Standard size

Reverse or replace

Replace

Clearance in adapter mounting parts


Adjust or replace

10-700

7


SEN03929-01 WA320PZ-6

1. Bucket 2. Bolt-on cutting edge

10-700

8

3. Bucket teeth (if equipped) 4. Adapter (if equipped)



SEN03929-01

Unit: mm

No. 5

Check item

Criteria Repair limit

31.8

19

90

5

Tooth

46

21

Tip tooth

48

36

Max. 0.5

—

Wear of cutting edge (thickness)

6

Wear of cutting edge (length)

7

Wear of bucket teeth

8

Remedy

Standard size

Reverse or replace

Replace

Clearance in adapter mounting parts


Adjust or replace

10-700

9

700 Work equipment Bucket positioner and boom kick-out

SEN03929-01

Bucket positioner and boom kick-out

1

WA320-6

1. Bucket positioner proximity switch 2. Boom kick-out proximity switch 3. Bar

4. Bucket cylinder 5. Lift arm 6. Plate Unit: mm

No.

Check item

Criteria

7

Clearance on bucket positioner proximity switch

3–5

8

Clearance on boom kick-out proximity switch

3–5

10-700

10

Remedy Adjust



SEN03929-01

Outline Bucket positioner q The bucket positioner is driven electrically. When the bucket is returned to an angle from the dump position to the tilt position, the bucket positioner returns the work equipment (bucket) control lever from the "tilt" position to the "hold" position to automatically stop the bucket at a proper digging angle. q Bar (3) is fixed to the rod side of bucket cylinder (4). And proximity switch (1) is fixed to the cylinder side. q Moving the work equipment (bucket) control lever from "dump" position to "tilt" position moves the rod of bucket cylinder (4) toward the machine front side. As bar (3) moves a specific distance, proximity switch (1) detects that it is away from the sensing face, and returns the work equipment (bucket) control lever to "hold" position. Boom kick-out q The boom kick-out is driven electrically. As the lift arm is raised to an angle before reaching the maximum height, the boom kick-out returns the work equipment (lift arm) control lever from the "raise" position to the "hold" position to stop the lift arm automatically at a desired height. q Plate (6) is fixed to lift arm (5). And proximity switch (2) is fixed to the front frame. q Moving the work equipment (lift arm) control lever from "lower" position to "raise" position moves lift arm (5) upward. As plate (6) moves a specific distance, proximity switch (2) detects that it is away from the sensing face, and returns the work equipment (lift arm) control lever to "hold" position.


10-700

11


SEN03929-01 Operation of proximity switch When bucket is tilted

q

While the bucket is dumped more than the position being set from the bucket positioner, bar (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch (1) lamp. At this point, bucket positioner relay (4) is "ON" and current flows to detent solenoid (6) of work equipment PPC valve (5) to energize the coil.

10-700

12

q

Shifting work equipment (bucket) control lever (7) toward the tilt position moves spool (8) to the position of the arrow. And spool is held there by the energized coil of detent solenoid (6). As a result, work equipment (bucket) control lever (7) is held at "tilt" position and the bucket tilts.



SEN03929-01 a

The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is turned off since L signal from alternator (10) is not sent to alternator relay (11) as long as the engine is stopped. As the result, the work equipment (bucket) control lever (7) cannot be moved and held in the tilt position as long as bar (2) is positioned in sensing face of proximity switch (1).

Function of proximity switch When object of sensing is over sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid

Turned ON ON Power ON Energized

When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid

q

Turned OFF OFF Power OFF De-energized

As the bucket is tilted and moved away from the position set by the positioner, in other words, as bar (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) goes off and bucket positioner relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held bucket spool (8) receives the reaction force of spring (9) and returns work equipment (bucket) control lever (7) to "hold" position.


10-700

13


SEN03929-01 When lift arm is raised

q

While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch (1) lamp. At this point, boom kick-out relay (4) is "ON" and current flows to detent solenoid (6) of work equipment PPC valve (5) to energize the coil.

10-700

14

q

Shifting work equipment (lift arm) control lever (7) toward the raise position moves spool (8) to the position of the arrow. And spool is held there by the energized coil of detent solenoid (6). As a result, work equipment (lift arm) control lever (7) is held at "raise" position and lift arm (3) rises.



SEN03929-01 a

The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is cut off since L signal from alternator (10) is not sent to alternator relay (11) as long as the engine is stopped. As the result, the work equipment (lift arm) control lever (7) cannot be moved and held in the raise position as long as plate (2) is positioned in sensing face of proximity switch (1).

Function of proximity switch When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid


When object of sensing is over sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid

q


As lift arm (3) is raised and moved away from the position set by the boom kick-out, namely as plate (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) goes off and boom kick-out relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held lift arm spool (8) receives the reaction force of spring (9) and returns work equipment (lift arm) control lever (7) to the "hold" position.


10-700

15


SEN03929-01 WA320PZ-6

1. Fork positioner proximity switch 2. Bucket positioner proximity switch 3. Boom kick-out proximity switch 4. Bar

5. Bucket cylinder 6. Lift arm 7. Plate

Unit: mm

No.

Check item

Criteria

8

Clearance on bucket positioner proximity switch

3–5

9

Clearance on boom kick-out proximity switch

3–5

10-700

16

Remedy Adjust



SEN03929-01

Outline Bucket positioner or fork positioner q The bucket positioner is driven electrically. When the bucket or fork is returned to an angle from the dump position to the tilt position, the bucket positioner returns the work equipment (bucket or fork) control lever from the "tilt" position to the "hold" position to automatically stop the bucket or fork at a proper digging angle or lift angle. q Bar (4) is fixed to the rod side of bucket cylinder (5). And proximity switches (1) and (2) are fixed to the cylinder side. q Moving the work equipment (bucket or fork) control lever from "dump" position to "tilt" position moves the rod of bucket cylinder (5) toward the machine front side. As bar (4) moves a specific distance, proximity switches (1) and (2) detect that it is away from the sensing face, and return the work equipment (bucket or fork) control lever to "hold" position. q While the attachment selector switch of the right-hand console is in the "BUCKET" position, proximity switch (2) operates. While the former is in the "FORK" position, proximity switch (1) operates. Boom kick-out q The boom kick-out is driven electrically. As the lift arm is raised to an angle before reaching the maximum height, the boom kick-out returns the work equipment (lift arm) control lever from the "raise" position to the "hold" position to stop the lift arm automatically at a desired height. q Plate (7) is fixed to lift arm (6). And proximity switch (3) is fixed to the front frame. q Moving the work equipment (lift arm) control lever from "lower" position to "raise" position moves lift arm (6) upward. As plate (7) moves a specific distance, proximity switch (3) detects that it is away from the sensing face, and returns the work equipment (lift arm) control lever to "hold" position.


10-700

17


SEN03929-01 Operation of proximity switch

When bucket is tilted a The case when the attachment selector switch is in the "BUCKET" position is shown below.

q

While the bucket is dumped more than the position being set from the bucket positioner, bar (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch (1) lamp. At this point, bucket positioner relay (4) is "ON" and current flows to detent solenoid (6) of work equipment PPC valve (5) to energize the coil.

10-700

18

q

Shifting work equipment (bucket) control lever (7) toward the tilt position moves spool (8) to the position of the arrow. And spool is held there by the energized coil of detent solenoid (6). As a result, work equipment (bucket) control lever (7) is held at "tilt" position and the bucket tilts.



SEN03929-01 a

The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is turned off since L signal from alternator (10) is not sent to alternator relay (11) as long as the engine is stopped. As the result, the work equipment (bucket) control lever (7) cannot be moved and held in the tilt position as long as bar (2) is positioned in sensing face of proximity switch (1).

Function of proximity switch When object of sensing is over sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid


When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid

q


As the bucket is tilted and moved away from the position set by the positioner, in other words, as bar (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) goes off and bucket positioner relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held bucket spool (8) receives the reaction force of spring (9) and returns work equipment (bucket) control lever (7) to "hold" position.


10-700

19


SEN03929-01 When lift arm is raised

q

While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch (1) lamp. At this point, boom kick-out relay (4) is "ON" and current flows to detent solenoid (6) of work equipment PPC valve (5) to energize the coil.

10-700

20

q

Shifting work equipment (lift arm) control lever (7) toward the raise position moves spool (8) to the position of the arrow. And spool is held there by the energized coil of detent solenoid (6). As a result, work equipment (lift arm) control lever (7) is held at "raise" position and lift arm (3) rises.



SEN03929-01 a

The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is cut off since L signal from alternator (10) is not sent to alternator relay (11) as long as the engine is stopped. As the result, the work equipment (lift arm) control lever (7) cannot be moved and held in the raise position as long as plate (2) is positioned in sensing face of proximity switch (1).

Function of proximity switch When object of sensing is over sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid


When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid

q


As lift arm (3) is raised and moved away from the position set by the boom kick-out, namely as plate (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) lamp goes off and boom kick-out relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held lift arm spool (8) receives the reaction force of spring (9) and returns work equipment (lift arm) control lever (7) to the "hold" position.


10-700

21

700 Work equipment Work equipment cylinder

SEN03929-01

Work equipment cylinder

1

WA320-6 Lift cylinder

Bucket cylinder

Unit: mm

No.

1

Check item


10-700

22

Criteria Cylinder name

Standard size

Lift Bucket

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

–0.030 –0.076

+0.279 +0.065

0.095 – 0.355

0.655

80

–0.030 –0.076

+0.258 +0.048

0.078 – 0.334

0.634

Replace bushing


700 Work equipment Work equipment cylinder

SEN03929-01

WA320PZ-6 Lift cylinder

Bucket cylinder

Coupler plunger

Unit: mm

No.

1

Check item


Criteria Cylinder name

Standard size

Lift

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

–0.030 –0.076

+0.279 +0.065

0.095 – 0.355

0.655

Bucket

110

–0.036 –0.090

+0.261 +0.047

0.083 – 0.351

0.651

Coupler plunger

20

–0.020 –0.072

-0.081 –0.009

0.011 – 0.153

0.453


Replace bushing

10-700

23

SEN03929-01



10-700

24

SEN03930-00





10

800 Cab and its attachments Cab ................................................................................................................................................................. 3 Air conditioner ................................................................................................................................................. 4


10-800

1

SEN03930-00

10-800

2

800 Cab and its attachments


800 Cab and its attachments Cab

SEN03930-00

Cab

1

1. Front working lamp 2. Radio antenna 3. Door (left) 4. Air conditioner external air filter 5. Front glass 6. Front wiper 7. KOMTRAX GPS antenna 8. KOMTRAX communication antenna 9. Door (right) 10. Rear wiper


10-800

3

800 Cab and its attachments Air conditioner

SEN03930-00

Air conditioner Air conditioner piping diagram

10-800

4

1 1



1. Hot water take-out piping 2. Compressor 3. Condenser 4. Receiver 5. Hot water return piping 6. Refrigerant piping 7. External air filter 8. Internal/external air changeover damper 9. Blower unit 10. Air conditioner unit 11. Dual pressure switch 12. Air outlet duct 13. Cool and hot box (if equipped) 14. Internal air filter


SEN03930-00 Specifications Refrigerant used

R134a

Refrigerant refilling level (g)

900

10-800

5


SEN03930-00 Refrigerant circuit diagram

1. Engine 2. Compressor 3. Condenser 4. Receiver 5. Air conditioner unit 6. Dual pressure switch Table of tightening torque for refrigerant piping adapter Unit: Nm {kgm}

No.

Check item

Criteria

7

Air conditioner unit refrigerant inlet side

12 – 15 {1.2 – 1.5} (screw size: M16 x 1.5)

8

Air conditioner unit refrigerant outlet side

30 – 35 {3.1 – 3.6} (screw size: M24 x 1.5)

9

Receiver refrigerant pipe set bolt

8 – 12 {0.8 – 1.2} (screw size: M16 x 1.0)

10 Compressor refrigerant piping lock bolt

20 – 25 {2.0 – 2.6} (screw size: M8 x 1.25)

11 Condenser refrigerant inlet side

20 – 25 {2.0 – 2.6} (screw size: M22 x 1.5)

12 Condenser refrigerant outlet side

12 – 15 {1.2 – 1.5} (screw size: M16 x 1.5)

10-800

6

Remedy

Retighten



SEN03930-00

Air conditioner unit

A: From receiver B: To compressor C: Hot water inlet D: Hot water outlet 1. Evaporator 2. Heater core 3. Air mix damper (upper) 4. Air mix damper (lower) 5. Expansion valve 6. Blower controller 7. Blower motor relay 8. Compressor clutch relay 9. Air mix damper actuator 10. Evaporator temperature sensor 11. Dual pressure switch

1

Outline q The vertical air conditioner unit on which evaporator (1) and heater core (2) is synchronized with the blower and intake unit to generate cool and hot air. q The temperature adjusting switch on the air conditioner panel controls air mix dampers (3) and (4) to adjust the spurting out temperature. Cooler The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling). q Air taken in by the blower and intake unit is cooled with evaporator (1) and then blown out from the duct and grill. q

Heater q The heater circulates engine coolant in heater core (2) to cause heat exchange (heating). q Air taken in by the blower and intake unit is heated with heater core (2) and then blown out through the duct and grill.


10-800

7


SEN03930-00 Functions of major components Evaporator q Evaporator fin is cooled by the low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fin. Heater core q Fin of the heater core is heated by the hot water (cooling) being sent from the engine. Air from the blower motor is heated as it passes through the fin. Expansion valve This valve converts high-pressure, high-temperature liquid refrigerant from the receiver to low-pressure, low-temperature misty refrigerant through the throttling function. It controls flow rate of refrigerant by changing level of throttling depending on the thermal load in the operator's cab.

q

Blower controller q It controls the blower motor speed receiving signal current from the air conditioner panel. Blower motor relay q Signal current from the air conditioner panel controls the relay coil. As the relay coil is energized and the switch is turned "ON", power is supplied to the blower motor.

Air mix damper actuator q It starts the built-in motor receiving signal current from the air conditioner panel in order to open or close the air mix damper through the link mechanism. q The motor rotating direction is determined as the air conditioner panel reads the position of the potentiometer being built in the actuator. This reading is done as the target temperature is set from the temperature adjustment switch on the air conditioner panel. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, moves away or signal current from the air conditioner panel is turned "OFF". Evaporator temperature sensor q In order to prevent freezing of the evaporator, it senses the evaporator temperature and sends necessary signals to the air conditioner panel. The signal sent to the air conditioner panel is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator. Dual pressure switch If abnormally low or high pressure was generated in the refrigerant circulation circuit, this switch releases the magnet clutch of the compressor to protect a series of cooler-related equipment.

q

Compressor clutch relay q Signal current from the air conditioner panel dual pressure switch is used for controlling the relay coil. As the relay coil is energized and the switch is turned "ON", the magnet clutch of the compressor is connected.

LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}

10-800

8



SEN03930-00

Blower and intake unit

1. Blower motor assembly 2. Internal/external air changeover damper actuator 3. Internal/external air changeover damper

1

Functions of major components Blower motor assembly q It suctions air by rotating the fin installed on the blower motor. And it is also used for sending the absorbed air to the evaporator and heater core. Internal/external air changeover damper actuator q Receiving signal current from the air conditioner panel, it starts the built-in motor to open or close the internal/external air changeover damper through the link mechanism. q The motor rotation direction is determined from the internal/external air changeover switch on the air conditioner panel. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, moves away or signal current from the air conditioner panel is turned "OFF".


10-800

9

SEN03930-00


Compressor

1

A: From air conditioner unit B: To condenser

Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications

10-800

10

Number of cylinders – Bore x Stroke (mm)

7 – 29.3 x 27.4

Piston capacity (cc/rev)

129.2

Allowable maximum speed (rpm)

4,000

Refrigerant oil used

Sanden: SP-10

Refrigerant oil refilling volume (cc)

135



SEN03930-00

Condenser

A: From compressor B: To receiver

1

Function q It cools and liquefies the high-pressure and high-temperature misty refrigerant from the compressor. a

If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.

Specifications


Fin pitch (mm)

1.5

Total heat dissipation area (m2)

6.55


3.6 {36}

10-800

11


SEN03930-00

Receiver

A: From condenser B: To air conditioner unit 1. Sight glass

1

Function q It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. q Sight glass (1) allows inspecting flow of the refrigerant. Specifications

10-800

12

Effective cubic capacity (cm3)

578

Weight of desiccating agent (g)

300




SEN03930-00

10-800

13


SEN03930-00

Air conditioner panel

1

Display unit No.

Display category

1 Gauge 2

3 Pilot 4

Display items

Display range

Display method

Spurting out temperature Air blasting volume

See above drawing See above drawing

All segments below applicable level come on (8-step display) All segments below applicable level come on (4-step display) The display indicates which is currently taking place - internal air circulation or external air introduction - responding to the operation of the internal/external air changeover switch.

Circulation of internal air and introduction of external air

When circulating internal air and introducing external air

Air conditioner

When air Turns "ON" air conditioner switch, this lamp conditioner switch lights up. is "ON"

Display Remarks color

Black

Liquid crystal

Switch block No.

Switch name

Function

Operation Circulation of internal air IO Introduction of external air OFF io ON

5

Internal/external air changeover switch

This switch is used to select either the circulation of internal air or introduction of external air (pilot display on the display unit is switched depending on the switch setting)

6

Air conditioner switch

It turns on or off the cooling and the dehumidifying heating function.

7

Main power switch

8

Fan switch

9

Temperature adjusting switch

10-800

14

It turns on or off main power supply of the air conditioner. ON: Settings done during "OFF" are indicated on the display unit. OFF: Turns off the display unit lamp and stops the fan. It controls volume of air sent from the fan. (adjusted in 4 steps [LO, M1, M2 and HI]) It controls the spurting out temperature (8-step adjustment)

OFF io ON LO io HI Low temperature IO High temperature



SEN03930-00

Outline q CPU (central processing unit) installed on the panel processes input signals from respective sensors and operation signals of the panel switches to display and output them. q The self-diagnosis function of CPU makes the troubleshooting easier. Input and output signals JAE IL-AG5-14P [CN-C48] Pin No.

Signal name

JAE IL-AG5-22P [CN-C47] Input and output signals

Pin No.

Input and output signals

Signal name

1

GND

—

1

NC

2

Sensor ground

—

2

NC

—

3

Internal/external air changeover damper actuator limiter

Input

3

Blower motor relay

4

External air temperature sensor

Input

4

Internal/external air changeover damper actuator output 1

Output

5

Internal/external air changeover damper actuator output 2

Output

— Input

5

Evaporator temperature sensor

Input

6

Internal air temperature sensor

Input

7

Starting switch (ON)

Input

6

Mode selector actuator output 2

Output

Input

7

Mode selector actuator output 1

Output

—

8

Air mix damper actuator output 2

Output

—

9

Air mix damper actuator output 1

Output

10

Actuator potentiometer power supply (5 V)

—

8 9 10

Night lamp signal NC NC

11

NC

—

12

NC

—

13

Day light sensor 2

Input

14

Day light sensor 1

Output


11

NC

—

12

NC

—

13

NC

—

14

NC

15

Magnet clutch

— Input

16

Air mix damper actuator limiter

Input

17

Mode selector actuator limiter

Input

18

Air mix damper actuator potentiometer

Input

19

Mode selector actuator potentiometer

Input

20

Blower gate

Input

21

Blower feedback

Input

22

Actuator potentiometer ground

—

10-800

15

SEN03930-00



10-800

16

SEN03931-01





10

910 Electrical system, Part 1 Machine monitor system ................................................................................................................................. 2 Machine monitor ............................................................................................................................................. 6


10-910

1

910 Electrical system, Part 1 Machine monitor system

SEN03931-01

Machine monitor system Outline q In the machine monitor system, each controller on the network monitors controls the machine condition with the sensors installed to various parts of the machine, and then sends the result as network information to the machine monitor, which displays the information to notify the operator of the machine condition. q

The machine monitor displays the information in the operator mode or service mode.

q

The operator mode is used to display the information to the operator normally. The major functions used in the service mode are as follows.

1.

Items always displayed q Meters (speedometer or engine tachometer) q Gauges (engine coolant temperature gauge, HST oil temperature gauge and fuel gauge) q Pilot indicators q Service meter

1

4.

In addition to the above, the following display, setting and adjustment functions are provided using the character display and the machine monitor mode selector switch, which is the operation switch of the character display. 1) Switching of traction level 2) Switching of HST reverse travel gear shifting pattern 3) Display the odometer 4) Resetting the filter or oil replacement time 5) Input the telephone number 6) Selecting the language 7) Adjusting the illuminance of nighttime light 8) Travel speed/engine speed display selecting function 9) Function for setting display/no-display of travel speed or engine speed to the character display

The following items are displayed according to the set state of the optional device selecting function. q Travel speed or engine speed indication on the character display 2.

Items displayed when abnormality is detected q Caution lamps q Action code (while an action code is displayed, if the machine monitor mode selector switch (>) is pressed and released, the failure code (6 digits) is displayed.)

3.

At the replacement period of a filter or oil, the character display displays that filter or oil. (maintenance monitoring function)

10-910

2



q

1.

The service mode function is provided for the ease of troubleshooting for the controllers on the network (including the machine monitor itself). The major functions used in this mode are as follows. Electrical system failure history display function The electrical system failures of each controller saved in the machine monitor are displayed. The information of those failures is also deleted with this function.

2.

Mechanical system failure history display function The mechanical system failures of each controller saved in the machine monitor are displayed.

3.

Real-time monitoring function The input and output signals recognized by each controller on the network are displayed in real time.

4.

Engine reduced-cylinder function This function is used for the purpose of specifying cylinder having defective combustion by stopping fuel injection to each cylinder from the fuel injector.

5.

No injection cranking function Before restarting engine after a long-term storing of the machine, this function is used to lubricate the engine internally.

6.

Adjustment function Functions are provided to correct and adjust the installation errors and manufacturing dispersion of the sensors, solenoid valves, etc. Function for changing control characteristics is provided on user request.

7.

Maintenance monitoring function Changes the filter or oil replacement time and makes ON/OFF selection of the function.

8.

Operating information display function Displays fuel consumption per operating hour.

9.

Optional device selecting function Verifies the installation of optional devices or changes their setting.


SEN03931-01 10. Machine serial number input function Enters the machine serial number to identify the machine. 11. Model selection function Enters the information of applicable model. 12. Initialize function Sets the machine monitor to the state set when the machine is delivered.

10-910

3

SEN03931-01


System circuit diagram a

Items marked with "*1" in drawing may or may not installed.

10-910

4




SEN03931-01

10-910

5

910 Electrical system, Part 1 Machine monitor

SEN03931-01

Machine monitor

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HST oil temperature gauge HST oil temperature caution lamp Engine coolant temperature gauge Engine coolant temperature caution lamp Speedometer or engine tachometer Turn signal pilot lamp (left) Head lamp high beam pilot lamp Turn signal pilot lamp (right) Fuel level caution lamp Fuel gauge Central warning lamp Brake oil pressure caution lamp Engine oil pressure caution lamp Water separator caution lamp Engine oil level caution lamp Radiator coolant level caution lamp HST oil filter clogging caution lamp Air cleaner clogging caution lamp Parking brake pilot lamp Brake oil temperature caution lamp

1

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Quick coupler operation pilot lamp (*2) Cooling fan reverse rotation pilot lamp Maintenance caution lamp Parking brake reminder caution lamp Battery charge circuit caution lamp Steering oil pressure caution lamp (*2) Emergency steering pilot lamp (*2) Meter display pilot lamp Character display portion Preheating pilot lamp Directional selector switch actuation pilot lamp (*2) Economy operation display lamp Shift hold pilot lamp (*1) S mode operation pilot lamp Traction control operation pilot lamp Travel speed range selector switch position pilot lamp Directional lever position pilot lamp

*1: Not used by this model *2: If equipped

10-910

6



SEN03931-01

List of items displayed on monitor

1

Condition for judging that the engine is running: If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the CAN communication occurs and the charge level exceeds the specified level. 1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered) 2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above after that) 3. Engine speed is 500 rpm or above Lamp

Lamp period

Alarm buzzer

Operating condition

Buzzer period

Priority

Period: 1,600 msec. ON: 800 msec. OFF: 800 msec. (duty 50%)

1

—

w: Intermittent sounds

Warning for dangerous condition (error or caution message is generated)

w: Flashing

Period: 1,600 msec. ON: 800 msec. OFF: 800 msec. (duty 50%)

A: Intermittent sounds

Caution for erroneous Period: 240 msec. operation (when an irregular ON: 80 msec. operation is done) OFF: 160 msec.

2

A: Intermittent

Period: 240 msec. ON: 80 msec. OFF: 160 msec.

E: Canceling sounds

Set cancellation such as calibration (inoperative state) ON: 1,000 msec. (1 time)

3

e: Completion sounds

Completion of setting such ON: 100 msec. as calibration (when normally OFF: 160 msec. ended) ON: 100 msec. (1 time)

4

1 2

HST oil temperature

Engine coolant temperature

LED

—

— —

—

When lamp switch is other than "OFF"

— —

—

— —

—

Other than below

— —

—

— —

—

Caution lamp: LED

10

1

w Q Q B@CRNS w Q Q B@CRNS

When abnormality is detected (out of input signal range)

20

5

— —

—

DGH1KX — —

—

— —

—

— —

—

9 10

3

0

—

Q —

—

Pointer: Movement Fuel level Caution lamp: LED


Display color

DGH1KX

Alarm: 105°C or above

w Q Q B@BCNS w Q Q B@BCNS

When abnormality is detected (high temperature)

— —

—

CA144

— —

—

CA144

When abnormality is detected (low temperature)

— —

—

CA145

— —

—

CA145

When engine speed display is selected

— —

—

— —

—

When travel speed display is selected

— —

—

— —

—

Other than below

— —

—

— —

—

Q —

10

1

—

When abnormality is detected (input voltage is 4 V or above and no incoming IGN-C signal is detected)

10

2

— —

—

—

DJF1KA

—

When a communication error is detected, the system displays "0". Max: 10 z Min: 85 z

Q —

— —

When the sensor is disconnected or hot shortcircuited: Max When sensor was disconnected or hot shortcircuited: Min

(selectable with the machine monitor setting) —

Min. 80 z

When the sensor is disconnected or hot shortcircuited: Max When sensor was disconnected or hot shortcircuited: Min

White range: 50 – 102°C Red range: 102 – 135°C

Q —

Caution lamp: LED

Pointer: Movement

Turned ON with errors (E03 and E02) of each controller, simultaneously displaying the message on the character display.

White range: 30 – 105°C Red range: 105 – 135°C

Alarm: 105°C or above

Pointer: Movement

Travel speed

Gauges and meters

Display of message

Red — —

Pointer: Movement

Engine speed 5

Alarm buzzer

Reset

For other than above, see "Operating condition, central warning lamp" of other items.

E

LED

Alarm: 102°C or above 3 4

E E E

E E E

Other than below

Gauges and meters

E

When error occurs

Remarks

White

Back light

Operating condition

Red

—

Central warning

Device

Red

Back light

11

Item

Engine is running

Red

Central warning lamp

No.

Operating condition Engine stopped Alarm buzzer

Category

Detection

Detecting time (sec)

Individual display Central warning lamp

—

Display of message

E: Separately set conditions


Q: ON

DJF1KA

When the sensor is grounded: Full When sensor was disconnected or hot shortcircuited: Empty

10-910

7


SEN03931-01

— —

—

— —

—

Engine speed

When engine speed display is selected

0

0

—

Q —

—

Q —

When travel speed display is selected

0

0

—

Q —

—

Q —

When F is selected (neutral safety is displayed as engine is stopped)

1

0

A Q Q

—

Q —

N

LED

When N is selected

0

0

—

Q —

—

Q —

R

LED

When R is selected (neutral safety is displayed as engine is stopped)

1

0

A Q Q

—

Q —

4

LED

When 4th gear speed is selected

0

0

—

Q —

—

Q —

3

LED

When 3rd gear speed is selected

0

0

—

Q —

—

Q —

2

LED

When 2nd gear speed is selected

0

0

—

Q —

—

Q —

1

LED

When 1st gear speed is selected

0

0

—

Q —

—

Q —

Turn signal

LED

When turn signal lever and hazard lamp switch signal is input

0

0

—

Q —

—

Q —

7

Head lamp high beam

LED

When head lamp is set to high beam (when head lamp is "ON" and dimmer switch is "ON")

0

0

—

Q —

—

Q —

Engine oil level

1

—

Below set pressure (OPEN) (detect time continues) and after 30 seconds elapsed since engine was started (no detection time)

5

1

— —

—

w Q Q

Normal oil pressure (CLOSE)

— —

—

— —

Low oil pressure (OPEN)

w Q Q B@BAZG w Q Q B@BAZG

Normal

— —

Water mixing with fuel

—

Normal oil level (CLOSE)

— —

Radiator coolant level

8

w Q Q

2G40ZG

Red

—

LED

—

— —

—

LED

Q — —

CA418

—

Q —

— —

CA418

—

LED 2

1

Normal coolant level (CLOSE)

—

Q — B@BAZK — — —

— —

—

— —

If low level is detected when starting switch is turned "ON", alarm is continued even after engine is started until adequate oil level is reached. Don't check the oil level for 300 sec, after stopping the engine.

—

LED Low coolant level (OPEN)

10-910

Display of message

1

Low oil level (OPEN)

16

—

Below set pressure (OPEN) (detection time continues) and 30 seconds after engine is started (no detection time)

Q —

Hazard lamp operates when starting switch is turned "OFF".

Red

Water separator

— —

Red

15

Engine oil pressure

LED

—

When error occurs in communication, condition is held until starting switch is turned "OFF".

Red

14

Brake oil pressure

— —

Green Green Green Green Green Green Orange Green

Travel speed range selector switch position

LED

6 8

13

km/h or MPH (setting of a desired value is available from the machine monitor)

Blue

Directional lever position

F

Normal oil pressure (CLOSE)

Other symbols

x 100 r/min (setting of a desired value is available from the machine monitor)

LED

Items related to gear shifting

12

Display color

Converts travel speed pulse into travel distance

Black

Odometer

Displays various codes and items according to the machine condition and switch operation.

Green

—

Green

— —

Travel speed

36

Alarm buzzer

—

LCD

28

37


— —

29

Remarks

Red

Unit

Engine is running

Operates when charging normally at 1 : 1 to the clock time

Service meter Character display

Operating condition

Display of message

Device

Alarm buzzer

Item

Operating condition Engine stopped Individual display Central warning lamp

No.

Reset

Category

Detection


30

1

—

Q — B@BCZK — Q — B@BCZK



SEN03931-01

Clogging (CLOSE) (HST oil temperature 50°C or above and no abnormality detected)

10

When abnormality is detected (clogging was detected as engine was stopped)

3

—

—

KEY — — OFF

—

— —

— —

LED

Other symbols

21

22

23

24

Quick coupler operation

Cooling fan reverse rotation

Maintenance

Parking brake reminder

— —

—

1

—

—

Q — AA1ANX

Q —

—

Q —

—

Released (CLOSE)

— —

—

— —

— —

—

A Q Q

— —

—

— —

0

0

—

—

Temperature rise (oil temperature: Min. 120°C (alarm)

5

5

—

Temperature rise (1. or 2.) 1. Oil temperature 130°C or above 2. Oil temperature 125°C or above and travel speed 35 km/h or above

5

5

w Q Q B@C6NS w Q Q B@C6NS

Q —

—

Q —

When abnormality is detected (ground fault)

— —

—

DGR2KB — —

—

DGR2KB

When abnormality is detected (disconnection or hot short-circuit)

— —

—

DGR2KZ — —

—

DGR2KZ

Other than below

— —

—

— —

—

LED

LED

LED

When quick coupler is disconnected

0

0

A Q — Remarks A Q — Remarks

Normal

0

0

— —

Reverse

0

0

—

Q — Remarks — Q — Remarks

Selecting reverse rotation

0

0

—

w —

Ordinary

— —

30 hours or less before maintenance or maintenance time

—

Other than below

— —

—

— —

—

—

Q — —

—

When parking brake is left unapplied (CLOSE)

0

0

Alarm buzzer is sounded when connection of quick coupler is reset. Error message is simultaneously displayed on the character display. "PIN DISCONNECT"

Error message is displayed on the character display as long as reverse rotation of fan is continued. "COOLING FAN REVERSE"

Message is simultaneously displayed on the character display.

Error message is displayed on the character display as long as parking brake is left unapplied. The alarm continues as long as starting switch is turned "OFF". This function can be enabled when "MECHA" is selected for "7: PKG BRAKE" from the "Option device selecting function" of the machine monitor.

w —

— —

E

To be released if the oil temperature is detected consecutively at lower than 125°C for 5 sec.

—

—

Q —

— —

E

—

LED


Display color

Display of message DHTCL6

Red

LED

2

Other than below

20

—

Operation (OPEN)

Engine is running, parking brake operated and the directional lever is at any position other than "N"

Brake oil temperature

—

Red

Parking brake

— —

LED Clogging (GND)

19

6091NX

Red

Air cleaner clogging

DHTCL6

Q —

Red

Normal (OPEN) 18

Alarm buzzer

— —

2

—

Orange

LED

— —

Red

HST oil filter clogging

—

Red

17

— —

Remarks

Red

Normal (OPEN)

Engine is running Individual display Central warning lamp

Operating condition

Display of message

Device


Item

Reset

No.

Operating condition Engine stopped Alarm buzzer

Category

Detection


w Q Q Remarks — — —

10-910

9


SEN03931-01

LED

Steering oil pressure

w Q Q AB00MA

1

— —

When abnormality is detected (unmatched engine condition and the signal)

3

1

w Q Q — —

—

Q —

0.5

0

—

3

(*) 1

— —

0

0

—

AB00L6

—

— —

—

— —

—

—

Display color

Display of message

—

30

LED

Alarm buzzer

— —

Engine is running, alternator voltage is below the specified level, and no incoming ING-C is present.

Oil pressure normal (OPEN)

26

—

Q —

Red

Battery charge circuit

If abnormality is detected when starting switch is turned "ON", alarm is continued even after engine is started.

— —

This function can be enabled when "ADD" is selected for "2: EMERG S/T" from the "Optional device selecting function" of the machine monitor. *: The function is reset immediately when engine is stopped. This function can be enabled when "ADD" is selected for "2: EMERG S/T" from the "Optional device selecting function" of the machine monitor.

Low oil pressure (CLOSE)

Oil pressure normal (OPEN) LED

— —

—

— —

—

Other than below

— —

—

— —

— Red

Low oil pressure (CLOSE)

LED 0

0

When directional lever is used

32

Directional selector switch actuation

Economy operation

35

10-910

10

S mode operation

Traction control operation

Q —

— —

—

—

Q —

— —

—

When directional selector switch is used

0

0

—

Directional lever priority caution

0

0

A w Q

A w Q

Directional selector switch neutral caution

0

0

A w Q

A w Q

Other than below

0

0

— —

— —

Economy mode operation

0

0

—

Q —

—

Q —

LED

—

—

LED

Other than below 34

—

Q —

— —

—

—

Q —

— —

—

LED S mode operation is selected

0

0

Other than below

—

Q —

— —

—

—

Q —

— —

—

LED Traction control operation is turned on

0

0

—

Q —

—

Q —

Green

When preheater is turned on

Other symbols

31

Q —

This function can be enabled when "ADD" is selected for "3: FNR" from the "Optional device selecting function" of the machine monitor. Not to be displayed when error is made in communication.

Green

Preheating

—

DDS5L6

Green

30

Q —

w — Q

Green

27

Emergency steering

—

Judgment for Abnormal o Normal: 12 V or above Judgment for Normal o Abnormal: 5 V or below

Red

25

Remarks

Green

Normal voltage

Engine is running Individual display Central warning lamp

Operating condition

Display of message

Device

Alarm buzzer

Item

Operating condition Engine stopped Individual display Central warning lamp

No.

Reset

Category

Detection


The lamp goes off when traction control is reset from max. traction switch. When traction control is reset with max. traction switch, the lamp is lit again when directional lever position is switched.



SEN03931-01

Machine monitor operation switch

1

1. Machine monitor mode selector switch 1 2. Machine monitor mode selector switch 2


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SEN03931-01 Setting of machine monitor


1

1. Spare rotary switch (SW1) 2. Spare rotary switch (SW2) 3. Spare rotary switch (SW3) 4. Spare dip switch (SW5-1) 5. Spare dip switch (SW5-2) 6. Spare dip switch (SW5-3) 7. Spare dip switch (SW5-4) 8. Spare dip switch (SW6-1) 9. Spare dip switch (SW6-2) 10. Spare dip switch (SW6-3) 11. Spare dip switch (SW6-4) a

It is prohibited to change setting of spare rotary switch and DIP switch.

Troubleshooting function q q q

1

The machine monitor monitors the input and output signals constantly for troubleshooting for the system. If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the machine monitor over the network. Abnormality information can be checked on the character display using the failure code display mode of the machine monitor.

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SEN03931-01

Character display function q q

a

1

Machine monitor display and setting can be changed by using the character display. The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure below. For the operating method in the operator mode, see the Operation and maintenance manual.

*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".


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SEN03931-01


Operator mode functions

1

Self-check screen (0th layer) q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON". q During a self-check, entry through the machine monitor operating switch is not accepted. q After ending the self-check, the self-check screen automatically moves to 1st layer.

Normal screen (1st layer) q If the item of "13: RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine monitor and the menu of "Engine speed display / non-display setting" is set to "rpm OFFoON" in the "Display of functions opened to the operator", engine speed is displayed to the character display when the travel speed is displayed at the center of the monitor. q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the character display. q Pressing the "U" switch changes the screen to the 2nd layer.

1. Engine speed display 2. Travel speed display A. In the case of "km/h" display B. In the case "MPH" display a

When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in "km/h".

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SEN03931-01

Failure code screen (1st layer) q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code screen. q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item of higher priority downward. If items have the same priority, the item that occurred most recently will be displayed first. Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)

*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 seconds in the Normal screen display. *2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the failure code screen or if a new alarm is turned ON. *3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial failure code screen.


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SEN03931-01


Display of functions opened to the operator (2nd layer or below) q Certain menus are not displayed unless the items in the "Optional device selecting function" of the machine monitor are set. q Pressing "U" switch allows selecting each menu. q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not pressed more than 60 seconds in the screen display of each menu. q The language will be displayed as set in the Language selection function. a See the "Operation and maintenance manual" for details of each menu.

*1: These menus are displayed when "ADD" is selected for "13: RPM/SPEED" item from the "Optional device selecting function" of the machine monitor. *2: These menus are displayed when "ADD" is selected for "12: RPM/OPT" item from the "Optional device selecting function" of the machine monitor. k

It is prohibited to select "ADD" for "12: RPM/OPT" from the "Optional device selecting function" of the machine monitor in the regions where the applicable law requires to display the travel speed.

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SEN03931-01

Service mode functions q q

Procedure for switching to Service Mode 1. Checking of the screen display Check that the character display is set to the 1st layer screen in the operator mode. 2.

1

The machine monitor is provided with service mode function for the ease of troubleshooting for the controllers on the network (including the machine monitor itself). Initial setting of the sensors and optional setting can be made in the service mode of the machine monitor.

3.

ID input and confirmation Operate the machine monitor mode selector switches 1 and 2 and enter ID. (ID: 6491)

Display of ID input initial screen Pressing "u" switch and "<" switch simultaneously for 5 seconds or more displays the ID entry initial screen. a Pressing down the 2 switches for 5 seconds or more makes the entire screen blank. As this state is recognized, release the switches.

1)

2)

3)

4)


The cursor (C) is located at the highestorder digit. Pressing "<" or ">" switch changes the value of this digit in the range of "0" to "9". Press "U" switch at the target value to validate it. a The cursor moves to the 2nd digit position. Confirm the values for the 2nd digit and onward following the same procedure. a If you have entered a wrong value to a p os it io n whe n the c ur s or was located at any position other than the highest-order digit, press "t" switch to move the cursor to the highestorder digit to enable to input correct value. In this case, the values already entered remain on the screen unchanged. a Pressing "t" switch when the cursor is located at the highest-order digit, the screen returns to the "1st layer" of the operator mode. a If switch is not operated more than 60 seconds on the "ID entry" screen, it automatically returns to the "1st layer" screen of the operator mode. If ID is acknowledged upon confirming the 4th digit, the screen changes to the "Electrical system failure history" selector screen.

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SEN03931-01


Service mode menu

a a a

Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequentially and endlessly. Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same menu. Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.

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SEN03931-01

Electrical system failure history display function (ELECTRIC FAULT)

Real-time monitoring function (REAL-TIME MONITOR)

a

"**" field displays total number of the failure history currently recorded. (max. 20 histories to be stored)

q

q

The history is used to check on the electrical system failures of each controller saved in the machine monitor. After repairing the failure content and verifying normal function, the failure history may be erased. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

a

a

This function is used to check on the input/output signals, etc. each controller on the network recognizes. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

Mechanical system failure history display function (MACHINE FAULT)

Engine reduced-cylinder function (CYLINDER CUT-OUT)

a

q

q

a

"**" field displays total number of the failure history currently recorded. (max. 20 histories to be stored) The history is used to check on the mechanical system failures of each controller saved in the machine monitor. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.


a

This function is used for the purpose of specifying cylinder having defective combustion by stopping fuel injection to each cylinder from the fuel injector. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

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SEN03931-01 No injection cranking function (NO INJECTION)

q

a

Before restarting engine after a long-term storing of the machine, this function is used to lubricate the engine internally. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

Adjustment function (TUNING)

q

a

This function is used for correcting and adjusting the installation errors and manufacturing dispersion of the sensors, solenoid valves, etc. Function for changing control characteristics is provided on user request. These functions are also used when sensors, valves and controllers are replaced or added. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

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Maintenance monitoring function (MAINTENANCE MONITOR)

q

a

This function is used for changing the filter and oil replacement timing and making ON/OFF selection of this function. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

Operating information display function (OPERATION INFO)

q

a

This function is used for displaying fuel consumption per operating hour. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.



Optional device selecting function (OPTIONAL SELECT)

SEN03931-01 Model selection function (MACHINE)

q q

a

This function is used for verifying the installed state of optional devices or when changing their setting. This function is also used for installing or removing optional devices. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

Machine serial number input function (MACHINE No. SET)

a a

Initialize function (INITIALIZE)

q q

a

This function is used for displaying or entering the serial number of machine. Serial number of the set machine is used for controlling the machine. For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.


This function is used for displaying or changing the setting of model information (machine name). For the operating procedure of this function, see "Special functions of machine monitor (EMMS)" in Testing and adjusting. The figure shows when "WA250" is selected.

a

This function is used to set the machine monitor to the state set when delivered. Since this function is specially handled by the factory, no modification is allowed.

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21


SEN03931-01 Input and output signals

1

AMP070-20P[CN-L24] Pin No.

Specifications

I/O

Group

Form of use

Signal name

1

(NC)

—

—

—

—

2

(NC)

—

—

—

—

3

(NC)

—

—

—

—

4

NSW power supply (+24 V)

I

—

Constant power supply (+24 V)


5


I

—

Constant power supply (+24 V)


6

SW power supply (+24 V)

I

—

Power supply (+24 V)


7


I

—

Power supply (+24 V)


8

(NC)

—

—

—

—

9

GND

I

—

GND

GND

10

GND

I

—

GND

GND

11

D_OUT_3 (+24 V, sink 200 mA)

O

A

D/O sink

ECSS relay

12

D_OUT_2 (+24 V, sink 200 mA)

O

A

D/O sink

Back-up lamp

13

(NC)

—

—

—

—

14

D_OUT_0 (+24 V, sink 200 mA)

O

A

D/O sink

Alarm buzzer

15

(NC)

—

—

—

—

16

(NC)

—

—

—

—

17

GND

I

—

GND

GND

18

GND

I

—

GND

GND

19

GND

I

—

GND

GND

20

GND

I

—

GND

GND

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22

Remarks

If equipped



SEN03931-01

AMP070-18P(1)[CN-L25] Pin No.

Specifications

I/O

Group

Form of use

Signal name

Remarks

1

D_IN_0 (24 V, 5 mA)

I

B

D/I (+24 V)

Head lamp

2

D_IN_2 (24 V, 5 mA)

I

B

D/I (+24 V)

Starting switch C signal

3

(NC)

—

—

—

—

4

D_IN_6 (24 V, 5 mA)

I

B

D/I (+24 V)

Quick coupler

If equipped

5

D_IN_8 (24 V, 5 mA)

I

B

D/I (+24 V)

ECSS switch

If equipped

6

(NC)

—

—

—

—

7

D_IN_12 (NSW24 V, 5 mA)

I

C

D/I (+24 V)

Turn signal lamp, right

8

D_IN_14 (NSW24 V, 5 mA)

I

C

D/I (+24 V)

U switch

9

GND

O

—

GND

Signal GND

10

D_IN_1 (24 V, 5 mA)

I

B

D/I (+24 V)

Cooling fan automatic reverse rotation switch (manual)

11

(NC)

—

—

—

—

12

(NC)

—

—

—

—

13

(NC)

—

—

—

—

14

D_IN_9 (24 V, 5 mA)

I

B

D/I (+24 V)

Cooling fan automatic reverse rotation switch (automatic)

15

(NC)

—

—

—

—

16

D_IN_13 (NSW24 V, 5 mA)

I

C

D/I (+24 V)

Turn signal lamp, left

17

D_IN_15 (NSW24 V, 5 mA)

I

C

D/I (+24 V)

t switch

18

A_IN_0 (0 – 30 V)

I

H

A/I

Alternator L signal


Specifications

I/O

Group

Form of use

Signal name

1

D_IN_16 (24 V/GND, 5 mA)

I

D

D/I (GND)

Brake oil pressure

2

(NC)

—

—

—

—

3

D_IN_20 (24 V/GND, 5 mA)

I

D

D/I (GND)


4

D_IN_22 (24 V/GND, 5 mA)

I

D

D/I (GND)

Traction control switch (S mode)

5

D_IN_24 (24 V/GND, 5 mA)

I

E

D/I (GND)

HST oil filter clogging

6

GND

O

—

GND

Sensor ground

7

D_IN_17 (24 V/GND, 5 mA)

I

D

D/I (GND)

ECSS cut off switch

8

D_IN_19 (24 V/GND, 5 mA)

I

D

D/I (GND)

(service mode 2 and 3)

9

D_IN_21 (24 V/GND, 5 mA)

I

D

D/I (GND)

ECSS cutoff switch dummy

10

(NC)

—

—

—

—

11

D_IN_25 (24 V/GND, 5 mA)

I

E

D/I (GND)

(optional switch)

12

A_IN_1 (0 – 30 V)

I

H

A/I

Clearance lamp and tail lamp


Remarks

If equipped

If equipped

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SEN03931-01


Specifications

I/O

Group

Form of use

Signal name

1

D_IN_26 (24 V/GND, 5 mA)

I

E

D/I (GND)

Parking brake

2

D_IN_28 (24 V/GND, 5 mA)

I

E

D/I (GND)

Parking brake left-unapplied prevention

3

D_IN_30 (24 V/GND, 5 mA)

I

E

D/I (GND)

Normal emergency steering

4

(NC)

—

—

—

—

5

D_IN_34 (24 V/GND, 5 mA)

I

F

D/I (GND)

Dimmer switch

6

D_IN_36 (24 V/GND, 5 mA)

I

G

D/I (GND)

Parking brake dummy

7

D_IN_38 (24 V/GND, 5 mA)

I

G

D/I (GND)

< switch

8

(NC)

—

—

—

—

9

GND

O

—

GND

GND

10

D_IN_27 (24 V/GND, 5 mA)

I

E

D/I (GND)

Coolant level

11

D_IN_29 (24 V/GND, 5 mA)

I

E

D/I (GND)

Engine oil level

12

(NC)

—

—

—

—

13

(NC)

—

—

—

—

14

D_IN_35 (24 V/GND, 5 mA)

I

F

D/I (GND)

Parking brake left-unapplied prevention dummy

15

D_IN_37 (24 V/GND, 5 mA)

I

G

D/I (GND)

> switch

16

D_IN_39 (24 V/GND, 5 mA)

I

G

D/I (GND)

Operation of emergency steering

17

(NC)

—

—

—

—

18

(NC)

—

—

—

—

Remarks

If equipped

If equipped


Specifications

I/O

Group

Form of use

Signal name

1

A_IN_2 (high-resistance input)

I

J

A/I

Fuel level sensor

2


I

J

A/I

HST oil temperature sensor

3

(NC)

—

—

—

—

4

(NC)

—

—

—

—

5

(NC)

—

—

—

—

6

GND

O

—

GND

GND

7


I

J

A/I

Brake oil temperature sensor

8

(NC)

—

—

—

—

9

(NC)

—

—

—

—

10

(NC)

—

—

—

—

11

GND

O

—

GND

(GND)

12

(NC)

—

—

—

—

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Remarks



SEN03931-01


Specifications

I/O

Group

Form of use

Signal name

1

(NC)

—

—

—

—

2

(NC)

—

—

—

—

3

CAN (+)

I/O

P

CAN

CAN (+)

4

(NC)

—

—

—

—

5

(NC)

—

—

—

—

6

GND

O

—

GND

GND

7

(NC)

—

—

—

—

8

CAN (–)

I/O

P

CAN

CAN (–)

9

(NC)

—

—

—

—

10

(NC)

—

—

—

—

11

(NC)

—

—

—

—

12

(NC)

—

—

—

—

Remarks

AMP070-14P[CN-L30] Pin No.

Specifications

I/O

Group

Form of use

Signal name

1

(NC)

—

—

—

—

2

(NC)

—

—

—

—

3

(NC)

—

—

—

—

4

(NC)

—

—

—

—

5

(NC)

—

—

—

—

6

(NC)

—

—

—

—

7

(NC)

—

—

—

—

8

(NC)

—

—

—

—

9

(NC)

—

—

—

—

10

(NC)

—

—

—

—

11

(NC)

—

—

—

—

12

(NC)

—

—

—

—

13

(NC)

—

—

—

—

14

(NC)

—

—

—

—


Remarks

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SEN03931-01

AMP040-8P Pin No.

Specifications

I/O

Group

Form of use

Signal name

Remarks

1

(NC)

—

—

—

—

Do not connect wiring harness on machine

2

(NC)

—

—

—

—


3

(NC)

—

—

—

—


4

(NC)

—

—

—

—


5

(NC)

—

—

—

—


6

(NC)

—

—

—

—


7

(NC)

—

—

—

—


8

(NC)

—

—

—

—


Setting switches (On circuit board) Switch No.

Specifications

I/O

Group

Form of use

Signal name

1

16 Posi rotary switch 1

I

—

—

(spare)

2


I

—

—

(spare)

3


I

—

—

(spare)

1

26 Posi DIP switch 1

I

—

—

(spare)

2


I

—

—

(spare)

3


I

—

—

(spare)

4


I

—

—

(spare)

1


I

—

—

(spare)

2


I

—

—

(spare)

3


I

—

—

(spare)

4


I

—

—

(spare)

Remarks

5

6

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SEN03931-01

10-910

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SEN03931-01



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SEN03932-02





10

920 Electrical system, Part 2 Electrical system (HST controller system) ...................................................................................................... 2 HST controller ............................................................................................................................................... 18 ECSS system................................................................................................................................................ 20 KOMTRAX system........................................................................................................................................ 22 Engine starting circuit.................................................................................................................................... 24 Engine stopping circuit.................................................................................................................................. 26 Preheating circuit .......................................................................................................................................... 27 Engine output derating function .................................................................................................................... 28 Automatic warm-up function ......................................................................................................................... 28 Parking brake circuit ..................................................................................................................................... 30 Coupler plunger control system .................................................................................................................... 32 Multi-function knob........................................................................................................................................ 33 Max. traction switch ...................................................................................................................................... 34 Sensor........................................................................................................................................................... 35


10-920

1

920 Electrical system, Part 2 Electrical system (HST controller system)

SEN03932-02

Electrical system (HST controller system) a

1

Except where otherwise specified, the displayed travel speed in this document represents the one when 20.5-25 tire is worn. Ao

o A HST motor 1 solenoid

Variable shift control switch

Ao

o D HST motor 2 solenoid relay

Traction control switch

Do

o A Clutch solenoid

Directional lever (F, N, R)

Do

o A Cooling fan motor flow rate control EPC valve

Directional selector switch (F, N, R)

Do

o D Cooling fan motor reverse rotation solenoid relay

Directional selector switch actuation switch

Do

o D Directional solenoid (F, R)

Parking brake lever intermediate switch

Do

o D HST controller power holding relay

Parking brake lever bottom switch

Do

o D HST safety relay

Speed sensor A

Po

o C Throttle upper limit (Eng_con)

Speed sensor B

Po

o C Throttle lower limit (Eng_con)

HST oil pressure sensor

Ao

o C Automatic warm-up cancel (Eng_con)

Engine speed (Eng_con)

Co

Accelerator pedal angle (Eng_con)

Co

Coolant temperature (Eng_con)

Co

Boost temperature (Eng_con)

Co

Co

Monitor display information (Eng_con) o C (Failure code, real-time monitor, pilot lamp, alarm buzzer, etc.) o C Travel speed (Mon) o C ECSS operation command (Mon)

CAN output

Monitor display information (Eng_con) (Failure code, real-time monitor, pilot lamp, alarm buzzer, etc.)

Solenoid output

Travel speed range selector switch

HST controller

Sensor input

Operating switch input

Input and output signals diagram

o C Back-up lamp operation command (Mon)

CAN input

o C Failure code signal (Mon) HST oil temperature (Mon)

Co

o C Real-time monitor signal (Mon)

Cooling fan manual reverse rotation (Mon)

Co

o C Pilot lamp signal (Mon)

Cooling fan automatic reverse rotation (Mon)

Co

o C Load frequency information (KOMTRAX)

ECSS (Mon)

Co

Traction control S mode (Mon)

Co

Model selection (Mon)

Co

Option device selecting (Mon)

Co

Automatic fan switching cycle to reverse rotation Co (Mon) Reverse rotation duration (Mon)

Co

Traction control level (A, B, C) (Mon)

Co

HST selector (A, B) (Mon)

Co

Tire selection (Mon)

Co

Service meter (Mon)

Co

Eng_con: Engine controller Mon: Machine monitor KOMTRAX: KOMTRAX terminal A: Analog signal D: Digital signal P: Pulse signal C: CAN signal 10-920

2



SEN03932-02

HST controller gear shifting control function

1

Gear shifting function q Receiving the travel speed range selector signal and the variable shift control signal, this function controls HST motor 1, HST motor 2 and transfer clutch in such that the maximum travel speed suited for the given state is produced. Selected speed range

Travel speed range (km/h)

Clutch solenoid output

HST motor 1 solenoid output

HST motor 2 solenoid output

Variable shift control signal input voltage (V)

0 – 13 1st

(depends on the variable shift control signal)

ON

MAX – MID

Fixed to MAX (ON)

0.9 – 4.1

2nd

0 – 13

ON

MAX – MID

Fixed to MAX (ON)

—

3rd

0 – 18.7

ON, OFF

MAX – 0

Fixed to MAX (ON)

—

4th

0 – 38

ON, OFF

MAX – 0

Fixed to MAX – Variable (ON, OFF)

—

Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation Transfer clutch Engaged o Disengaged (B) Disengaged o Engaged (C)

Accelerator pedal angle (%) 0 – 65 65 – 90 90 – 100 8 km/h

8 – 10 km/h

10 km/h

7 km/h

7 – 9 km/h

9 km/h

Relationship between accelerator pedal angle and travel speed (A) for switching HST motor 2 capacity HST motor 2 capacity Max. fixed (D) Free (E)

Accelerator pedal angle (%) 0 – 65 65 – 90 90 – 100 8 km/h 8 – 10 km/h 10 km/h 9 km/h 9 – 11 km/h 11 km/h


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SEN03932-02

1. HST pump 2. HST motor 1 3. HST motor 2 4. Transfer clutch


5. Clutch solenoid valve 6. HST motor 1 solenoid valve 7. HST motor 2 solenoid valve 8. Transfer output shaft

Gear shifting display function q The HST controller displays the state of input signals related to gear shift on the monitor by sending them to the machine monitor via network. 1.

Directional indicators The directional lever position pilot lamps of the machine monitor indicate the state of the directional lever based on the input data to the HST controller. When the directional lever is at the neutral position and no input signal is sent to the HST controller, all the directional lever position pilot lamps of the machine monitor go off. If two independent signals were sent to the HST controller by accident, two directional lever position pilot lamps of the machine monitor may turn on at the same time. As the directional lever is set to "R (reverse)" the HST controller activates the backup lamp relay to light the reverse lamp and sound the back-up alarm.

2.

Speed range indicator The travel speed range selector switch position pilot lamp of the machine monitor displays the state of the travel speed range selector switch being sent to the HST controller.

Variable shift control system When the travel speed range selector switch is set to the 1st speed, the variable shift control signal allows adjusting the maximum speed in the range of 4 - 13 km.

q

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SEN03932-02

Transfer clutch control function q In order to reduce impacts resulting from connecting the transfer clutch or to prevent inadequate torque due to delayed connection of the transfer clutch, this function adjusts the clutch oil pressure to an optimum level for the machine state (travel speed, travel load, HST oil temperature, directional lever and accelerator opening ratio) by referencing the modulation table of the HST controller. q In order to reduce lack of the torque, this function maintains the modulation control when the clutch is released. Traction control function q Receiving the traction control signal, this function derates the maximum capacity of HST motor 1 to control the traction force. q "Traction level selecting function" of the machine monitor allows selecting a desired traction force out of 3 levels (A, B and C). q The traction control operation pilot lamp remains turned on as long as the traction control operation is continued. a For the operating method of this function, see the "Operation and maintenance manual". S mode function q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very slippery road surface (on the snow-covered road, sandy terrain, etc.). q This function restricts sudden start in forward travel by reducing skidding of tires through control of the drive force. And by securing smooth start of the machine, this function offers enhanced operating performance. q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode operation is continued. a The traction force control in the S mode is enabled when the directional lever is set to the "forward" position and the machine is traveling forward or stopped. a For the operating method of this function, see the "Operation and maintenance manual".

Switch position 1 (OFF)

Features Pilot lamp Traction level OFF

2 (ON)

2B 2C

3 (S mode)

3 (ON)

Material

Road condition

Guideline

1 2A

2 (ON)

Traction

3


Suitable for loading work. Improves work efficiency and provides antislip by selecting Un-slippery traction level depending on material and I road conditions. O Slippery Select when operating with the special attachment which requires small traction force. Provides the best driving force on very Select when the machine tends to slip when slippery road surfaces covered by snow, forwarding, such as on snow or sand sand, etc. Prevents the tires from slipping covered road surface. to facilitate work. Powerful I O Soft

Hard-packed I O Loose

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SEN03932-02


The maximum traction force available when the travel speed range selector switch is set to "1st" and the traction control switch is set to "ON"

q

q

q

When the travel speed range selector switch (1) is set to "1st" and the variable shift control switch (2) is turned fully to the left, setting the traction control switch to the ON position does not reduce the maximum traction force. In this case, the maximum traction force remains at the same level as when the traction control switch is set to the "OFF" position. As clockwise turning of the variable shift control switch (2) is continued, the traction force approaches the maximum traction force being set from the "Traction level selecting function" of the machine monitor. It is possible to obtain the maximum traction force, which has been set from the traction control switch and "Traction level selecting function" of the machine monitor, by turning the variable shift control switch (2) fully to the right.

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SEN03932-02

Max. traction function q Pressing the max. traction switch while the traction control is "ON" or the S mode is selected cancels the traction control or the S mode temporarily to increase the maximum drawbar pull. q If the directional lever or directional selector switch is operated, or the max. traction switch is pressed again while the traction control or S mode is cancelled from the max. traction switch, the traction "ON" state or S mode is restored. q As long as the traction control or S mode is cancelled from the max. traction switch, the traction control operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off. a Holding down the max. traction switch for a second or longer cancels the traction control or S mode as long as it is held down. The traction control or S mode is restored at the moment the switch is released. a If the traction control is sequentially turned "ON" and "OFF" in less than a second, the traction control or S mode is cancelled temporarily just like the max. traction switch is held down for less than a second.

1. Traction control switch 2. Max. traction switch 3. HST controller 4. Machine monitor a. Traction control switch signal b. S mode signal c. CAN signal


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SEN03932-02 HST controller protection function

1

HST motor 1 overrun prevention function 1 q If the 1st or 2nd speed is selected while the machine is traveling at a high speed with the travel speed range selector switch being set to the 3rd or 4th, the transfer clutch is engaged during the high speed travel, preventing HST motor 1 to overrun beyond the allowable rotating speed. q In order to prevent the overrun, this function disables the gear shift from the 3rd or 4th to the 2nd or 1st when the transfer clutch is released. q As above gear shift is disabled, this function generates "OVERRUN PROTECT" message on the machine monitor character display and activates the alarm buzzer. q This error status is reset as the transfer clutch is engaged or the travel speed range selector switch is set to an allowable gear shift position. a Above error message is not sent to KOMTRAX terminal. Gear shift operation Switch position State of transfer before gear clutch after gear shift shift 1st

2nd

Behavior after gear shift Switch position after gear shift

Actual speed range after gear shift

2nd

2nd

3rd

3rd

4th

4th

Connected

Connected

Connected 3rd (*1) Other than the connected state

Connected 4th (*1) Other than the connected state

1st

1st

3rd

3rd

4th

4th

1st

1st

2nd

2nd

4th

4th

1st

3rd

2nd

3rd

4th

4th

1st

1st

2nd

2nd

3rd

3rd

1st

3rd

2nd

3rd

3rd

3rd

Display of message

Remarks

Not displayed

Gear shift available independent of traveling speed

Not displayed

Gear shift available independent of traveling speed

Not displayed

Displayed

Gear shift to 1st or 2nd becomes available only when the clutch is engaged.

Not displayed Not displayed

Displayed

Gear shift to 1st or 2nd becomes available only when the clutch is engaged.

Not displayed

*1: The clutch is released including the ongoing clutch connection modulation (*2) and clutch release modulation state. *2: It indicates the period 1.2 seconds after the clutch connection modulation has been started while the machine is traveling at 7 up to 9 km/h.

Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation Transfer clutch Engaged o Disengaged (B) Disengaged o Engaged (C)

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Accelerator pedal angle (%) 0 – 65 65 – 90 90 – 100 8 km/h

8 – 10 km/h

10 km/h

7 km/h

7 – 9 km/h

9 km/h



SEN03932-02

HST motor 1 overrun prevention function 2 q Downhill travel at 1st or 2nd gear speed tends to allow the machine to increase the travel speed. This function prevents the rotational speed of HST motor 1 goes beyond the allowable rotating speed. q In order to restrict the travel speed, the function controls the HST motor 1 capacity to the allowable maximum if the travel speed goes beyond 14 km/h. Travel speed control function Downhill travel at a high speed tends to allow the machine to exceed the speed limit because the rotational speed of HST motor 2, axle and engine goes beyond the allowable rotating speed. q In order to restrict the travel speed, the function fixes the HST motor 2 capacity to the allowable maximum if the travel speed goes beyond 40 km/h. q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the machine monitor character display and activates the alarm buzzer. q This error state is reset as the travel speed goes below 39.5 km/h or less. a Above error message is not sent to KOMTRAX terminal. q

Engine overrun prevention function q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a high speed, the HST pump and engine rotation becomes high speed. This function prevents the HST motor 2 to overrun beyond the allowable rotating speed. q This function prevents the HST motor 2 solenoid valve to be set to "ON" (fixed to MAX) when the travel speed is more than 30 km/h and the engine speed is more than 2,925 rpm. If the HST motor 2 solenoid valve is already set to "ON", the solenoid valve is forcibly set to "OFF" to prevent the HST pump and engine from overrun. q This function is canceled when the engine speed goes below 2,825 rpm. q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the machine monitor character display and activates the alarm buzzer. Neutralizer function When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this function, independent of the directional lever position, holds HST pump at the neutral in order to prevent dragging of the parking brake.

q

Economy operation pilot lamp function q q q

a

1

In order to prompt the operator for the low fuel consumption operation, this function lights up the economy operation pilot lamp as long as the low fuel consumption operation is continued. The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at less than 75% for 0.5 seconds or longer. The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4: ECO LAMP" item from the "Optional device selecting function" of the machine monitor. For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.


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SEN03932-02


Cooling fan control function

1. HST controller 2. Machine monitor 3. Engine controller 4. Cooling fan pump 5. Cooling fan motor 5a. Cooling fan motor flow rate control EPC valve 5b. Cooling fan reverse solenoid valve 6. Cooling fan reverse switch 7. Machine monitor mode selector switch 1 8. Machine monitor mode selector switch 2 9. Cooling fan reverse solenoid valve relay 10. HST oil temperature sensor 11. Boost pressure and oil temperature sensor 12. Coolant temperature sensor 13. Engine speed sensor 14. Engine 15. Radiator

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1

Input and output signals HST controller a. CAN signal b. Cooling fan motor flow rate control signal c. Cooling fan reverse signal Machine monitor d. Cooling fan automatic reverse signal e. Cooling fan manual reverse signal f. CAN signal g. "U" switch signal h. "t" switch signal i. ">" switch signal j. "<" switch signal k. HST oil temperature signal Engine controller l. CAN signal m. Boost pressure and temperature signal n. Engine speed signal o. Coolant temperature signal



SEN03932-02

Fan control q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low temperature environment. q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the information of HST oil temperature received by the machine monitor are sent to the HST controller via the network. q Based on the received information, the HST controller sends the signal current to the cooling fan motor flow rate control EPC valve in order to set the fan speed to a level suitable for the respective temperature levels and the engine speed. Fan speed in accordance with temperature

*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air temperature data, whichever is the highest. *2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and boost air temperature. *3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan speed is decreased to increase the oil and coolant temperature (heater spurting out temperature) and cut the warm-up operation time. (the fan speed in this area is controlled based on the hysteresis of each temperature.)


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SEN03932-02


Control at start of engine q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan speed is temporarily increased immediately after the engine is started to aid start of the fan rotation. q After the basic control is turned on, normal fan control is carried on based on the procedure described in the section of "Fan speed in accordance with temperature". a The fan control (derating of the minimum fan speed) at start of the engine is conducted only once after the starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once and then turned "ON" again, the control is implemented one more time if the control starting conditions are met. The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the following table is met. Condition 1

Starting switch is turned "ON".

Condition 2

Engine speed is 700 rpm or above.

Condition 3

Engine is rotating forward. [above, however, does not apply as a condition if the controller recognized that switching in the rotating direction is taking place.]

Condition 4

After the starting switch is turned "ON", the control at start of engine has not been carried out yet.

*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air temperature is 20°C or above. Point A: Starting switch is turned "ON" (when engine is stopped) Point B: Control starting conditions are met Area C: Minimum fan speed is restricted Area D: Basic control is turned on

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SEN03932-02

Fan reverse rotation function q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse rotation solenoid valve of the cooling fan motor is activated, reverse rotating the fan. 1.

Fan manual reverse rotation function The operator can select the desired fan rotation direction by pressing the fan reverse rotation switch to "MANUAL" for 0.5 seconds or longer. As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor keeps blinking to inform the operator that the switching is underway. And when the fan rotation is reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on blinking until the preparation for switching is completed. As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restricting signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the switching is underway. Above control, however, is not applicable when the HST oil temperature is 30°C or above. The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is continued. The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met. Condition 1

The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.

Condition 2 (*1)

Engine speed over 500 rpm and below 1,200 rpm. [above is required to prevent generation of peak pressure in the process of switching the direction.] Coolant temperature is below 102°C. [above is required to prevent overheating.] HST oil temperature is below 100°C. [above is required to prevent overheating.] Boost air temperature is below 80°C. [above is required to prevent overheating.] 30 seconds minimum have elapsed since the engine is started (since the engine speed reached 500 rpm or above). [above is required to secure the oil to be supplied to the brake accumulator.]

Condition 3 Condition 4 Condition 5 Condition 6

The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met. Condition 1 (*1) Condition 2 (*1)

While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine speed went to below 1,200 rpm. After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than 1,200 rpm.

Condition 3

The engine has stopped.

*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is 30°C or above. 2.

Overheat prevention function If overheat in the coolant temperature, HST oil temperature or boost air temperature was recognized while the fan was rotating reverse, the reverse rotation is forcibly stopped and the forward rotation is turned on in order to increase the air flow to the radiator.

3.

Fan speed during reverse rotation While the reverse fan rotation is continued, this function sets the fan speed to the maximum by cutting off the command current (sets the command current to 0 mA) to the fan motor flow rate control EPC valve. Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the cleaning work easier.


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SEN03932-02 4.

Fan automatic reverse rotation function Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching cycle and the reverse rotation duration at a specific interval. As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor keeps blinking to inform the operator that the switching is underway. And when the fan rotation is reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on blinking until the preparation for switching is completed. The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is continued. The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met. Condition 1 Condition 2 Condition 3 Condition 4 Condition 5 Condition 6

The fan reverse rotation switch is set to "AUTO". Coolant temperature is below 102°C. [above is required to prevent overheating.] HST oil temperature over 13°C and below 100°C. [the upper limit of 95°C is required to prevent overheating.] Boost air temperature is below 80°C. [above is required to prevent overheating.] 30 seconds minimum have elapsed since the engine is started (since the engine speed reached 500 rpm or above). [above is required to secure the oil to be supplied to the brake accumulator.] The fan rotation direction switching cycle has elapsed.

The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.

5.

Condition 1

Set the fan reverse rotation swith to any position other than "AUTO" during the reverse fan rotation.

Condition 2

The specified reverse rotation duration elapses.

Condition 3

The engine has stopped.

Adjustment of the automatic fan switching cycle to reverse rotation and duration Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse operation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting function of the machine monitor. a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

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SEN03932-02

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15

SEN03932-02 System circuit diagram a


1

Items marked with "*1" in drawing may or may not installed.

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SEN03932-02

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920 Electrical system, Part 2 HST controller

SEN03932-02

HST controller

1

Input and output signals DEUTSCH-40P [CN-HST] Pin No.

Signal name

Input/Output signal

Pin No.

Signal name

Input/Output signal

1

VB (controller power)

Input

21 GND (controller GND)

—

2

Starting switch ACC signal

Input

22 HST sensor power 5V

Input

3

Wake up

Input

23 Travel speed adjusting dial

Input

4

Directional selector switch F

Input

24 Directional selector switch R

Input

5

Directional lever N

Input

25 Directional selector switch operating switch

Input

6

Parking brake lever intermediate switch

Input

26 Speed sensor A

Input

7

HST controller power holding relay

8

NC

9

Clutch solenoid

Output —

10 HST pump F solenoid

27 HST motor 2 solenoid relay 28 CAN0_H

Output Input/Output

Output

29 Cooling fan motor flow rate control EPC

Output

30 VIS (solenoid power)

Output Input

11 VB (controller power)

Input

31 GND (controller GND)

—

12 Starting switch ACC signal

Input

32 GND (sensor GND)

—

13 Alternator L signal

Input

33 HST oil pressure sensor

Input

14 Directional selector switch N

Input

34 Directional lever F

Input

15 Directional lever R

Input

35 Traction control switch

Input

16 Parking brake lever bottom switch

Input

36 Speed sensor B

17 HST safety relay 18 NC

Output —

Input

37 Cooling fan motor reverse rotation solenoid relay 38 CAN0_L

Input/Output

19 HST motor 1 solenoid

Output

39 Travel speed range selector switch

20 HST pump R solenoid

Output

40 SOL_COM (solenoid common GND)

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18

Output Input —


920 Electrical system, Part 2 HST controller


SEN03932-02

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920 Electrical system, Part 2 ECSS system

SEN03932-02

ECSS system

1

(If equipped) a ECSS: Abbreviation for Electronically Controlled Suspension System

1. HST controller 2. Machine monitor 3. ECSS switch 4. ECSS relay 5. ECSS solenoid valve 6. Speed sensor 7. Bucket tilt PPC oil pressure switch 8. Lift arm lower PPC oil pressure switch Input and output signals HST controller a. Travel speed signal A b. Travel speed signal B c. CAN signal Machine monitor d. CAN signal e. ECSS switch "ON" signal f. ECSS operation signal g. ECSS cut off signal h. ECSS cut off (dummy) signal

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Outline q When the machine travels at high speed, the damping effect of the accumulator charged with high-pressure gas and the automatic control of the lift cylinder circuit relief pressure under each travel condition damp the vertical movement of the work equipment and reduce rocking of the chassis. As a result, the operator comfort is improved, spillage of material is prevented, and the working efficiency is improved. Setting method q The ECSS can be enabled only when "ADD" is selected for "5: E.C.S.S." item from the "Optional device selecting function" of the machine monitor. a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.


920 Electrical system, Part 2 ECSS system

SEN03932-02

Operation q The operating condition of ECSS is as follows. ECSS switch

Travel speed [km/h]

OFF

0 – Max. (*2) Max. 4 (*1) Min. 5

ON

ECSS operation signal

q

The operating condition of PPC oil pressure switch is as follows.

OFF ON

PPC oil pressure switch operating point Operating oil pressure [MPa{kg/cm2}]

ECSS switching point

A

B

Travel speed [km/h]

(*2) 4

(*1) 5

A

B

0.29 {3}

0.49 {5}

*1. It is allowed to select any travel speed at the ECSS switching point (B) in the range of 5 to 8 km/h by adjusting the items "Adjustment of ECSS operation travel speed" with the adjusting function of the machine monitor. *2. The travel speed available at ECSS switching point (A) is obtained by deducting 1 km/h from that available at the switching point (B) (namely, 4 - 7 km/h). a When tilting the bucket or lowering the lift arm, turn "OFF" the ECSS operation signal to reset ECSS. (WA320PZ-6) a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.


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SEN03932-02

920 Electrical system, Part 2 KOMTRAX system

KOMTRAX system

q

1

KOMTRAX terminal wirelessly transmits various machine information. KOMTRAX operators refer to the information in their offices and can provide customers with various services accordingly. a

To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.

KOMTRAX terminal transmits the following information: 1. Operation map 2. Service meter 3. Location information 4. Error history etc.

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920 Electrical system, Part 2 KOMTRAX system

SEN03932-02

KOMTRAX terminal

1

Model: TC301 q Satellite wave is used.

1. Communication antenna connector 2. GPS antenna connector 3. Machine harness connector (DEUTSCH-40P) Input and output signals DEUTSCH-40P [CN-L80] Pin No.

Signal name

Input/Output signal

Pin No.

Signal name

Input/Output signal

1

NC

—

21

Operation mode selection 1

Input

2

NC

—

22

Operation mode selection 2

Input

3

NC

—

23

NC

—

4

NC

—

24

NC

—

5

NC

—

25

NC

—

6

NC

—

26

NC

7

CAN0_L

Input/Output

27

Starting switch C signal

Input

—

8

CAN0_H

Input/Output

28

Alternator L signal

Input

9

NC

—

29

NC

—

10

NC

—

30

NC

—

11

NC

—

31

NC

—

12

NC

—

32

NC

—

13

NC

—

33

NC

—

14

NC

—

34

NC

—

15

NC

—

35

NC

16

NC

—

36

Starting switch ACC signal

— Input

17

NC

—

37

Power supply GND

18

NC

—

38

Power supply GND

19

NC

—

39

Constant power supply (24 V)

Input

20

Immobilize signal

Output

40

Constant power supply (24 V)

Input

Outline q The KOMTRAX controller can send information via wireless communication antenna, acquiring various information of the machine from the network signal in the machine and the input signal. Also, the controller incorporates CPU (Central Processing Unit) and provides the wireless communication function and the GPS (Global Positioning System) function.


q

q

— —

There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps are used for the testing and the troubleshooting. KOMTRAX terminal can be used only in the countries specified by the communication contract.

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920 Electrical system, Part 2 Engine starting circuit

SEN03932-02

Engine starting circuit

1. Battery 2. Battery relay 3. Slow-blow fuse 4. Fuse box 1 5. Fuse box 2 6. Starting switch 7. Directional lever 8. Neutral safety relay 9. KOMTRAX engine cut-out relay 10. HST controller power holding relay 11. Starting motor safety relay 12. Starting motor 13. Alternator 14. HST controller 15. Engine controller 16. Machine monitor 17. KOMTRAX terminal 18. Engine controller cut-out relay 19. CAN resistor 20. Directional selector switch operating switch 21. Directional selector switch

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1

Function 1. The neutral safety circuit is employed to secure safety when the engine is started. q The engine can not be started while the directional lever is at any position other than N (neutral). q When the directional selector switch operating switch is turned "ON", the directional lever and the directional selector switch must be at "N (neutral)" to start the engine. 2.

The KOMTRAX engine cut-out circuit is employed to disable the engine from starting when the KOMTRAX terminal receives an engine cut command issued through external operation. (if equipped)


920 Electrical system, Part 2 Engine starting circuit

SEN03932-02

Operation 1. When starting switch is turned "ON" q As the starting switch is turned "ON", terminals B and BR of the starting switch are closed and the current flows from the battery through the starting switch and battery relay coil to the ground, thereby closing the contact of the battery relay. As a result, the power is supplied to each circuit of the machine. At this time, the ACC signal is sent from terminal ACC of the starting switch to the engine controller, readying the engine for startup. 2.

Neutral safety circuit q Setting the directional lever to "N (neutral)" conducts the current from contact N of the directional lever to the neutral safety relay to activate it. q When the directional selector switch is used (when the directional selector switch operating switch is turned "ON"), if both the directional lever and directional selector switch are at "N (neutral)" at this point, the neutral safety relay is activated.

3.

When starting switch is set to "START" q As the starting switch is set to "START", the current flows through the starting switch terminal C, KOMTRAX engine cutout relay and neutral safety relay to the starting motor safety relay to start the engine. q When the directional lever is set to any position other than "N (neutral)", the neutral safety relay is not activated and interrupts the engine startup. q When the directional selector switch is used (when the directional selector switch operating switch is turned "ON"), if either of the directional lever and the directional selector switch is not at "N (neutral)", the neutral safety relay is not activated and thus the engine is not started. q As KOMTRAX terminal receives the externally applied engine cut-out command, KOMTRAX engine cut-out relay is activated, shutting down the circuit from the starting switch terminal C to the starting motor safety relay. Thus, engine start-up becomes unavailable.


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SEN03932-02

Engine stopping circuit

920 Electrical system, Part 2 Engine stopping circuit

1

Operation q Setting the starting switch to "OFF" cuts off ACC signal from the starting switch terminal ACC to the engine controller. q Although ACC is cut off, the engine controller keeps the engine controller cut-out relay working to maintain the current flow to the engine controller until its internal processing is complete. q As ACC signal is cut off, the engine lowers its speed and stops. At the same time, the alternator stops power generation, stopping supply of the voltage from the alternator terminal L. And the current from the starting switch terminal BR is also stopped and the contacts of the battery relay are opened. Consequently, the power supplied to each circuit of the machine is stopped.

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920 Electrical system, Part 2 Preheating circuit

SEN03932-02

Preheating circuit

1. Battery 2. Battery relay 3. Slow-blow fuse 4. Fuse box 1 5. Starting switch 6. Engine controller 7. Machine monitor 8. Electrical intake air heater relay 9. Electrical intake air heater 10. Boost pressure and temperature sensor

1

Operation q Set the starting switch to "ON" to start the engine controller. At this time, if intake air temperature is -4°C or below, the engine controller starts up the electrical intake air heater immediately after the starting switch is turned "ON" to initiate preheating by the electrical intake air heater. q The preheating time is set as shown below.

Outline q The automatic preheating system is installed so that the engine will start easily in a cold district. q The automatic preheating system is capable of cutting the preheating time short as the starting switch is set to "ON". This system is also capable of automatically setting the preheating duration referencing temperature of intake air. q Setting the starting switch to "ON" lights the preheater pilot lamp of the machine monitor and starts preheating of intake air with the electrical intake air heater. The engine controller sets the preheating duration referencing the intake air temperature being sent from the boost pressure sensor and temperature sensor. q The pilot lamp remains turned on as long as preheating is continued. Keep the starting switch in the "ON" position during this time. Setting the starting switch to "START" from this state resets preheating.


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27

920 Electrical system, Part 2 Engine output derating function

SEN03932-02

Engine output derating function

1

q

If the engine controller detects a failure, it protects the engine by derating the engine torque or speed.

q

Following figure shows the engine torque performance when the torque was derated.

A:

Derated to approximately 30% of the maximum torque point Derated to approximately 50% of the rated output point

Automatic warm-up function q

q

B:

q

A:

Following figure shows the engine torque performance when the engine speed was derated.

1

When starting the engine in a cold district, this function warms it up by increasing the engine low idle speed. If the coolant temperature is below 20°C at starting of the engine, this function increases the low idle speed to 1,000 rpm. The condition required for increasing the low idle speed depends on the coolant temperature as shown in the figure below.

The automatic warm-up function is reset and the engine speed returns to 825 rpm as any of the following conditions is met. The coolant temperature reaches 30°C or Condition 1 above while the automatic warm-up function is enabled. The accelerator pedal angle remains at Condition 2 70% for 3 seconds or more. The automatic warm-up function remains Condition 3 being enabled for 30 minutes or more. The directional lever is set to "Forward" or "Reverse" while the automatic warm-up function is enabled. Condition 4 (When the directional lever is returned to "Neutral" to stop the machine, the automatic warm-up function restarts.)

Derated near to the engine speed at maximum torque point

10-920

28


920 Electrical system, Part 2 Automatic warm-up function


SEN03932-02

10-920

29

SEN03932-02

Parking brake circuit

920 Electrical system, Part 2 Parking brake circuit

1

1. Parking brake lever intermediate switch 2. Parking brake lever bottom switch 3. HST controller 4. Machine monitor 5. Alarm buzzer 6. HST controller power holding relay 7. HST safety relay 8. Clutch solenoid valve 9. HST motor 1 solenoid valve 10. HST pump forward solenoid valve 11. HST pump reverse solenoid valve

10-920

30


920 Electrical system, Part 2 Parking brake circuit

SEN03932-02

Operation Starting switch position

OFF

ON

State of engine Parking brake lever area Parking brake lever intermediate switch (1) Parking brake lever bottom switch (2) [for parking brake pilot lamp operation] Parking brake reminder caution lamp (Alarm buzzer)

Stopped Free

Mid

Close Close

Parking brake pilot lamp

Lock Open Open

[*1], [*2] ON (Sounded)

OFF (Reset)

OFF

When the parking brake lever is set to "Free" position q When the parking brake lever is set to the free position, the intermediate switch (1) and bottom switch (2) are both closed. q The parking brake pilot lamp goes off independent of the given state. q The parking brake is released. *1: When the starting switch is turned from "ON" to "OFF": q The parking brake reminder caution lamp turns on and the alarm buzzer sounds. q The HST controller power holding relay remains turned on, conducting current to the HST controller and maintaining the HST motor 1 solenoid valve and clutch solenoid valve being activated. Thus, the machine is protected from slipping through a slope. *2: If the parking brake lever is set to any position other than "Lock" when the starting switch is at "OFF", the parking brake reminder caution lamp remains turned off and the alarm buzzer is also not activated. And HST motor 1 solenoid valve and clutch solenoid valve remain inactivated.


Running

Free

Mid

Lock

Close Close [*1] ON (Sounded) OFF

Open Open

Free

Lock

Close Close

Open Open

OFF (Reset)

OFF (Reset) ON

Mid

OFF

ON

When the parking brake lever is set to "Mid" position q When the parking brake lever is set to the mid position, the bottom switch (2) is open but intermediate switch (1) is closed. q The parking brake pilot lamp comes on only when the starting switch is "ON". q As bottom switch (2) opens, the output to the forward and reverse solenoid valves of HST pump is stopped to prevent dragging of the parking brake. And, at the same time, the directional lever and the directional selector switch are disabled to turn on the machine travel in both the forward and reverse direction. *1: When the starting switch is turned from "ON" to "OFF": q The parking brake reminder caution lamp turns on and the alarm buzzer sounds. q The HST controller power holding relay remains turned on, conducting current to the HST controller and maintaining the HST motor 1 solenoid valve and clutch solenoid valve being activated. Thus, the machine is protected from slipping through a slope. When the parking brake lever is set to "Lock" position q Pulling the parking brake lever fully opens both the intermediate switch (1) and bottom switch (2). q The parking brake pilot lamp comes on only when the starting switch is "ON". q The parking brake reminder caution lamp goes off independent of the given state. q As bottom switch (2) opens, the output to the forward and reverse solenoid valves of HST pump is stopped to prevent dragging of the parking brake. And, at the same time, the directional lever and the directional selector switch are disabled to turn on the machine travel in both the forward and reverse direction. q The parking brake is activated. 10-920

31

SEN03932-02

Coupler plunger control system

920 Electrical system, Part 2 Coupler plunger control system

1

WA320PZ-6 Outline q The coupler plunger is extracted or retracted by operating the quick coupler attachment switch to connect and release each attachment and the coupler. Operation When quick coupler attachment switch is in "Release" position q If the quick coupler attachment switch (1) is set in the "Release" position, quick coupler solenoid valve (2) is energized. If the work equipment (bucket) control lever is moved to the tilt side, the oil flows into the head side of coupler plunger (3). Then, coupler plunger (3) is retracted and the attachment and coupler are released.

10-920

32

When quick coupler attachment switch is in "Connect" position q If the quick coupler attachment switch (1) is set in the "Connect" position, quick coupler solenoid valve (2) is de-energized. If the work equipment (bucket) control lever is moved to the tilt side, the oil flows into the bottom side of coupler plunger (3). Then, coupler plunger (3) is extracted and the attachment and coupler are connected.


920 Electrical system, Part 2 Multi-function knob

SEN03932-02

Multi-function knob

1. Directional selector switch 2. Max. traction switch 3. Option switch [Reserved]


1

Function q Directional selector switch (1) is an alternate type. Its control signal sent to the HST controller causes switching between the forward and reverse travel. q Max. traction switch (2) and option switch (3) are momentary type. Max. traction switch (2) control signal sent to the HST controller cancels the traction control temporarily.

10-920

33

SEN03932-02

Max. traction switch

920 Electrical system, Part 2 Max. traction switch

1

2-lever type (If equipped)

1. 2. 3. 4.

Switch A (white wiring harness) Switch B (yellow wiring harness) Spring Wiring harness

10-920

34

Function q These switches are installed on the knob of the lift arm control lever. Switch A (1) functions as the max. traction switch and switch B (2) does not function. q Both of switch A (1) and switch B (2) are of momentary type, that is, their contacts are closed only while they are pressed.


920 Electrical system, Part 2 Sensor

SEN03932-02

Sensor

1

Speed sensor

1. Hall IC 2. Circuit board 3. O-ring 4. Housing

5. Heat shrink tube 6. Protective tube 7. Lead wire 8. Connector

Function q This sensor is installed on the transfer case. It generates two different types of pulses depending on the rotational direction and speed of the gear.


10-920

35


SEN03932-02 HST oil temperature sensor Brake oil temperature sensor

1. Connector

2. Plug

3. Thermistor

Function q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2 hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as variation in the resistance of the thermistor. HST oil pressure sensor

1. Sensor

2. Lead wire

3. Connector

Function This sensor is installed on the motor 2 solenoid block to measure the oil pressure in the HST circuit and generate the corresponding signal.

q

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36



SEN03932-02

HST oil filter clogging sensor

1. Terminal

2. Plug

Function q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the pressure goes beyond the specified level, the switch is set to "ON". Coolant level sensor

1. Float 2. Sensor

3. Connector 4. Sub-tank

Function This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves down, and the switch is set to "OFF".

q


10-920

37


SEN03932-02 Fuel level sensor

1. 2. 3. 4.

Connector Float Arm Body

5. Spring 6. Contact 7. Spacer

Function q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The float moves the variable resistor through the arm. The resistance changes according to the operating angle and signal voltage is generated from the source voltage according to the change of the resistance.

10-920

38



SEN03932-02

Accelerator pedal sensor

1. Pedal 2. Connector 3. Sensor

Output characteristics

Function q This sensor is installed on the surface of the floor. It outputs the accelerator signal or idle validation signal depending on the accelerator pedal pressing angle. Accelerator signal Magnitude of the accelerator pedal displacement being detected by the sensor is output in variable voltage from No. 2 pin.

q

Idle validation signal The sensor detects the accelerator pedal operation. As the accelerator pedal is released, it outputs the signal being entered to No. 5 pin from No. 4 pin. And as the accelerator pedal is pressed, it outputs the signal being entered to No. 6 pin from No. 4 pin.

q


10-920

39


SEN03932-02 Air cleaner clogging sensor

1. Indicator 2. Spring

3. Adapter 4. Connector

Function q This sensor is installed in the air cleaner outlet. It outputs the signal as the air cleaner is clogged and the pressure is decreased to the specified level (negative pressure). Water-in-fuel sensor

1. Connector 2. Tube

3. Sensor 4. O-ring

Function q This sensor is installed in the cup of the fuel pre-filter. It outputs the signal as entrainment of water in fuel is sensed.

10-920

40



SEN03932-02

Boom kick-out proximity switch Bucket positioner proximity switch

1. Switch 2. Locknut

3. Operation indication lamp 4. Connector

Function q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame. And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".


10-920

41

SEN03932-02



10-920

42

SEN03933-00




20 Standard value table

20

100 Standard service value table Standard service value table for engine .......................................................................................................... 2 Standard service value table for chassis......................................................................................................... 3


20-100

1

100 Standard service value table Standard service value table for engine

SEN03933-00

Standard service value table for engine

1

Machine model

WA320-6

Engine Item Engine speed

SAA6D107E-1

Measurement conditions High idle (*)

Standard value for new machine

Service limit value

2,250 ± 50

2,250 ± 50

825 ± 25

825 ± 25

°C

Max. 550

600

kPa {mmHg}

Min. 127 {Min. 950}

100 {750}

Unit rpm

Low idle (*)

Exhaust temperature All revolution ranges (Turbocharger outlet tem(Atmospheric temperature: 20°C) perature) Intake air pressure (Boost pressure)

• At rated output • At aftercooler outlet side

Exhaust gas color

At rated output Engine coolant temperaPollution ture: Within operating range At sudden acceleration level %

Valve clearance

Normal temperature

Blow-by pressure

• At rated output • Engine coolant temperature: Within operating range

Oil pressure

At high idle SAE0W30E0S Engine coolant temperature: Within operating range SAE0W40E0S SAE10W30DH At low idle SAE15W40DH Engine coolant temperaSAE30DH ture: Within operating range

Oil temperature

Belt tension

20-100

2

Intake valve Exhaust valve

All engine speed ranges (Inside oil pan) Deflection under finger presIdler pulley – sure of approx. 58.8 N crankshaft pulley {approx. 6 kg} Deflection under finger pressure of approx. 98 N {approx. 10 kg}

Air conditioner compressor – crankshaft pulley

mm kPa {mmH2O}

MPa {kg/cm2}

°C

Max. 12

22

Max. 25

35

0.25 ± 0.05

0.152 – 0.381

0.51 ± 0.05

0.381 – 0.762

Max. 0.98 {Max. 100}

1.96 {200}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

80 – 110

Min. 120

Auto-tensioner

Auto-tensioner

11 – 14.5

11 – 14.5

mm


100 Standard service value table Standard service value table for chassis

SEN03933-00

Standard service value table for chassis

1

Speed switch (Dial switch)

Directional lever

Category

Machine model Item

WA320-6

Measurement conditions

13.7 {1.4}

5.9 (+5.9/0) {0.6 (+0.6/0)}

13.7 {1.4}

45 ± 10

45 ± 20

45 ± 10

45 ± 20

7.8 ± 4.9 {0.8 ± 0.5}

15.7 {1.6}

7.8 ± 4.9 {0.8 ± 0.5}

15.7 {1.6}

3rd – 4th

7.8 ± 4.9 {0.8 ± 0.5}

15.7 {1.6}

1st – 2nd

30 ± 5

30 ± 10

N {kg}

Operating effort N– REVERSE N– FORWARD

• •

Engine stopped Measure at 10 mm from top of lever mm

N– REVERSE 1st – 2nd

Operating effort 2nd – 3rd

Travel

2nd – 3rd

• •

•

Engine stopped Measure at 10 mm from end of switch knob

Engine stopped

N {kg}

deg.

30 ± 5

30 ± 10

30 ± 5

30 ± 10

HOLD o RAISE

10.8 (+4.9/0) {1.1 (+0.5/0)}

16.7 {1.7}

RAISE o HOLD

7.8 (+4.9/0) {0.8 (+0.5/0)}

11.8 {1.2}

HOLD o LOWER

10.8 (+4.9/0) {1.1 (+0.5/0)}

16.7 {1.7}

—

—

20.6 (+4.9/0) {2.1 (+0.5/0)}

31.4 {3.2}

FLOAT o HOLD

20.6 (+4.9/0) {2.1 (+0.5/0)}

31.4 {3.2}

HOLD o DUMP

12.3 (+4.9/0) {1.25 (+0.5/0)}

18.6 {1.9}

HOLD o TILT

10.8 (+4.9/0) {1.1 (+0.5/0)}

16.7 {1.7}

TILT o HOLD

7.8 (+4.9/0) {0.8 (+0.5/0)}

11.8 {1.2}

HOLD o RAISE

37 ± 9

37 ± 9

HOLD o LOWER

37 ± 9

37 ± 9

13.5 ± 9

13.5 ± 9

HOLD o DUMP

50.5 ± 9

50.5 ± 9

HOLD o TILT

37 ± 9

37 ± 9

3rd – 4th

Lift arm • Operating effort Work equipment control lever

Standard value for Service limit value new machine 5.9 (+5.9/0) {0.6 (+0.6/0)}

N– FORWARD

Travel

Unit

• •

Engine coolant temperature: Operating range Engine speed: Low idle Hydraulic oil temperature: 60 – 80°C

Bucket

Lift arm Travel

• • •

Bucket


Engine coolant temperature: Operating range Engine speed: Low idle Hydraulic oil temperature: 60 – 80°C

LOWER o HOLD LOWER o FLOAT

LOWER o FLOAT

N {kg}

mm

20-100

3


SEN03933-00

Steering wheel

Category

Machine model Item

Unit

Play

• Engine stopped • Machine facing straight to front

mm

20 ± 20

Max. 60

Operating effort

• Flat, level, straight, dry, and paved road • Engine speed: Low idle (Bucket empty)

N {kg}

9.8 ± 2.9 {1.0 ± 0.3}

Max.14.7 {Max. 1.5}

Turns (Not including play)

• Engine speed: High idle • Left lock – right lock

Turns

3.7 ± 0.4

3.7 ± 0.8

3.7 ± 0.4

Max. 4.8

3.7 ± 0.3

3.7 ± 1

24.5 – 37.8 {2.5 – 3.9}

—

45.5 – 58.8 {4.6 – 6.0}

—

45 ± 2

—

17 ± 2

—

294 ± 30 {30 ± 3.0}

Min. 238 {Min. 24.3}

50

—

30 (+2/0)

—

5±1

—

2,210 ± 100

2,210 (+90/–200)

2,150 ± 100

2,150 (+150/–200)

Low idle

Accelerator pedal

High idle

Operating effort

Beginning of depression Full open

Operating angle

Neutral (α1) stroke (α)

Brake pedal

Operating effort

Operating angle

Neutral (α1) Max. (α2)

Play

• Engine started • Hydraulic oil temperature: Within operating range • Left lock – right lock • Engine started • Measure at 150 mm from fulcrum of pedal.

sec.

N {kg}

a For measuring posture, see Fig. A at end of this section • Engine started • α = α1 – α2

deg.

• Operating angle: 20° • Engine speed: Low idle • Hydraulic oil temperature: Within operating range

N {kg}

a For measuring posture, see Fig. B at end of this section • Engine speed: Low idle • Hydraulic oil temperature: Within operating range

deg.

HST stall Hydraulic stall

• Engine coolant temperature: Within operating range • HST oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C

rpm

HST stall + hydraulic stall

2,030 (+130/–200) 2,030 (+230/–300) 1st

Power train (HST)

Standard value for Service limit value new machine


Operating time

Engine speed

WA320-6

Travel speed (Bucket empty)

20-100

4

4 ± 0.2

4 ± 0.3

13 ± 0.7

13 ± 0.9

3rd

18.7 ± 0.9

18.7 ± 1.3

4th

38 ± 1.9

38 (+1.9/–2.7)

2nd FORWARD

km/h



SEN03933-00

Category

Machine model Item

WA320-6


Unit

1st

Power train (HST)

Low pressure relief pressure (Work equipment PPC circuit pressure)

Servo piston control oil pressure

Servo piston operating pressure

18.7 ± 0.9

18.7 ± 1.3

4th

38 ± 1.9

38 (+1.9/–2.7)

44.1 ± 1.2 {450 ± 12}

44.1 (+1.2/–3.0) {450 (+10/–30)}

3.0 (+0.2/0) {31 (+2/0)}

3.0 (+0.2/–0.1) {31 (+2/–1)}

3.0 (+0.2/0) {31 (+2/0)}

3.0 (+0.2/–0.1) {31 (+2/–1)}

Max. 0.6 {Max. 6}

Max. 0.6 {Max. 6}

Hydraulic oil temperature: 45 – 55°C Gear speed selector switch: 1st Travel speed control dial: “1” on Min. side Directional lever: Measure in both forward and reverse position. Measure while driving at full throttle (Max. speed: 5 km/h).

3.0 (+0.2/0) {31 (+2/0)}

3.0 ± 0.2 {31 ± 2}

Hydraulic oil temperature: 45 – 55°C Directional lever: FORWARD Speed switch: 3rd or 4th speed Travel at a speed of at least 10 km/h

3.0 (+0.2/0) {31 (+2/0)}

3.0 (+0.2/–0.1) {31 (+2/–1)}

20.6 (+1.0/–0.5) {210 (+10/–5)}

20.6 ± 2.0 {210 ± 20}

m

Max. 14

Max. 14

mm

1 ± 0.1

Max. 0.6

—

Holds position

Holds position

Engine speed: Full speed Hydraulic oil temperature: 45 – 55°C Directional lever: N

•

•

• • • •

•

Steering

3rd

• •

•

Wheel brake

13 ± 0.9

Engine speed: Full speed Hydraulic oil temperature: 45 – 55°C Directional lever: FORWARD Speed switch: 2nd speed Traction control switch: ON

•

Clutch control pressure

Steering relief pressure

Performance

• • •

Engine speed: Full speed Hydraulic oil temperature: 45 – 55°C Directional lever: N

When brake pedal releasing

When brake pedal depressing

• •

Engine speed: High idle Hydraulic oil temperature: 45 – 55°C

•

•

Flat, horizontal, straight, dry paved road surface Speed when applying brake: 35 km/h Braking delay: Within 0.1 sec. Brake pedal operating effort: 322 N {33 kg} Tire inflation pressure: Specified pressure Measure braking distance

•

Thickness of lining

• • • •

Disc wear Parking brake

13 ± 0.7 km/h

• • • • •

•

Transfer

4 ± 0.3

REVERSE

High pressure cut-off pressure

HST oil pressure

4 ± 0.2

2nd

Travel speed (Bucket empty)


• Performance


Tire inflation pressure: Specified pressure • Flat paved road with 1/5 (11°20') grade • Machine at operating condition a For measuring posture, see Fig. C and Fig. D at the end of this section

MPa {kg/cm2}

20-100

5


SEN03933-00

Work equipment control valve Category

Machine model Item

Lift arm Speed Bucket Work equipment


• •

Relief pressure

Engine speed: High idle Hydraulic oil temperature: 45 – 55°C • Steering valve: Neutral • Apply no load a For measuring posture, see Fig. E – Fig. H at the end of this section

MPa {kg/cm2}

RAISE


20.6 ± 0.4 {210 ± 4}

20.6 ± 2.0 {210 ± 20}

5.7 ± 0.5

Max. 8.6

3.5 ± 0.5

Max. 5.3

1.9 ± 0.3

Max. 2.9

1.2 ± 0.3

Max. 1.8

1.2 ± 0.3

Max. 2

Max. 20

Max. 30

Max. 17

Max. 26

*1 LOWER

Sec.

TILT *2 DUMP TILT

*3

Bucket no load Position of work equipment: Lift arm and bucket in level position Engine stopped Hydraulic oil temperature: 45 – 55°C Stop engine and leave for 5 minutes, then measure for 15 minutes. For measuring posture, see Fig. J at the end of this section

mm

Max. fan speed

• • • •

Engine speed: High idle Engine coolant temperature: Min. 90°C Boost temperature: Min. 70°C HST oil temperature: Min. 95°C

rpm

1,690 ± 50

1,690 ± 200

Fan drive pressure

• • • •

Engine speed: High idle Engine coolant temperature: Min. 90°C Boost temperature: Min. 70°C HST oil temperature: Min. 95°C

MPa {kg/cm2}

14.7 ± 1.5 {150 ± 15}

14.7 ± 2.3 {150 ± 23}

3–5

—

3–5

—

Lift arm cylinder • • • Bucket cylinder

Hydraulic drive fan

Unit

Engine speed: High idle Hydraulic oil temperature: 45 – 55°C

• •

• •

Hydraulic drift

Proximity switch

WA320-6

Clearance between bucket positioner switch Clearance between boom kick-out switch

a

•

Hydraulic oil temperature: 45 – 55°C

mm

*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift arm. *2: Time taken to move bucket from max. tilt to max. dump. *3: Time taken to move bucket from horizontal position to max. tilt.

20-100

6



SEN03933-00

Machine posture and procedure for performance measurement a

Fig. A

a

Fig. D

a

Fig. B

a

Fig. E

a

Fig. C

a

Fig. F


20-100

7

SEN03933-00 a

Fig. G

a

Fig. H

a

Fig. J

20-100

8





SEN03933-00

20-100

9

SEN03933-00



20-100

10

SEN03934-02




30 Testing and adjusting

30

110 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Measuring engine speed................................................................................................................................. 8 Measuring exhaust gas color ........................................................................................................................ 10 Adjusting valve clearance ............................................................................................................................. 12 Measuring compression pressure................................................................................................................. 14 Measuring blow-by pressure......................................................................................................................... 17 Measuring engine oil pressure...................................................................................................................... 18 Measuring intake air (boost) pressure .......................................................................................................... 19 Handling fuel system equipment................................................................................................................... 21 Releasing residual pressure in fuel system .................................................................................................. 21 Measuring fuel pressure ............................................................................................................................... 22 Measuring fuel return rate and leakage ........................................................................................................ 24 Bleeding air from fuel circuit.......................................................................................................................... 28 Checking leakage in fuel system .................................................................................................................. 29 Handling cylinder cut-out mode operation .................................................................................................... 30 Handling no-injection cranking operation...................................................................................................... 30 Handling controller voltage circuit ................................................................................................................. 31 Check of muffler and muffler stack for looseness and damage .................................................................... 31 Check of muffler function .............................................................................................................................. 32 Check of installed condition of cylinder head and manifolds ........................................................................ 32 Check of engine piping for damage and looseness ...................................................................................... 33 Testing and adjusting air conditioner compressor belt tension ..................................................................... 33 Replacing alternator belt ............................................................................................................................... 34 WA320, 320PZ-6 (KA SPEC.)

30-110

1

SEN03934-02

30-110

2

110 Testing and adjusting, Part 1


110 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting

SEN03934-02

Tools for testing, adjusting, and troubleshooting Testing and adjusting item

Symbol

Measuring exhaust gas color

A

Adjusting valve clearance

B

Measuring compression pressure

C

Measuring blow-by pressure

Measuring engine oil pressure

Measuring intake air (boost) pressure

F

2

Commercially Smoke meter available

1

1

795-799-1131 Gear

1

2

Commercially Clearance gauge available

1

1

795-799-6700 Puller

1

For 107E-1 engine

2

795-502-1590 Gauge assembly

1

0 – 7 MPa {0 – 70 kg/cm2}

3

795-790-4410 Adapter

1

For 107E-1 engine

4

6754-11-3130 Gasket

1

For 107E-1 engine

799-201-1504 Blow-by checker

1

0 – 5 kPa {0 – 500 mmH2O}

1

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

2

790-301-1230 Nipple

1

3

799-101-5160 Nipple

1

4

799-401-2320 Gauge

1

1


1

2

799-201-2202 Boost gauge kit

1

–101 – 200 kPa {–760 – 1,500 mmHg}


1


790-261-1204 Digital hydraulic tester

1

Pressure gauge: 60 MPa {600 kg/cm2}

6732-81-3170 Adapter

1

10 × 1.0 mm o R1/8

6215-81-9710 O-ring

1

3


1

4

795-790-5110 Screw

1

5

799-201-2202 Boost gauge kit

1

1

795-790-4700 Tester kit

1

2

795-790-6700 Adapter

1

6754-71-5340 Connector

1

6754-71-5350 Washer

1

4

Commercially Measuring cylinder available

1

5

Commercially Stopwatch available

1

6

Commercially Hose available (Inside diameter: 14 mm)

1

79A-264-0021 Push-pull scale

1

0 – 300 N {0 – 30 kg}

1


1

0 – 300 N {0 – 30 kg}

2

Commercially Scale available

1

799-101-5002 Analog hydraulic tester

1



1


3 Measuring fuel return rate and leakage

H

Testing accelerator pedal

J

Testing directional lever K

Testing and adjusting HST oil pressure

Remarks

1

2

G

Q'ty

799-201-9001 Handy smoke checker

1

Measuring fuel compression pressure

Part Name

1

D

E

Part No.

1

L


Bosch index: Level 0 – 9



30-110

3


SEN03934-02

Testing and adjusting item

Symbol

Q'ty

Remarks


1



1


799-401-3200 Adapter

1

02896-11009 O-ring

1


1

0 – 300 N {0 – 30 kg}


1



1


799-205-2200 Tachometer kit

1

Digital display: 6 – 99999.9 rpm


1



1


799-401-3400 Adapter

1

02896-11015 O-ring

1


1



1


1

793-605-1001 Brake test kit

1

1 Testing clutch control pressure

M 2

Testing steering wheel

N

Testing and adjusting steering oil pressure

P 1

Testing hydraulic fan

2

Q

3 Testing and adjusting accumulator charge pressure

Testing wheel brake oil pressure

R

S

Part No.

Part Name

2

790-101-1430 Coupler

1

3

790-101-1102 Pump

1

4

790-301-1720 Adapter

1

5

799-101-5160 Nipple

1

6

799-401-2220 Hose

1

7

790-261-1130 Coupling

1

For hose size #03

For hose size #05

20 × 1.5 mm o R1/8 Length: 5 m

Holding work equipment position

T

793-463-1100 Stopper

1

Testing and adjusting parking brake control cable

V


1

0 – 300 N {0 – 30 kg}

1


1

0 – 300 N {0 – 30 kg}

2

Commercially Scale available

1


1



1



1



1


Testing work equipment lever

W

Testing and adjusting work equipment oil pressure

X

Testing and adjusting work equipment PPC oil pressure

Y

30-110

4




Diagnosis for engine related controller, sensor actuator and harness

Diagnosis for chassis related controller, sensor actuator and harness

Symbol

Z

Z


Part No.

SEN03934-02

Part Name

Q'ty

Remarks

799-601-7400 T-adapter assembly

1

AMP040 Connector


1

AMP070 Connector


1

DT, HD30 Connector


1

DRC26-40 (5 pins)

799-601-7360 Adapter

1

REL-5P (5 pins)

799-601-7310 T-adapter

1

SWP (12 poles)

799-601-7070 T-adapter

1

SWP (16 poles)


1

Connected with engine

795-799-5530 • T-adapter

1


799-601-4230 • T-adapter

1

Boost temperature/pressure sensor

799-601-4130 • T-adapter

1

Ne sensor, CAM sensor

799-601-4160 • T-adapter

1

Hydraulic pressure sensor

799-601-4211 • T-adapter

1

Controller (50 poles)

799-601-4220 • T-adapter

1


799-601-4140 • T-adapter

1

Atmospheric pressure sensor

799-601-4340 • T-adapter

1

Pump actuator

799-601-4260 • T-adapter

1


799-601-4190 • T-adapter

1

Common rail pressure sensor

799-601-2500 or 799-601-2700 or 799-601-2800 or T-adapter 799-601-2900 or 799-601-7100 or 799-601-8000

1

799-601-2900 is not supplied

799-601-2600 • T-adapter box

1

Econo (Excl. 799-601-2700)

799-601-2740 • Adapter for MIC

1

For MIC-5P


1

799-601-4211 • Adapter for DRC

1

For DRC50

799-601-9020 • Adapter for DT

1

For DT2P


1

For DT3P

799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000

1

799-601-7010 • Adapter for X

1

For X1P

799-601-7020 • Adapter for X

1

For X2P

799-601-7030 • Adapter for X

1

For X3P

799-601-7040 • Adapter for X

1

For X4P

799-601-7050 • Adapter for SWP

1

For SWP6P

799-601-7060 • Adapter for SWP

1

For SWP8P (Excl. 799-601-8000)

30-110

5


SEN03934-02


Diagnosis for chassis related controller, sensor actuator and harness

Symbol

Z

Part No.

Part Name

Q'ty

799-601-7080 • Adapter for M

1

For M1P (Excl. 799-601-7000 and 799-601-7100)

799-601-7090 • Adapter for M

1

For M2P

799-601-7110 • Adapter for M

1

For M3P

799-601-7120 • Adapter for M

1

For M4P

799-601-7130 • Adapter for M

1

For M6P

799-601-7150 • Adapter for S

1

For S10P

799-601-7180 • Adapter for AMP040

1

For A8P (799-601-7400 only)

799-601-7190 • Adapter for AMP040

1

For A12P (Excl. 799-601-7000 and 799-601-7100)

799-601-7330 • Adapter for S

1

For S16PW (799-601-8000 only)

799-601-7320 Adapter for SWP

1

For SW16P

799-601-7340 Adapter for M

1

For M8P

799-601-7360 Adapter for relay

1

For REL-5P


1

For REL-6P


1

799-601-7520 • Adapter for 070

1

For 070-12P

799-601-7530 • Adapter for 070

1

For 070-14P

799-601-7540 • Adapter for 070

1

For 070-18P

799-601-7550 • Adapter for 070

1

For 070-20P

799-601-9000 T-adapter assembly or 799-601-9200

1


1

For DT2P (Incl. in 799-601-4101 and 799-601-4201)


1

For DT3P


1

For DT4P (Incl. in 799-601-4101 and 799-601-4201)


1

For DT6P

799-601-9060 • Adapter for DT (Gray)

1

For DT8PGR

799-601-9070 • Adapter for DT (Black)

1

For DT8PB

799-601-9080 • Adapter for DT (Green)

1

For DT8PG

799-601-9110 • Adapter for DT (Gray)

1

For DT12PGR

799-601-9120 • Adapter for DT (Black)

1

For DT12PB

799-601-9130 • Adapter for DT (Green)

1

For DT12PG

799-601-9140 • Adapter for DT (Brown)

1

For DT12P


1


1

For DRC-40


1

For DRC-24

• Multi-adapter for DT2–4, DTM2

1

For DT2–4, DTM2

799-601-9890 Measuring coolant and oil temperature

—

799-101-1502 Digital thermometer

1

Measuring time and speed

—


1

Measuring voltage and resistance

—

Commercially Tester available

1

30-110

6

Remarks




Symbol

Removal and installation of boost pressure and temperature sensor

—

Part No.

SEN03934-02

Part Name

Commercially TORX wrench available

—

795T-981-1010 Socket

—

Commercially Socket available

Removal and installation of engine coolant temperature sensor

Q'ty

Remarks

1

3.26 mm TORX wrench (KTC Q4T15 or equivalent)

1

19 mm deep socket (MITOLOY 4ML-19 or equivalent) (Appleid engine serial number: 26530193–)

1

21mm deep socket (MITOLOY 4ML-21 or equivalent) (Appleid engine serial number: 26500006–26530192)

Sketches of special tools Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketched. Socket


30-110

7

110 Testing and adjusting, Part 1 Measuring engine speed

SEN03934-02

Measuring engine speed k k

1

Put chocks under the tires securely. When measuring, check that there are no persons around the machine.

a

Measure the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q HST oil temperature: Within operating range

1.

Measuring engine speed (low idle and high idle) 1) Referring to “Special function of machine monitor”, select the real time monitoring function of the service mode. 2) Display “ENG SPEED” from the monitoring items of the machine monitor. a Monitoring item Code No. 01001: ENG SPEED (Engine speed)

3)

30-110

2.

Measuring HST stall speed 1) Referring to “Special function of machine monitor”, select the real time monitoring function of the service mode. 2) Select the two-item simultaneous monitoring (2 ITEMS) and then enter the following code numbers directly. a Monitoring items [1] Code No.01001: ENG SPEED (Engine speed) [2] Code No.04408: HST OIL TEMP (HST oil temperature)

3) 4)

Start the engine. Lower the bucket to near the ground, then drive the machine forward and thrust the bucket into the stockpile of soil or rock (portion a).

5)

While running the engine at high idle, press the accelerator pedal gradually. When the HST stalls, measure the engine speed. a Measure the stall speed 2 – 3 times. a Do not keep stalling the HST for more than 20 seconds. Take care that the HST oil temperature will not exceed 120°C.

Start the engine, set it in the measuring condition, and measure the engine speed.

8


110 Testing and adjusting, Part 1 Measuring engine speed

3.

Measuring hydraulic stall speed 1) Referring to “Special function of machine monitor”, select the real time monitoring function of the service mode. 2) Display “ENG SPEED” from the monitoring items of the machine monitor. a Monitoring item Code No. 01001: ENG SPEED (Engine speed)

3) 4)

Run the engine at high idle. Relieve the lift arm cylinder or bucket cylinder on the extraction side and measure the engine speed. a Finish measurement in a short time so that the hydraulic oil temperature will not exceed 120°C.


SEN03934-02 4.

Measuring HST stall and hydraulic stall (full stall) speed 1) Set the machine monitor as in “2. Measuring HST stall speed”. 2) Start the engine. 3) Lower the bucket to near the ground, then drive the machine forward and thrust the bucket into the stockpile of soil or rock (portion a).

4)

While running the engine at high idle, stall the HST and relieve the lift arm cylinder or bucket cylinder on the extraction side simultaneously and measure the engine speed at this time. a Do not keep stalling the HST for more than 20 seconds. Take care that the HST oil temperature will not exceed 120°C.

30-110

9

110 Testing and adjusting, Part 1 Measuring exhaust gas color

SEN03934-02

Measuring exhaust gas color a

Necessary tools

Symbol A k

a

a

1.

1

Part No.

Part Name

1

799-201-9001

Handy smoke checker

2

Commercially available

Smoke meter

When installing and removing the measuring instruments, take care not to touch a hot part. If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. Measure the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range Measuring with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in the muffler (exhaust pipe). 3) Start the engine and heighten the engine coolant temperature to the operating range. 4) Accelerate the engine suddenly and run it at HST stalling and hydraulic stalling, and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas.

2.

Measuring with smoke meter A2 1) Insert the probe of smoke meter A2 in the outlet of the muffler (exhaust pipe) and fix it to the exhaust pipe with a clip.

2)

3)

4)

5)

5) 6)

30-110

Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Keep the pressure of the supplied compressed air at 1.5 MPa {15 kg/ cm2} or below. Connect the power cable to a 100 V AC receptacle. a Confirm that the smoke meter power switch is in the OFF position, before connecting the power cable to an outlet. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter A2.

Take out the filter paper and compare it with the attached scale for judgement. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

10


110 Testing and adjusting, Part 1 Measuring exhaust gas color

6)

7)

8)

9)

SEN03934-02

Start the engine and keep it running until the engine coolant temperature rises to the operating range. Accelerate the engine suddenly or run it at high idle and press the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Put the polluted filter paper on non-polluted filter paper (more than 10 sheets) in the filter paper holder, and read the indicated value. After finishing work, remove the used instruments and return the removed parts.


30-110

11

110 Testing and adjusting, Part 1 Adjusting valve clearance

SEN03934-02

Adjusting valve clearance a

Part No.

Rotate the crankshaft forward (clockwise, seeing from the fan) with gear B1 and set wide slit (b) of the rotation sensor ring to projection top (a) of front cover. a Projection top (a) must be within the range of wide slit (b) when it is seen from the air conditioner compressor side. a If you can see the yellow marks (c) of projection top (a) and the damper periphery, you may set them to each other. a After the above positioning, the No. 1 cylinder or No. 6 cylinder is not at the top dead center (TDC). Take care. (The cylinder is at 76 – 88° before the top dead center.)

4.

Check the movement of the rocker arm of the No. 1 cylinder to judge the valve to be adjusted.

Part Name

1

795-799-1131

Gear

2


Clearance gauge

a

Adjust the valve clearance under the following condition. q Engine coolant temperature: Normal temperature

1.

Remove cylinder head cover (1). For details, see Disassembly and assembly, “Removal and installation of cylinder head assembly”. a Removal of the engine hood is unnecessary.

2.

3.

Necessary tools

Symbol B

1

Remove plate (2) and plug (3) at the bottom of the starting motor and insert gear B1.

a

a

a

30-110

12

If you can move the rocker arms of air intake valves (IN) with the hand by the valve clearance, adjust the valves marked with Q in the valve arrangement drawing. If you can move the rocker arms of exhaust valves (EX) with the hand by the valve clearance, adjust the valves marked with q in the valve arrangement drawing. Valve arrangement drawing


110 Testing and adjusting, Part 1 Adjusting valve clearance

5.

Adjust the valve clearance according to the following procedure. 1) While fixing adjustment screw (10), loosen locknut (11). 2) Insert clearance gauge B2 in the clearance between rocker arm (12) and crosshead (13) and adjust the valve clearance with adjustment screw (10). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the clearance gauge lightly. 3) While fixing adjustment screw (10), tighten locknut (11). 3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening the locknut, check the valve clearance again.

6.

Rotate the crankshaft forward by 1 turn and set wide slit (b) to projection top (a) according to step 3.

7.

Adjust the other valve clearances according to steps 4 and 5. a If the valves marked with q in the valve arrangement drawing were adjusted in steps 4 and 5, adjust the valves marked with Q. a If the valves marked with Q in the valve arrangement drawing were adjusted in steps 4 and 5, adjust the valves marked with q.

8.

After finishing adjustment, remove the adjusting tools and return the removed parts. a Remove gear B1 without fail. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}


SEN03934-02

30-110

13

110 Testing and adjusting, Part 1 Measuring compression pressure

SEN03934-02

Measuring compression pressure1 a

k

a

Part No.

Part Name

1

795-799-6700

Puller

2

795-502-1590

Gauge assembly

3

795-790-4410

Adapter

4

6754-11-3130

Gasket

When measuring the compression pressure, take care not to burn yourself on the exhaust manifold or muffler or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C)

1.

Remove cylinder head cover (1). For details, see Disassembly and assembly, “Removal and installation of cylinder head assembly”.

2.

Disconnect 3 injector wiring harness connectors (2) and move the wiring harnesses.

3.

Loosen injector terminal nut (4) and remove the terminal from the injector.

5.

Set the cylinder to be checked to the compression top dead center. a How to turn the crankshaft, refer to “Adjusting valve clearance”. a When the cylinder is at the compression top dead center, the rocker arm of the cylinder can be moved by the valve clearance with the hand.

6.

Remove rocker arm assembly (5).

7.

Remove retainer (6) and fuel inlet connector (7).

8.

Remove holder (8).

9.

Remove injector (9). a Using puller C1, remove the injector with impacts of a slide hammer. a Do not remove the injector by prying its top up.

Necessary tools

Symbol

C

4.

Disconnect fuel high-pressure tube (3).

30-110

14



SEN03934-02 16. Rotate the engine with the starting motor and measure the compression pressure. a Read the gauge when its pointer is stabilized.

10. Fit gasket C4 to the end of adapter C3 and insert them in the injector mounting portion.

17. After finishing measurement, remove the measuring tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) While matching projection (a) of the injector to notch (b) of the holder, set the injector to the cylinder head. a When setting the injector, direct the above matching position toward the fuel inlet connector insertion side.

11. Fix adapter C3 with injector holder. a Tighten the holder mounting bolts alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 12. Connect gauge assembly C2 to adapter C3. a If engine oil is applied thinly to the connecting parts of the adapter and gauge, air does not leak easily. 13. Install rocker arm assembly (5). 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm}

2) 3)

14. Adjust the valve clearance. a See “Adjusting valve clearance”. 4)

5)

Tighten injector holder mounting bolts (10) by 3 – 4 turns. Set fuel inlet connector (7). a Push in the fuel inlet connector until the O-ring is fitted and the connector clicks. Temporarily tighten retainer (6) of fuel inlet connector (7). a Tighten the above retainer in step 6). 3 Retainer: 15 ± 5 Nm {1.5 ± 0.5 kgm} Tighten injector holder mounting bolts (10) alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}

15. Referring to “Special functions of machine monitor (EMMS)”, set the engine in the no-injection cranking mode. k If the engine is not set in the no-injection cranking mode, it starts during measurement and that is dangerous. Accordingly, be sure to set the engine in the no-injection cranking mode.


30-110

15

SEN03934-02 6)

Permanently tighten retainer (6) of fuel inlet connector (7). 3 Retainer: 50 ± 5 Nm {5.1 ± 0.51 kgm}

7)

Tighten the sleeve nut of the fuel highpressure tube on the head side and then tighten that on the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}

8)

Connect the injector harness connector.


a

After installing the rocker arm assembly, adjust the valve clearance. For details, see “Adjusting valve clearance”. 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm}

a

Tighten the injector terminal nut to the following torque. 3 Terminal nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}

a

Tighten the head cover to the following torque. Head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3

30-110

16


110 Testing and adjusting, Part 1 Measuring blow-by pressure

SEN03934-02

Measuring blow-by pressure a

1

5.

While pressing the brake pedal, set the directional lever or switch to the F (forward) or R (reverse) position. k Keep pressing the brake pedal securely.

6.

Press the accelerator pedal gradually to the high idle. While running the engine at HST stalling and hydraulic stalling, measure the blow-by pressure. a Do not keep stalling the HST for more than 20 seconds. Take care that the HST oil temperature will not exceed 120°C. a 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 HST stalling and hydraulic stalling. a If it is impossible to run the engine at the rated output or HST stalling and hydraulic stalling, measure while the engine is running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output. a Precaution for measuring blow-by pressure: 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.

7.

Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

Necessary tools

Symbol

Part No.

D

799-201-1504

Part Name Blow-by checker

a

Measure the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q HST oil temperature: Within operating range

1.

Stop the engine. Install nozzle [1] and hose [2] of blow-by checker D to blow-by hose (1) and connect them to gauge [3].

a

Blow-by hose (1) comes out from the rear left of the engine and its end is fixed to the machine lower frame.

2.

Start the engine and increase the engine coolant temperature to the operating range.

3.

Press the left brake pedal securely.

4.

Release the parking brake.


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17

110 Testing and adjusting, Part 1 Measuring engine oil pressure

SEN03934-02

Measuring engine oil pressure a

Part No.

Part Name

1

799-101-5002

Hydraulic tester

2

799-301-1230

Nipple

3

799-101-5160

Nipple

4

799-401-2320

Gauge

a

Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range

1.

Open the engine left side cover.

2.

Remove plug (1) from oil filter head.

3.

4.

Start the engine and heighten the coolant temperature to the operating range.

5.

While running the engine at low idle and high idle, measure the oil pressure.

6.

Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

Necessary tools

Symbol

E

1

Install nipples E2 and E3, then connect hydraulic tester E4 (1 MPa {10 kg/cm2}).

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18


110 Testing and adjusting, Part 1 Measuring intake air (boost) pressure

Measuring intake air (boost) pressure a

k

k k

a

1.

2. 1

Necessary tools

Symbol F

SEN03934-02

Part No.

Measurement with measuring tool 1) Open the engine right side cover. 2) Remove air boost pressure pickup plug (1) (R1/8).

Part Name

1

799-101-5002

Hydraulic tester

2

799-201-2202

Boost gauge kit

When installing and removing the measuring instruments, take care not to touch a hot part of the engine. Put chocks under the tires securely. When measuring, check that there are no persons around the machine. Measure the intake air pressure (boost pressure) under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q HST oil temperature: Within operating range

3)

Install elbow [1] in hydraulic tester F1 and nipple [2] in boost gauge kit F2 and connect pressure gauge [3].

4)

Start the engine and increase the coolant temperature to the operating range. Run the engine at medium or higher speed to drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you may drain the oil by using the oil draining coupling (790-261-1130) in that kit. a If the oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. Press the left brake pedal securely. Release the parking brake. While pressing the brake pedal, set the directional lever to the F (forward) or R (reverse) position. k Keep pressing the brake pedal securely.

Measurement with monitoring function 1) Referring to “Special functions of machine monitor (EMMS)”, select the real-time monitoring function in the service mode. 2) Display “CHG PRESS-A” in the monitoring functions of the machine monitor. a Monitoring item Code No. 36500: CHG PRESS-A (Boost pressure)

5)

3)

a

Press the accelerator pedal gradually to the high idle and measure the boost pressure when HST stalling and hydraulic stalling. Do not keep the HST stalled for more that 20 seconds so that the HST oil temperature will not exceed 120°C.


6) 7) 8)

30-110

19

SEN03934-02 9)

110 Testing and adjusting, Part 1 Measuring intake air (boost) pressure

Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the HST and hydraulic work equipment and measure the intake air pressure (boost pressure). a Do not keep stalling the HST for more than 20 seconds. Take care that the HST oil temperature will not exceed 120°C.

10) Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

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20


110 Testing and adjusting, Part 1 Handling fuel system equipment

Handling fuel system equipment a

a

SEN03934-02

1

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacement of fuel filter cartridge The fuel filter cartridge used must be a genuine Komatsu part. The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) consist of more precision parts than those used for the current pumps and nozzles. This system, therefore, employs a special filter with highly efficient filtering performance to prevent mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause troubles in the fuel system. It is strictly prohibited to use such part.


Releasing residual pressure in fuel system a

a

a

k

1

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

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21

110 Testing and adjusting, Part 1 Measuring fuel pressure

SEN03934-02

Measuring fuel pressure a

1

k k

a

k

1.

2)

Install adapter G2 and nipple [1] of hydraulic tester G1 and connect them to oil pressure gauge [2]. a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.

3)

Run the engine at low idle and measure the pressure in the fuel low-pressure circuit. a If the pressure in the fuel low-pressure circuit is in the following range, it is normal.

Necessary tools

Symbol

G

1

2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

6732-81-3170

Adapter (10 × 1.0 mm o PT1/8)

6215-81-9710

O-ring

3

799-401-2320

Hydraulic tester

4

795-790-5110

Screw

5

799-201-2202

Boost gauge kit

Put chocks under the tires securely. When measuring, check that there are no persons around the machine. Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply pump and in the return circuit between the supply pump/common rail/ injector and fuel tank. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the fuel injector is very high, it cannot be measured. Measuring pressure in fuel low-pressure circuit 1) Remove fuel pressure pickup plug (1) from the fuel main filter.

k

4)

30-110

22

During cranking

0.3 – 1.1 MPa {3.1 – 11.3 kg/cm2}

At low idle

0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

If the engine cannot be started, you may measure the fuel pressure while rotating the engine with the starting motor. Do not rotate for more than 20 seconds continuously, however, for protection of the starting motor.

After finishing measurement, remove the measuring tools and return the removed parts. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.2 kgm}


110 Testing and adjusting, Part 1 Measuring fuel pressure

2.

SEN03934-02

Measuring pressure in fuel return circuit 1) Remove fuel pressure pickup plug (2) from the fuel return block.

2)

Install nipple [3] of hydraulic tester G1 and nipple [1] and connect them to hydraulic tester G3. a Nipple [3]: 790-301-1181, 07002-11223

3.

Measuring fuel negative-pressure circuit pressure 1) Remove joint bolt (2) of fuel hose (1) between the prefilter and supply pump.

2) a

3)

3)

Run the engine at low idle and measure the pressure in the fuel return circuit. a If the pressure in the fuel return circuit is in the following range, it is normal. During cranking At low idle

Max. 0.02 MPa {Max. 0.19 kg/cm2}

4)

k

4)

Connect fuel hose (1) to supply pump (3) by tool G4 instead of joint bolt (2). When installing tool G4, fit the gaskets to both sides of the fuel hose joint. 3 Tool G4: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} Connect tool G5 to tool G4.

If the engine cannot be started, you may measure the fuel pressure while rotating the engine with the starting motor. Do not rotate for more than 20 seconds continuously, however, for protection of the starting motor. After finishing measurement, remove the measuring tools and return the removed parts. 3 Fuel pressure pickup plug: 24 ± 4 Nm {2.4 ± 0.4 kgm}


5)

6)

Run the engine at high idle and measure the circuit negative pressure. Circuit standard negative pressure: Max. –50.7 kPa {–380 mmHg} If the negative pressure is higher than the standard pressure, the fuel prefilter may be clogged. In this case, replace the fuel prefilter and measure again. After finishing measurement, remove the measuring instruments and return the removed parts. 3 Joint bolt (2): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

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23

110 Testing and adjusting, Part 1 Measuring fuel return rate and leakage

SEN03934-02

Measuring fuel return rate and leakage a

Necessary tools

Symbol

a

k k

1.

Part No.

1

795-790-4700 Tester kit

2

795-790-6700 Adapter

3 H

1

Part name

6754-71-5340 Connector 6754-71-5350 Washer

4

Commercially Measuring cylinder available

5


6

Commercially Hose (Inside diameter 14 mm) available

4)

Prepare receiving pan of about 20 liters to receive the fuel flowing out during measurement. Put chocks under the tires securely. When measuring, check that there are no persons around the machine. Measuring supply pump delivery 1) Open the engine right side cover. 2) Loosen clamp (1) of supply pump discharge tube (2) and disconnect the tube.

3)

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Install test hose H6 to the nipple on the discharge side of the supply pump. a Fix the hose with a wire etc. a Adjust the route of the test hose so that it will not slacken and put its end in receiving pan.

24

5)

Crank the engine for 30 seconds and measure the delivery with measuring cylinder H4. a Adjust the route of the test hose so that it will not slacken and put its end in receiving pan. a Do not crank the engine for more than 30 seconds to protect the starting motor in any case other than this measurement. a If the supply pump delivery is in the following standard range, it is normal. At cranking speed (125 rpm)

Min. 75 cc

At cranking speed (150 rpm)

Min. 90 cc

After finishing measurement, remove the measuring instruments and return the removed parts. 3 Tube sleeve nut: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}



2.

Measuring return rate from supply pump 1) Open the engine right side cover. 2) Disconnect return hose (1) from the supply pump. a The return hose is connected by a quick coupler.

SEN03934-02 5)

Run the engine at low idle and measure the return rate in 25 seconds with measuring cylinder H4. a If the return rate from the supply pump is in the following range, it is normal. At low idle k

3)

4)

Max. 400 cc

If the engine cannot be started, you may measure the return rate while rotating the engine with the starting motor. Do not rotate for more than 25 seconds continuously, however, for protection of the starting motor.

Install connector H3 and cap nut [1] of tester kit H1 to the return hose to stop the fuel from flowing out. Connect test hose [2] of tester kit H1 to the supply pump. a Lay the test hose so that it will not slacken and put its end in the receiving pan. 6)


After finishing measurement, remove the measuring tools and return the removed parts. a When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to their original positions. a When measuring the leakage from the injector: Leave the removed parts as they are and keep the test hose end in the receiving pan.

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25


SEN03934-02 3.

Measuring leakage from pressure limiter 1) Open the engine right side cover. 2) Remove the main fuel filter bracket mounting bolt (2), and move the fuel filter and bracket assembly (3).

6)

Run the engine at low idle and measure the leakage in 1 minute with measuring cylinder H4. a If the leakage from the pressure limiter is in the following range, it is normal. At low idle

3)

Disconnect return hose (4) from the pressure limiter. a Install the seal washer to the connector bolt.

7)

4.

4)

5)

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Install removed connector bolt (5) and cap nut [1] of tester kit H1 to the return hose to stop the fuel from flowing out. Install connector H3 to the common rail and connect test hose [2] of tester kit H1. a Lay the test hose so that it will not slacken and put its end in the receiving pan.

26

0 cc (No leakage)

After finishing measurement, remove the measuring tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

Measuring return rate from injector a The leakage from the injector is measured while the return hose of the pressure limiter is connected. Accordingly, before measuring the leakage from the injector, check that the leakage from the pressure limiter is normal. 1) Referring to “Measuring return rate from supply pump”, set the supply pump for measurement. k The fuel returning from the supply pump flows out during measurement of the return rate from the injector. Accordingly, keep the test hose end in the receiving pan. 2) Remove connector bolt (6) of the return block.



SEN03934-02

3)

Install connector bolt [3] of adapter H2 instead of the removed connector bolt and connect test hose [4]. a Lay the test hose so that it will not slacken and put its end in the receiving pan.

4)

Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder H4. a If the return rate from the injector is in the following range, it is normal.

k

5)

During cranking

Max. 90 cc

At low idle

Max. 180 cc

If the engine cannot be started, you may measure the return rate while rotating the engine with the starting motor. Do not rotate for more than 20 seconds continuously, however, for protection of the starting motor.

After finishing measurement, remove the measuring tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}


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27

110 Testing and adjusting, Part 1 Bleeding air from fuel circuit

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Bleeding air from fuel circuit a k

1

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely.

1.

Fill the fuel tank with fuel.

2.

Open the right side cover of the engine.

3.

Turn feed pump knob (1) to the left to pull it out and operate it forward and backward. a Keep the operation of the knob until becomes hard to operate. a The plug at the top of the fuel main filter does not need to be removed.

4.

After bleeding air, push in knob (1) and turn it to the right to fix it.

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28


110 Testing and adjusting, Part 1 Checking leakage in fuel system

Checking leakage in fuel system k

a

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1

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, check it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.

2.

Run the engine at a speed below 1,000 rpm and stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.

4.

Run the engine at low idle.

5.


6.

Run the engine at high idle.

7.


8.

Start the engine and stall the HST or relieve the hydraulic pump to apply some load on the engine.


9.

Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage. a If no fuel leakage is detected, check is completed.

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29

110 Testing and adjusting, Part 1 Handling cylinder cut-out mode operation

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Handling cylinder cut-out mode operation a

1.

1

Cylinder cut-out mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal).

2.

When a cylinder is selected for the cylinder cut-out mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Compression leakage through cylinder head gasket q Defective injection q Defective piston, piston ring, or cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system

3.

Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a The reduced cylinder mode operation is set from the service mode of the machine monitor. For details, see “Special functions of machine monitor (EMMS)”, “Cylinder cutout mode operation function”.

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30

Handling no-injection cranking operation a

q

a

1

No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. When a machine or engine has been stored for a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure. The no-injection cranking operation is set from the service mode of the machine monitor. For details, see “Special functions of machine monitor (EMMS)”, “No-injection cranking function”.


110 Testing and adjusting, Part 1 Handling controller voltage circuit

Handling controller voltage circuit 1.

2.

When disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.


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Check of muffler and muffler stack for looseness and damage

1

1.

Check the muffler and muffler stack visually for a crack and damage. If any part is damaged, replace it.

2.

Check the mounting bolts and nuts of the muffler and muffler stack for looseness. If they are loosened, retighten them.

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31

110 Testing and adjusting, Part 1 Check of muffler function

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Check of muffler function q

1

Check the muffler for abnormal sound and difference in sound from a new machine. If it makes abnormal sound, repair it, referring to the Troubleshooting Volume.

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32

Check of installed condition of cylinder head and manifolds

1

Check the installed condition of the cylinder head and air intake manifold and exhaust manifold. If they are loosened, retighten them. a For the tightening torque, see the "Disassembly and assembly" volume.


110 Testing and adjusting, Part 1 Check of engine piping for damage and looseness

Check of engine piping for damage and looseness

SEN03934-02

1

Air intake and exhaust systems: Check the piping for damage, looseness of the mounting bolts and nuts, and suction of air and leakage of exhaust gas through the joints. If it is loosened or damaged, retighten or repair. Cooling system: Check the piping for damage, looseness of the mounting bolts and nuts, and leakage of water through the joints. If it is loosened or damaged, retighten or repair.

Testing and adjusting air conditioner compressor belt tension

1

Testing q Press the middle point between air conditioner compressor pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg} a Standard deflection (a): 11 – 14.5 mm

Fuel system: Check the piping for damage, looseness of the mounting bolts and nuts, and leakage of fuel through the joints. If it is loosened or damaged, retighten or repair.

Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen compressor bracket upper mounting bolts (1) and lower fixing nut (2). 2. Loosen locknut (3) and adjust the belt tension by turning adjustment bolt (4). 3. After the tension is adjusted to the reference value, tighten locknut (3), fixing nut (2) and compressor bracket mounting bolts (1).


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33

110 Testing and adjusting, Part 1 Replacing alternator belt

SEN03934-02

Replacing alternator belt a a k

1

The auto-tensioner is provided for the alternator belt. Thus, testing and adjustment of the belt is usually no necessary. Remove air conditioner compressor belt before replacing the alternator belt. Stop the machine on a flat ground and lower the work equipment to the ground.

1.

Open the engine left side cover.

2.

Apply wrench (a) to part A (width across flats T 12.7 mm) of tensioner assembly (1) and turn it in the arrow direction to decrease the tension of fan belt (2). k Make sure that the wrench (a) is secured at portion (A) before rotating it. (The spring of tensioner assembly (1) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing alternator belt (2), return tensioner assembly (1) slowly with care. k Be careful not to get your fingers caught between the pulley and alternator belt (2) during work.

3.

Replace alternator belt (2). Check each pulley for breakage and crack.

q

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34


110 Testing and adjusting, Part 1 Replacing alternator belt


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35

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30

120 Testing and adjusting, Part 2 Checking operating force of accelerator pedal ............................................................................................... 3 Checking directional lever............................................................................................................................... 4 Testing and adjusting HST oil pressure .......................................................................................................... 5 Testing clutch control pressure ....................................................................................................................... 9 Testing and adjusting steering wheel ............................................................................................................ 10 Testing and adjusting steering oil pressure................................................................................................... 12 Bleeding air from steering circuit................................................................................................................... 14 Testing hydraulic fan ..................................................................................................................................... 15 Measuring brake pedal ................................................................................................................................. 17 Testing and adjusting brake pedal linkage .................................................................................................... 18 Measuring brake performance ...................................................................................................................... 19 Testing and adjusting accumulator charge pressure..................................................................................... 20 Testing wheel brake oil pressure................................................................................................................... 22 Testing wear of brake disc ............................................................................................................................ 25 Bleeding air from wheel brake circuit ............................................................................................................ 26 Releasing residual pressure in brake accumulator circuit............................................................................. 27 Testing parking brake performance............................................................................................................... 28 Testing and adjusting parking brake control cable ........................................................................................ 29 Measuring and adjusting work equipment control lever................................................................................ 30 Testing and adjusting work equipment hydraulic pressure ........................................................................... 31 Testing work equipment PPC oil pressure .................................................................................................... 32 Bleeding air from hydraulic circuit ................................................................................................................. 34 Releasing remaining pressure in hydraulic circuit......................................................................................... 35 WA320, 320PZ-6 (KA SPEC.)

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1

SEN03935-02

120 Testing and adjusting, Part 2

Testing and adjusting bucket positioner ........................................................................................................ 36 Testing and adjusting of boom kick-out switch .............................................................................................. 37 Checking proximity switch operation pilot lamp ............................................................................................ 38 Procedure for testing diodes ......................................................................................................................... 39 Preparation work for troubleshooting for electric system .............................................................................. 40 Starting KOMTRAX terminal operations........................................................................................................ 44 Indicator lamps of KOMTRAX terminal ......................................................................................................... 48

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2


120 Testing and adjusting, Part 2 Checking operating force of accelerator pedal

Checking operating force of accelerator pedal

SEN03935-02 a

After greasing, wipe off grease completely (No grease is adhered on roller surface and roller sliding surface).

5.

After finishing the work, remove the measuring instruments and return the removed parts.

1

Necessary tools Symbol

Part No.

Part Name

J

79A-264-0021

Push-pull scale

k

Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely.

Testing accelerator pedal operating effort 1.

Set push-pull scale J at a position 150 mm from pedal fulcrum (a). a Put the center of push-pull scale J in contact with a point 150 mm from the pedal fulcrum.

Testing accelerator pedal operating angle 1. 2.

3.

2.

3. 4.

Start the engine. Measure operating angle (α) when the pedal is operated from the low idle position to the high idle position. Apply angle gauge [1] to accelerator pedal (1) and measure pressing angle between low idle angle α1 and high idle angle α2 (α = α1 – α2).

Start the engine, then measure the maximum value when the pedal is pushed in from the low idle position to the end of its travel (high idle). Stop the engine. If the squeak noise is heard from accelerator pedal when checking, lubricate from grease nipple (1) of roller shaft. 2 Roller shaft: Grease (G2-LI)


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3

120 Testing and adjusting, Part 2 Checking directional lever

SEN03935-02

Checking directional lever

1


Part No.

Part Name

1

79A-264-0021

Push-pull scale

2


Scale

K k


Checking operating effort of directional lever 1. 2.

Stop the engine. Install push-pull scale K1 or a spring balance to a point 10 mm from the tip of the directional lever, then measure the operating effort when the lever is pulled in the direction of actuation. a Carry out the measurement in each speed range.

Checking travel of directional lever 1. 2.

Stop the engine. Make mark (a) on the center of the knob of the directional lever, then measure the travel with scale K2 when the lever is operated in the direction of actuation.

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4


120 Testing and adjusting, Part 2 Testing and adjusting HST oil pressure

Testing and adjusting HST oil pressure

SEN03935-02

1


Part No.

Part Name

799-101-5002

Analog type hydraulic tester

790-261-1204

Digital type hydraulic tester

L k

a a

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. HST oil temperature when measuring: Within operating range The high-pressure relief pressure is the same as the safety pressure of the main circuit, so it cannot be measured. (Normally, the cut-off valve is actuated first, so it does not rise to the safety valve set pressure)

Testing Testing high-pressure cut-off oil pressure [Testing with monitoring function] 1. Referring to “Special functions of machine monitor (EMMS)”, select the real-time monitoring function in the service mode. 2. Display “HST PRESS” among the monitoring items of the machine monitor. a Monitoring item Code No. 32600: HST PRESS (HST oil pressure) [Testing with tools] 1. Open the engine hood side cover. 2. Install oil pressure gauge L (60 MPa {600 kg/ cm2}) to pressure measurement nipple (1). q Nipple (1): For FORWARD circuit (port: MA) q Nipple (2): For REVERSE circuit (port: MB) a Install the oil pressure gauge L to nipple (1) of the forward circuit.

3.

Measure the high-pressure cut-off oil pressure under the following conditions. 1) Lower the bucket to near the ground, then drive the machine forward and thrust the bucket into the stockpile of soil or rock (portion a). a Set the directional lever to FORWARD and the speed selector switch to 2nd and traction control switch to ON.

2)

3)

4)


Run the engine at full throttle and press the bucket into part “a” until the machine does not move forward. k Carry out the measurement on hard ground where it is difficult for the tires to slip. Keep the engine running at full throttle, check that the tires are not turning, then measure the oil pressure. After finishing the work, remove the measuring instruments and return the removed parts.

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5


SEN03935-02 Testing low-pressure relief pressure (basic pressure of work equipment PPC circuit) [Testing with monitoring function] See “Testing high-pressure cut-off oil pressure”. [Testing with tools] 1. Remove low-pressure relief pressure measurement plug (3) (10 mm, P = 1.25 mm) from under the machine. a The oil pressure pickup plug is installed to the accumulator bottom near the lower right of the transfer on the right side of the rear frame. 2.

3.

4.

2.

Remove servo piston control pressure measurement plug (5) (DA pressure) (10 mm, P = 1.25 mm).

3.

Install nipple L [3], then connect oil pressure gauge L [1], L [2] (6 MPa {60 kg/cm2}).

4.

Place the directional lever at N, run the engine at high idle, and measure the control pressure when the brake pedal is depressed and when it is released. a The brake pedal is connected to the inching valve and controls the control pressure. After finishing the work, remove the measuring instruments and return the removed parts.

Install a nipple, then connect oil pressure gauge L (6 MPa {60 kg/cm2}).

Place the directional lever at N, run the engine at high idle, and measure the low-pressure relief pressure. After finishing the work, remove the measuring instruments and return the removed parts.

Testing servo piston control pressure (DA pressure) 1. Remove floor frame cover (4) (bottom left of operator's cab). 5.

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6



Testing servo piston actuating pressure 1. Remove servo piston actuation pressure measurement plug (6) or (7) (G 1/4) (width across flats for hexagonal head wrench: 8 mm). q Plug (6): For FORWARD circuit (port: X1) q Plug (7): For REVERSE circuit (port: X2)

2.

Install a nipple L [3], then connect oil pressure gauge L [1], L [2] (6 MPa {60 kg/cm2}).

3.

Measure the servo piston actuating pressure under the following conditions. 1) Set the gear speed selector switch in the “1st” position and set the travel speed control dial in the “1” position on the lowest speed side. 2) Measure the oil pressure while driving forward at full throttle (5 km/h). Similarly, measure while driving in reverse. a Do not press the brake pedal. After finishing the work, remove the measuring instruments and return the removed parts.

4.

SEN03935-02 Adjusting a

The high-pressure relief pressure is also the safety pressure of the main circuit, so it cannot be measured. (Normally, the cut-off valve is actuated first, so it does not rise to the safety valve set pressure) Adjusting high-pressure cut-off valve a If the high-pressure cut-off pressure is not correct, adjust high-pressure cut-off valve (8) as follows. 1. Remove the engine hood. 2. Loosen locknut (9) of high-pressure cut-off valve (8), then turn adjustment screw (10) to adjust. a Turn the adjustment screw to adjust as follows. q To INCREASE pressure, turn CLOCKWISE. q To DECREASE pressure, turn COUNTERCLOCKWISE. a Amount of adjustment for one turn of adjustment screw: 9.1 MPa {93 kg/cm2} 3. After adjusting, tighten locknut (9). 3 Locknut: 37.2 Nm {3.8 kgm}

a


After completion of adjustment, repeat the measurement procedure to check the high-pressure cut-off oil pressure again.

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7


SEN03935-02 Adjusting low-pressure relief valve a If the low-pressure relief pressure is not correct, adjust the low-pressure relief valve as follows. 1. Remove the engine hood. 2. Remove cap (12) and loosen low-pressure relief valve (11) and locknut (13) and rotate adjustment screw (14) to adjust the pressure. a Turn the adjustment screw to adjust as follows. q To INCREASE pressure, turn CLOCKWISE. q To DECREASE pressure, turn COUNTERCLOCKWISE a Amount of adjustment for one turn of adjustment screw: 0.38 MPa {3.9 kg/cm2} 3. After adjusting, tighten locknut (13). 3 Locknut: 69.6 Nm {7.1 kgm}

Adjusting DA valve a If the servo piston control pressure is not correct, adjust the DA valve as follows. 1. Remove the engine hood. 2. Loosen locknut (16) of DA valve (15), then turn adjustment screw (17) to adjust. a Turn the adjustment screw to adjust as follows. q To DECREASE pressure, turn CLOCKWISE. q To INCREASE pressure, turn COUNTERCLOCKWISE a Amount of adjustment for one turn of adjustment screw: 0.34 MPa {3.5 kg/cm2} 3. After adjusting, tighten locknut (16). 3 Locknut: 64.7 Nm {6.6 kgm}

a a

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After completion of adjustment, repeat the measurement procedure to check the lowpressure relief pressure again.

8

After completion of adjustment, repeat the measurement procedure to check the control pressure again.


120 Testing and adjusting, Part 2 Testing clutch control pressure

SEN03935-02

Testing clutch control pressure

1

3.

Connect hydraulic tester M1 (6 MPa {60 kg/cm2}) and adapter M2 (Hose size: For # 03).

4.

Set the speed selector switch to 3rd or 4th, travel at a speed of at least 10 km/h, and measure the clutch inlet pressure (clutch solenoid valve output pressure).

5.



Part No.

Part Name

799-101-5002


790-261-1204


799-401-3200

Adapter

02896-11009

O-ring

1 M 2 k

When removing the measurement plug and disconnecting the hose, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1.

Remove the rear frame left side cover (1).

2.

Disconnect clutch solenoid valve output pressure (clutch inlet pressure) hose (2).


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9

120 Testing and adjusting, Part 2 Testing and adjusting steering wheel

SEN03935-02

Testing and adjusting steering wheel

Measuring operating effort of steering wheel 1


Part No.

N

79A-264-0021

a

Measurement conditions q Road surface: Flat, horizontal, dry paved surface q Engine coolant temperature: Within green range on engine coolant temperature gauge q Hydraulic oil temperature: 45 – 55°C q Tire inflation pressure: Specified pressure q Engine speed: Low idle (bucket empty)

1.

Install push-pull scale N to the steering wheel knob (2).

2.

Start the engine. a After starting the engine, raise the bucket approx. 400 mm and remove the frame lock bar.

3.

Pull push-pull scale N in the tangential direction and measure the value when the steering wheel moves smoothly. a Do not use the value when the steering wheel starts to move.

4.


Part Name Push-pull scale

Measuring play of steering wheel a

Measurement conditions q Engine speed: Stopped q Machine posture: Facing straight forward

1.

Move the steering wheel (1) 2 or 3 times lightly to the left and right, check that the steering mechanism is at the neutral position, then make mark (A) on the outside frame of the machine monitor. Turn the steering wheel to the right, and make mark (B) at the position where the operating effort starts to become heavy.

2.

3.

Turn the steering wheel to the left in the opposite direction from Step 2, and make mark (C) a t t h e p o i nt w h e r e t h e o p e r a t i n g e ff o r t becomes heavy (when the steering valve lever starts to move). Then measure the distance in a straight line between marks (B) and (C).

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10


120 Testing and adjusting, Part 2 Testing and adjusting steering wheel

SEN03935-02

Measuring operating time for steering wheel a

Measurement conditions q Road surface: Flat, horizontal, dry paved surface q Engine coolant temperature: Within green range on engine coolant temperature gauge q Hydraulic oil temperature: 45 – 55°C q Tire inflation pressure: Specified pressure q Engine speed Low idle and high idle

1.

Start the engine. a After starting the engine, raise the bucket approx. 400 mm and remove the frame lock bar. Operate the steering wheel to the end of its stroke to turn the machine to the left or right. Measure the time taken to operate the steering wheel to the end of the stroke to the right or left. a Turn the steering wheel smoothly at a speed of 60 rpm. a Carry out the measurements both at low idle and high idle, and to both the left and right.

2. 3.


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11

120 Testing and adjusting, Part 2 Testing and adjusting steering oil pressure

SEN03935-02

Testing and adjusting steering oil pressure 1

3.

Fit a nipple P [3] to the steering circuit pressure measurement plug hole, then install oil pressure gauge P [1] and P [2] (40 MPa {400 kg/cm2}).

4.

Start the engine, run the engine at high idle, then turn the steering wheel to the left or right and measure the pressure when the relief valve is actuated.


Part No.

Part Name

799-101-5002


790-261-1204


P

a

Measuring condition q Hydraulic oil temperature:45 – 55°C q Engine speed: High idle

Measuring main relief pressure 1.

2.

Fit frame lock bar (1) between front frame and rear frame.

Remove oil pressure pickup plug (2) of the steering cylinder circuit.

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12


120 Testing and adjusting, Part 2 Testing and adjusting steering oil pressure

Adjusting main relief pressure 1. 2.

Stop the engine. Remove cover (1) at the lower right of the operator's cab.

3.

Disconnect hose (3) and fitting (4) connected to port (T) of the priority valve (2).


SEN03935-02 4.

Loosen lock screw (5), and then turn adjustment screw (6) to adjust. a Turn the adjustment screw to adjust as follows. q To INCREASE pressure, turn CLOCKWISE. q To DECREASE pressure, turn COUNTERCLOCKWISE. a Pressure adjustment for one turn of adjustment screw: Approx. 6.9 MPa {70 kg/cm2} a Tool [1] for adjusting adjustment screw: Size 7/32 inch, hexagonal a Do not carry out any adjustment if the relief pressure cannot be measured accurately. 3 Adjustment screw (6): 2.3 – 6.8 Nm {0.23 – 0.69 kgm} 3 Lock screw (5): 14.7 ± 2 Nm {1.5 ± 0.2 kgm}

5.


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13

SEN03935-02

120 Testing and adjusting, Part 2 Bleeding air from steering circuit

Bleeding air from steering circuit 1 a

Bleed the air from the circuit as follows if the steering valve or steering cylinder have been removed and installed again.

1.

Start the engine and run at idle for approx. 5 minutes.

2.

Run the engine at low idle and turn 4 – 5 times to the left and right. a Operate the piston rod to approx. 100 mm before the end of its stroke. Be careful not to relieve the circuit.

3.

Repeat Step 2 with the engine at full throttle.

4.

Run the engine at low idle and operate the piston to the end of its stroke to relieve the circuit.

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14


120 Testing and adjusting, Part 2 Testing hydraulic fan

SEN03935-02

Testing hydraulic fan

1

3.

Install tachometer P1 to the tripod. a Set tachometer P1 perpendicular to reflector tape [1].

4.

Start the engine, run at high idle, and measure the fan speed.

5.


Necessary tools Symbol 1 Q

2 3

k

k

a a

Part No.

Part Name

799-205-1100

Tachometer KIT

799-101-5002


790-261-1204


799-401-3400

Adapter

02896-11015

O-ring

Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely. When removing the measurement plug and disconnecting the hose, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Measurement conditions q Hydraulic oil temperature: 45 – 55°C Test the fan in a place where the fan blade and probe will not be exposed to direct sunlight or strong light.

Testing fan speed 1.

Open the radiator grille.

2.

Stick reflector tape [1] of tachometer P1 to a metallic part of the fan.


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15

120 Testing and adjusting, Part 2 Testing hydraulic fan

SEN03935-02 Testing fan drive oil pressure 1.

Open the radiator grille.

2.

Remove the fan motor cover (1).

3.

4.

Start the engine and measure the fan drive oil pressure.

5.


Disconnect hose (2), install oil pressure gauge Q2 (40 MPa {400 kg/cm 2 }) and adapter Q3 (Hose size: For #04), and connect hose (2) again.

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16


120 Testing and adjusting, Part 2 Measuring brake pedal

Measuring brake pedal a q q

SEN03935-02

1

Measurement conditions Engine coolant temperature: Within green range on engine coolant temperature gauge Engine speed: Low idle

1.

Install push gauge [1] to the operator's foot. a Set the push gauge at a point 150 mm from the fulcrum of the pedal.

2.

Start the engine, and measure pedal angle “α1” when running at low idle.

3.

Apply angle gauge [2] to the brake pedal and measure pressing angle (α) between pressing angles (α1) and (α2) (α = α1 – α2). q Operating effort at (α2): 196 N {20 kg}.


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17

SEN03935-02

120 Testing and adjusting, Part 2 Testing and adjusting brake pedal linkage

Testing and adjusting brake pedal linkage 1 Testing 1.

Check for play in linkage mounting pin (7), pinhole of lever (6), and lever bushing.

2.

Measure length of link (1), and check that it is within the standard value. Standard link length (a): 184 mm a Measure the length from the center of pin (5) to the center of ball joint (3).

3.

Measure the distance of movement of rod (8) and check that clearance (b) is within the standard value. Standard clearance (b): 0 – 0.3 mm a When doing this, check that the brake pedal is in contact with the stopper.

Adjusting Adjusting link length (a) 1. Remove pin (5) and ball joint (3), then remove rod (1). 2. Loosen locknut (4), then turn yoke (2) and ball joint (3) to adjust the length. 3. After adjusting the length of link (a), connect it to the brake pedal. a Standard value (a): 184 mm Adjusting clearance (b) 1. Loosen locknut (7), turn rod (8) so that the tip of the rod contacts the booster cylinder piston, then turn rod (8) back 1/4 turn. 2. Tighten locknut (7). a Standard value (b): 0 – 0.3 mm

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18


120 Testing and adjusting, Part 2 Measuring brake performance

SEN03935-02

Measuring brake performance

1

9JF01100

a

Measurement conditions q Road surface: Flat, horizontal, dry paved surface q Travel speed: 35 km/h when brakes are applied q Tire inflation pressure: Specified pressure q Tire size: 20.5 – 25 q Delay in applying brakes: 0.1 sec q Specified operating effort: 322 N {33 kg}

Measurement method 1.

Start the engine and drive the machine.

2.

Set the speed selector switch to 4th and drive the machine.

3.

When the travel speed reaches 35 km/h, depress the left brake pedal with the specified operating effort. a Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point.

4.

Measure the distance from the point where the brakes were applied to the point where the machine stopped. a Repeat this measurement three times and take the average.


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19

120 Testing and adjusting, Part 2 Testing and adjusting accumulator charge pressure

SEN03935-02

Testing and adjusting accumulator charge pressure

1


Part No.

Part Name

799-101-5002


790-261-1204


R k


Measuring 4. q

Hydraulic oil temperature: 45 – 55°C Stop the engine, then depress the brake pedal at least 100 times to release the pressure inside the accumulator circuit.

1.

Remove the rear frame left side cover (1).

k

Measure the accumulator charge cut-in pressure. Start the engine, run the engine at low idle, and measure the oil pressure when the brake pressure caution lamp on the monitor panel goes out. q Cut-in pressure: +2 5.9 +0.2 0 MPa {60 0 kg/cm } 2

5.

Measure the accumulator charge cut-out pressure. a After the accumulator charge cut-in is actuated, measure the oil pressure when the indicator of the oil pressure gauge has risen and suddenly starts to drop. q Cut-out pressure: 9.8 +0.98 MPa {100 +10 0 0 kg/cm } 2

6.

2.

Remove plug (2).

3.

Install measurement nipple and oil pressure gauge R (40 MPa {400 kg/cm2}).

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20



120 Testing and adjusting, Part 2 Testing and adjusting accumulator charge pressure

SEN03935-02

Adjusting a

When the accumulator charge cut-out pressure is adjusted, the cut-in pressure also changes in proportion to the ratio of the valve area.

1.

Loosen locknut (4) of unload relief valve (accumulator charge cut-out valve) (3), then turn adjustment screw (5) to adjust. a Turn the adjustment screw to adjust as follows. q To RAISE pressure, turn CLOCKWISE q To LOWER pressure, turn COUNTERCLOCKWISE a Pressure adjustment for one turn of adjustment screw: 1.45 MPa {14.8 kg/cm2}

2.

After adjusting, tighten locknut (4). 3 Locknut: 11.8 – 16.7 Nm {1.2 – 1.7 kgm}

a

After completion of adjustment, repeat the measurement procedure given above to check the accumulator cut-in pressure and cutout pressure again.


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21

120 Testing and adjusting, Part 2 Testing wheel brake oil pressure

SEN03935-02

Testing wheel brake oil pressure a

1

2.

Remove brake tube (2) of the measured side. a The right side is shown as an example in the figure.

3.

Remove union (3) and install adapter S4 and nipple S5. a Use the O-ring fitted to the union.

4.

Connect brake test kit S1 to nipple S5. a For the composition and connection, see the figure on the following page.

5.

Connect hose [1] and loosen bleeder screw (4) to bleed air. a Operate tool S3 to bleed air.

Necessary tools

Symbol

Part No.

Part Name

1 793-605-1001 Brake test kit 2 790-101-1430 Coupler 3 790-101-1102 Pump S

4 790-301-1720 Adapter 5 799-101-5160 Nipple 6 799-401-2220 Hose 7 790-261-1130 Coupling T

k

k

a a

1.

793-463-1100 Stopper

Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely. Apply the parking brake. Measure the oil pressure of the front brakes (right and left) and rear brakes (right and left) similarly. Measuring condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range Remove front frame inspection cover (1). k When raising the lift arm to remove the inspection cover, place a stand [1] under it to support securely. Instead, you may set stopper T to the lift arm cylinder to prevent the work equipment from lowering.

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22



SEN03935-02

Composition and connection diagram of brake test kit S


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23

SEN03935-02 6.

Tighten bleeder screw (4), operate pump S3 to increase the pressure to 4.1 MPa {42 kg/cm2}, and tighten stop valve [2] (a component part of S1).

7.

Leave the brake circuit pressurized for 5 minutes and check lowering of the pressure. a If the hose is moved while the pressure is m ea s u re d , t h e p re s s u re f l u c t u at e s . Accordingly, do not move the hose. a After testing the pressure, operate pump S3 to lower the pressure in brake test kit S1, and then remove brake test kit S1. a After finishing testing, install the brake tube and bleed air from the brake circuit.

8.


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24



120 Testing and adjusting, Part 2 Testing wear of brake disc

Testing wear of brake disc k

SEN03935-02

1

a

Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely. There are caps for inspection on the right and left sides of the front and rear axles. Check at all of the 4 caps similarly.

1.

Remove cap (1) from the axle housing.


2.

Press the brake pedal to the stroke end.

3.

With shaft (2) pushed in, measure projection (x) from surface (a) of guide (3) (wear). a Keep pressing the brake pedal while measuring the wear. a If shaft (2) is projected from the end of guide (3) to the groove, replace the disc. q Wear: (x) from (a) q Wear limit: (y) from (a) (1.6 mm) a If surface (b) of shaft is seen, it is wear limit.

4.

After testing, return cap (1). 3 Cap (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}

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25

120 Testing and adjusting, Part 2 Bleeding air from wheel brake circuit

SEN03935-02

Bleeding air from wheel brake circuit

3.

Connect hose [1] to bleeder screw (2) and place hose [1] in the oil receive pan. a Work on the rear side similarly from underside of the machine.

4.

Press the brake pedal and then loosen bleeder screw (2) to bleed air. a Return the brake pedal slowly after tightening bleeder screw (2).

5.

Repeat this operation until the oil flowing through hose [1] becomes free from bubbles. Then press the pedal fully and tighten bleeder screw (2) while the oil is flowing. a As accumulated pressure in the accumulator is decreased, start the engine to accumulate pressure in the accumulator. Then bleed air using the same procedure as described above. a After finishing bleeding air, run the engine at low idle and check the oil level in the hydraulic tank. If the level is low, add oil up to the specified level.

6.


1

Necessary tools Symbol T k

a a a a

Part No.

Part name

793-463-1100 Stopper

Stop the machine on a level ground, lower the work equipment to the ground, and set chocks under the tire securely. If a brake circuit part is removed and installed, bleed air from the brake circuit according to the following procedure. Bleed air from the front brake circuit and rear brake circuit similarly (2 places each). When a complete bleeding is required, it is advisable to start the operation from the brake cylinder situated farthest from the brake pedal. The work on the front right side is shown as an example. Work on each brake cylinder similarly.

1.

Start the engine to accumulate pressure in the accumulator and then stop the engine.

2.

Remove front frame inspection cover (1). k When raising the lift arm and removing the inspection cover, place support stand [1] under the lift arm to support the lift arm securely or set stopper T to the lift arm cylinder to prevent the work equipment from falling.

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26


120 Testing and adjusting, Part 2 Releasing residual pressure in brake accumulator circuit

Releasing residual pressure in brake accumulator circuit k

q q

SEN03935-02

1

Before disconnecting any of the following brake accumulator circuits, release residual pressure in that brake circuits. Piping between accumulator charge valve and brake accumulator Piping between brake accumulator and brake valve on both sides

1.

Stop the engine.

2.

Press the brake pedal at least 100 times to release the pressure from the brake accumulator circuit.


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27

120 Testing and adjusting, Part 2 Testing parking brake performance

SEN03935-02

Testing parking brake performance a

1

Measurement condition q Tire inflation pressure: Specified pressure q Road: 1/5 gradient (11° 20'), flat, and dry road q Machine: Ready for operation

Measuring method 1. Start the engine and set the machine in the straight travel position, and then drive up a slope of 1/5 gradient with no load in the bucket. 2.

Press the brake pedal to stop the machine, set the directional lever in the N position, and stop the engine.

3.

Pull the parking brake lever fully, release the brake pedal gradually, and check that the machine is kept stopped. a Measure the parking brake performance on an uphill and a downhill.

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28


120 Testing and adjusting, Part 2 Testing and adjusting parking brake control cable

Testing and adjusting parking brake control cable

SEN03935-02

1


Part No.

V

79A-264-0021

k

Part Name Push-pull scale


Testing 1. Install push-pull scale V to a position at dimension (a) from the end of parking brake lever (1) (excluding the button) and pull it with a force of about 294 N {about 30 kg}. q Dimension (a): 55 mm 2.

Adjusting 1. Release the parking brake. a Check that the pawl of the parking brake lever is at the lowest position.

If the parking brake lever is pulled by 9 teeth or more, check the fixing parts of the parking brake control cable (on both lever side and brake side) for looseness. If the fixing parts are loosened, tighten them, and then perform the following adjustment.


2.

Loosen locknut (2) and remove clevis pin (3).

3.

Pull parking brake lever (4) on the transfer side in the release direction. (Add the play of the parking brake lever to the upper side, however.)

4.

Under the above condition, tighten clevis (5) to match its hole to the hole of parking brake lever (4).

5.

Install clevis pin (3) and tighten locknut (2). 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm} a After finishing adjustment, pull parking brake lever (1) again with a force of about 294 N {about 30 kg} and check that it travels 7 – 8 clicks.

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29

120 Testing and adjusting, Part 2 Measuring and adjusting work equipment control lever

SEN03935-02

Measuring and adjusting work equipment control lever

1


k q q q

Part Name

1

79A-264-0021

Push-pull scale

2


Scale

W

a

Part No.

Measuring travel of work equipment control lever Measure the travel at each position when operating the work equipment control lever. a Mark the lever knob and use a scale W2 to measure. a If the stroke is not within the standard value, check for play in the work equipment PPC valve.

Install the frame lock bar to the frame. Measuring condition Engine coolant temperature: Operating range of engine coolant thermometer Hydraulic oil temperature: 45 – 55°C Engine speed: Low idle

Measuring operating effort of work equipment control lever Install tool W1 to the work equipment control lever and secure it in position. a Install tool W1 to the center of the knob. a Operate the control lever at the same speed as for normal operations, and measure the minimum value for the effort needed to operate the knob.

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30


120 Testing and adjusting, Part 2 Testing and adjusting work equipment hydraulic pressure

Testing and adjusting work equipment hydraulic pressure

Adjusting 1


Part No.

Part Name

799-101-5002


790-261-1204


793-463-1100

Stopper

SEN03935-02

a k

X T k

Always stop the engine before adjusting the oil pressure. When carrying out the operation with the lift arm raised, set support [1] or lift arm drop prevention stopper T in position before starting the operation.

1.

Remove front frame inspection cover (1).

2.

Remove cap nut (2) of relief valve (5).

3.

Loosen locknut (3) of relief valve (5), then turn adjustment screw (4) to adjust. a Turn the adjustment screw to adjust the set pressure as follows. q TIGHTEN to INCREASE pressure q LOOSEN to DECREASE pressure a Pressure adjustment for one turn of adjustment screw: Approx. 4.2 MPa {Approx. 42.8 kg/cm2} a Do not carry out any adjustment if the relief pressure cannot be measured accurately.

4.


Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank, then operate the control lever several times to release the remaining pressure in the hydraulic piping.

Measuring condition Hydraulic oil temperature: 45 – 55°C

q

Measuring 1.

2.

Install hydraulic tester X (40 MPa {400 kg/cm2}) to the oil pressure measurement nipple.

Start the engine, raise the lift arm approx. 400 mm, run the engine at high idle, then operate the control lever to tilt back the bucket, and measure the pressure when the relief valve is actuated.


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31

120 Testing and adjusting, Part 2 Testing work equipment PPC oil pressure

SEN03935-02

Testing work equipment PPC oil pressure

1


Part No.

Part Name

799-101-5002


790-261-1204


793-463-1100

Stopper

Y T k

Checking PPC valve output pressure 1. Remove the inspection cover (1) of the front frame. k Except for measuring the oil pressure, when carrying out preparatory operations with the lift arm raised, set support [1] or lift arm drop prevention stopper T in position before starting the operation.

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the pressure in the piping.

Measuring condition Hydraulic oil temperature: 45 – 55°C

q

k

When leaving the operator's seat, apply the work equipment lock lever securely.

Testing PPC valve basic pressure 1. Remove plug (4) (10 mm, P = 1.25 mm) for measuring the work equipment PPC valve basic pressure (same as low-pressure relief pressure) from under the machine. 2. Fit a nipple, then install oil pressure gauge Y (6 MPa {60 kg/cm2}). 3. Start the engine. 4. Run the engine at high idle, then operate the work equipment control lever and measure the oil pressure.

5.

2.

3. 4.

Remove PPC output pressure measurement plug of the circuit to be measured, then install oil pressure gauge Y (6 MPa {60 kg/cm2}). Start the engine, then remove support [1] or boom drop prevention stopper T. Operate the work equipment control lever at high idle and measure the oil pressure.


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32


120 Testing and adjusting, Part 2 Testing work equipment PPC oil pressure

a

5.

SEN03935-02

A: Bucket TILT B: Bucket DUMP C: Lift arm RAISE D: Lift arm LOWER



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33

120 Testing and adjusting, Part 2 Bleeding air from hydraulic circuit

SEN03935-02

Bleeding air from hydraulic circuit

1

Bleeding air from work equipment PPC circuit 1. Operate each work equipment lever fully and hold it in position to relieve the circuit for approx. 1 minute. Carry out this operation once for each work equipment lever stroke end. Bleeding air from cylinders 1. Start the engine and run at idle for approx. 5 minutes. 2. Run the engine at low idle, then raise and lower the lift arm 4 – 5 times in succession. a Operate the piston rod to a point approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3. Run the engine at full throttle and repeat Step 2. After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4. Repeat Steps 2 and 3 to bleed the air from the bucket and steering cylinders. a When the cylinder has been replaced, bleed the air before connecting the piston rod.

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34


120 Testing and adjusting, Part 2 Releasing remaining pressure in hydraulic circuit

Releasing remaining pressure in hydraulic circuit

SEN03935-02

1

Releasing remaining pressure between each hydraulic cylinder and control valve a If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. 1. Lower the work equipment to the ground, and stop the engine. 2. Loosen the oil filler cap slowly to release the pressure inside the tank. 3. Operate the control lever. a When the lever is operated 5 – 6 times to release all the remaining pressure. Releasing remaining pressure in brake accumulator circuit a If the piping between the ACC charge valve and brake accumulator, between the ACC charge valve and parking brake valve, and between the accumulator and brake valve is to be disconnected, release the remaining pressure from the circuit as follows. 1. Stop the engine. 2. Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit. Releasing remaining pressure in PPC accumulator circuit a If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from the circuit as follows. 1. Lower the work equipment to the ground, and stop the engine. 2. Operate the control lever 5 – 6 times to release all the remaining pressure from the circuit.


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35

120 Testing and adjusting, Part 2 Testing and adjusting bucket positioner

SEN03935-02

Testing and adjusting bucket positioner a

2) 1

Measuring condition q Engine coolant temperature: White range of engine coolant thermometer q Hydraulic oil temperature: 45 – 55°C

Testing 1. Stop the engine and check that clearance (a) between proximity switch (1) and detection bar (2) is in the standard range. a Standard clearance (a): 3 – 5 mm

2.

Run the engine at same as usual working speed and check the operating point. (Measure 3 times and obtain the average.)

2.

Adjust and secure clearance (a) between the sensitive surface of proximity switch (1) and detection bar (2) to the standard range with the shim and mounting bolt of the proximity switch bracket. a Standard clearance (a): 3 – 5 mm a Adjust detection bar (2) with the shim so that clearance (a) will be in the standard range through the stroke of the detection bar (2).

Adjusting installing position (stopping position). 1) Lower the bucket to the ground and set it to a desired digging angle, then return the lever to the HOLD position and stop the engine. 2) Adjust with switch mounting nut (4) so that clearance (b) of the detection bar (2) of proximity switch (1) is within the standard value, then secure in position. 3 Switch mounting nut: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} q The installing position may be checked by checking the operation of the pilot lamp of the proximity switch with the starting switch at the ON position. a For ON/OFF of the pilot lamp, see “Checking proximity switch working pilot lamp”.

Adjusting 1. Adjusting clearance. 1) Adjust and secure clearance (b) between the tip of switch protector (3) and the sensitive surface of the switch to the standard range with switch nuts (4). a Standard clearance (b): 0.5 – 1.0 mm 3 Mounting nut: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}

a

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36

After adjusting, start the engine and operate the work equipment control lever to check that the bucket positioner sets the bucket at the desired position.


120 Testing and adjusting, Part 2 Testing and adjusting of boom kick-out switch

Testing and adjusting of boom kick-out switch

SEN03935-02 4. 1

Testing 1.

With the engine stopped, check that clearance (a) between detection surface of switch (1) and plate (2) is the standard value. a Standard clearance (a): 3 – 5 mm

2.

Start the engine, run at high idle, and check the actuation point. (Check three times and take the average.)

Adjust the switch so that clearance (a) between the sensing surface of the switch and plate (2) is the standard value, then secure in position. 3 Switch mounting nut: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} q The installing position may be checked by checking the operation of the pilot lamp of the proximity switch with the starting switch at the ON position. a For ON/OFF of the pilot lamp, see “Checking proximity switch working pilot lamp”. a After adjusting, start the engine, operate the work equipment control lever and check that the boom kickout is actuated at the desired position.

Adjusting 1.

k

2. 3.

Raise the lift arm to the desired height, then mark the lift arm to show the position where the center of the switch is aligned with the bottom of the plate. Always be sure to apply the work equipment lock lever. Lower the lift arm and stop the engine. Align the marks and adjust the position of the plate so that the center of switch (1) is at the bottom of plate (2), then secure in position with bolt (3).


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37

120 Testing and adjusting, Part 2 Checking proximity switch operation pilot lamp

SEN03935-02

Checking proximity switch operation pilot lamp

1

The proximity switch has a pilot lamp to indicate its operating condition. Use this pilot lamp when adjusting the proximity switch. q A: Operation pilot lamp (Red)

Proximity switch Bucket positioner Boom kick-out

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38

Positional relationship between sensitive surface of proximity switch and sensing object

Operation pilot lamp

Remarks

Near

ON

Operates when center of switch is near

Far

OFF

Near

ON

Far

OFF

Operates when center of switch is far


120 Testing and adjusting, Part 2 Procedure for testing diodes

Procedure for testing diodes a a

SEN03935-02

1

Check an assembled-type diode (8 pins) and independent diode (2 pins) in the following manner. The conductive directions of the assembledtype diode are indicated on the surface of the diode as shown in the following figure.

2.

a

The conductive directions of the single diode is indicated on the surface of the diode as shown in the following figure.

1.

When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. a Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode, and confirm the indicated value. 3) Determine acceptability of the diode from the indicated value. q Indicated value remains unchanged: Conduction is absent (Failure) q The indicated value changes: The diode has conductivity (Normal) (See a below.) a A value between 460 to 600 is indicated for silicon diodes.


When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Apply the leads of the tester as explained below and check the movement of the pointer. 1] Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode. 2] Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side. 3) Determine if a specific diode is good or no good by the way the pointer swings. q With the connection 1] above, the pointer is not moved. It swings, however, wh en the conn ectio n 2 ] is employed. Normal (However, magnitude of the pointer's move (indicating the resistance value) varies depending on the given tester model and the measurement range selected). q The pointer swings with both the connections of 1] and 2]: Defective (Internal short circuit) q The pointer does not swing with both the connections of 1] and 2]: Defective (Internal breaking of wire)

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39

120 Testing and adjusting, Part 2 Preparation work for troubleshooting for electric system

SEN03935-02

Preparation work for troubleshooting for electric system a

a

1.

1

When carrying out troubleshooting for an electric circuit related to the machine monitor, transmission controller, work equipment controller, or KOMTRAX terminal, expose the related connectors according to the following procedure. Disconnect and connect the connectors of special lock types according to the following procedure. Machine monitor 1) Disconnect the following connectors from cover (1). q Connector L06: Hazard switch q Connector L07: Front working lamp switch q Connector L08: Rear working lamp switch q Connector L09: ECSS switch (If equipped) q Connector L10: Machine monitor mode selector switch 1 q Connector L11: Machine monitor mode selector switch 2 a Pull the switch out of the cover and disconnect each connector. a If you insert your hands from under the cover and disconnect a connector forcibly, you many damage the connector or switch. Take care.

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40

2)

Remove cover (1).

3)

Remove 3 bracket mounting bolts (3) of machine monitor (2) and reverse the machine monitor. a Take care not to pull the wiring harness forcibly.



4)

2.

Connect diagnosis T-adapters to connectors L24 to L30 of machine monitor (2).

HST controller 1) Remove cover (1) from the rear of the cab.

2)

SEN03935-02 3.

KOMTRAX terminal 1) Open right door (1) and remove console cover (2).

2)

Connect diagnosis T-adapter to connector L80 of KOMTRAX terminal (3). a If the connector cannot be disconnected and connected easily, remove the KOMTRAX terminal. a Since the connector is secured with screws, loosen those screws before disconnecting. a When connecting the connector again, tighten its screws to the specified torque. 3 Screw: 2.2 – 2.8 Nm {0.23 – 0.29 kgm}

Connect diagnosis T-adapters to HST connector of HST controller (2).


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41

SEN03935-02 4.

Boost pressure and temperature sensor (BOOST PRESS & IMT) a Disconnection and connection of connector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

a

5.

Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. See Testing adjusting, “Troubleshooting tools table”.

Supply pump IMV solenoid (FUEL REGULATOR) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

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42


6.

Common rail pressure sensor (FUEL RAIL PRESS) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

a

Precautions for disconnecting connector The direction of the lock of the connector varies with the tightened position of the sensor and the lock may be in a direction in which it is difficult to reset (on the underside or engine side). In this case, pinch the lock in direction (a) with bent-nose nippers (commercially available), and the lock is reset. Since the lock clicks when it is reset, disconnect the connector after a click is heard.



a

7.

Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular notch (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular notch (f)).

Engine coolant temperature sensor (COOLANT TEMP) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.

a

SEN03935-02 8.

Ambient pressure sensor (AMBAIR PRESSURE) Engine Ne speed sensor (CRANK SENSOR) Engine Bkup speed sensor (CAM SENSOR) Engine oil pressure switch (OIL PRESSURE SWITCH) a Disconnection and connection of connectors The connectors of the ambient pressure sensor, engine Ne speed sensor, engine Bkup speed sensor, and engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) – (c) and connect them according to steps (d) – (f) as shown below. Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect connector. Connection: (d) Connect connector – (e) Lock – (f) Slide lever.

a

Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See Testing adjusting, “Troubleshooting tools table”.

Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See Testing and adjusting, “Troubleshooting tools table”.


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120 Testing and adjusting, Part 2 Starting KOMTRAX terminal operations

SEN03935-02

Starting KOMTRAX terminal operations

3)

When about 5 seconds elapsed after the starting switch was set to ACC, make sure that the 7-segment indicator lamp changes to hyphen “–” on the KOMTRAX terminal.

4)

Disconnect check connector 1, and wait for about 3 to 5 seconds as it is. a Ensure that the connector is disconnected. Reconnect check connector 1, and wait for about 5 seconds as it is. a If the KOMTRAX terminal detects that the connector was disconnected and connected, the dot on the 7-segment indicator lamp blinks a few times.

1

In the case where the KOMTRAX terminal has already been installed at the plant before shipment: a Implement the following procedure in the case where the KOMTRAX terminal has already been installed at the plant before shipment (as standard equipment). 1.

Notification of model, part number and serial number Notify the KOMTRAX operations administrator of model, part number and serial number.

2.

Registration of machine The KOMTRAX operations administrator shall use a KOMTRAX client PC to register the machine. a Refer to “Manual for KOMTRAX operations administrator” for the procedure. a Now the terminal is ready for use.

In the case where the KOMTRAX terminal is retrofitted: a When retrofitting the KOMTRAX terminal after shipment (retro-fitted machine), follow the steps below. 1.

Station opening check in machine side a Complete steps 3) to 5) within 60 seconds. If 60 seconds or above elapsed, begin with step 1) again. 1) Turn OFF the starting switch and then, after making sure 5 seconds have elapsed, proceed to the next step. 2) Visually check that two check connectors are connected. q Check connector 1: CHK0 q Check connector 2: CHK1

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5)



6)

SEN03935-02 a

Make sure that the 7-segment indicator lamp is indicated normally on the KOMTRAX terminal. a If so, the 7-segment indicator lamp will indicate characters “d”, “0”, and “–” repeatedly for 30 seconds after step 5) was ended. a Those characters, even if displayed normally, will change to a character other than hyphen “–”after 30 seconds or above elapsed. The display may change to a character other than “0” even within 30 seconds.

a

7)

8)

9)


As [Normal] is indicated, proceed to the next step. If “–” remains displayed, execute steps 1) to 5) again.

Turn the starting switch to START position for about 3 to 5 seconds, and make sure that the engine does not start. a If the engine starts, re-execute the procedure above from step 1). a Do not return the starting switch to OFF position. Turn the starting switch from ACC position to START position again, and make sure that the engine starts. Make sure that the KOMTRAX terminal's indicator lamps are normally turned on. a Move on to the next step if you can check that the display is [Normal]. (It takes from 90 seconds to 15 minutes before the display turns normal.) a If [GPS position data detection trouble] is indicated, check if there is any abnormality on the GPS antenna or cable. If there is any abnormality, repair it and start from procedure 1) again. a If [Reception trouble] is indicated, check if there is any abnormality on the appearance of the communication antenna or cable. If there is any abnormality, repair it then repeat from procedure 1) again. a If [GPS position data detection trouble and reception trouble] is indicated, check if there is any abnormality on the GPS antenna/cable or communication antenna/cable. If there is any abnormality, repair it and start from procedure 1) again.

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SEN03935-02 a

If [Network trouble] is indicated, check the display of [LED-C4] referring to “Lamp display of KOMTRAX terminal”. If the CAN is not recognized, check the CAN harness of the KOMTRAX terminal, and then if there is any abnormality, repair it and start from procedure 1) again. [A]: Normal [B]: GPS position data detection trouble [C]: Reception trouble [D]: GPS position data detection trouble and reception trouble [E]: Network trouble


10) Turn the starting switch OFF. 11) Make sure that the 7-segment indicator lamp is displayed normally after 5 seconds elapsed. a When [Normal] appears, station opening check is completed. a If [Abnormal] appears, station opening check does not end normally, so you should perform the procedure above from step 1) again. a If station opening check ends normally, it should not be rechecked.

12) When station opening check ended norm a l l y, a c o m m u n i c a t i o n w i t h t h e KOMTRAX server starts automatically, and settings are stored in KOMTRAX. (This requires about 25 minutes to 4 hours.) a During this time, you may turn the starting s witc h off and start the engine. a During the communication and check above, you should park the machine outside to enable a frequent communication with the ORBCOMM satellite. The station opening check may not be completed in doors that cause radio waves from the satellite to be intercepted.

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2.

SEN03935-02

Application for the start of use a Application for the start of use should be made only after the sign-up test is finished. 1) Notify the KOMTRAX operations administrator of the following information about the machine that completed the station opening check in the machine side. 1] Information (model, part number, and serial number) about the machine that completed the station opening check in the machine side 2] Part number and serial number of KOMTRAX terminal 3] Value of service meter when the KOMTRAX terminal was installed (in 0.1 hours)

2)

The KOMTRAX operations administrator shall use a KOMTRAX client PC to register the machine. a Refer to “Manual for KOMTRAX operations administrator” for the procedure. a Now the terminal is ready for use.


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120 Testing and adjusting, Part 2 Indicator lamps of KOMTRAX terminal

SEN03935-02

Indicator lamps of KOMTRAX terminal

LED lamps for CPU 1. LED-C1 (State of R or ACC signal) 2. LED-C2 (Starting output state) 3. LED-C3 (State of S-NET or C signal) 4. LED-C4 (CAN state) 5. LED-C5 (Download write state) 6. LED-C6 (Download write state)

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1

7-segment and dot displays for CPU 7. 7 segments (Number of unsent mails) 8. Dot (GPS positioning state)



SEN03935-02

In the KOMTRAX system, various information and processing details are displayed on the LED on the upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following checks. q Check of antennas q Check of terminal LED displays Before using the KOMTRAX system, make sure that the application for starting its use is completed as well as the station opening check in the machine side. Check of antennas a Before checking the LED displays, check that there is no abnormality around the communication antenna and GPS antenna. q The communication antenna should not be off or damaged. q The communication antenna cable should not be broken and normally be connected to the KOMTRAX terminal. q The GPS antenna should not be off or damaged. q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal. Check of terminal LED displays 1. Meaning of CPU LED displays a The LED displays should be checked with the starting switch ON, starting switch START, or with the engine started. No.

1

2

3

4

LED

Name/function

Display (*1)

ON States of starting switch Fast blink LED-C1 ACC signal and alternator R Slow blink signal OFF LED-C2 State of engine control signal

LED-C3

ON

6

LED-C6

Starting switch ACC signal: OFF, Alternator R signal: ON Starting switch ACC signal: ON, Alternator R signal: OFF Starting switch ACC signal: OFF, Alternator R signal: OFF Engine control signal: ON

OFF

Engine control signal: OFF

ON

S-NET: Connected, Starting switch C signal: OFF

OFF

S-NET: Not connected, Starting switch C signal: OFF

ON

CAN: Connected (without fuel sensor)

Fast blink CAN: Connected (with fuel sensor) Slow blink CAN: Not connected (with fuel sensor) OFF

LED-C5

Starting switch ACC signal: ON, Alternator R signal: ON

States of S-NET connection Fast blink Starting switch C signal: ON and starting switch C signal Slow blink (Not used)

LED-C4 State of CAN connection

5

Description

CAN: Not connected (without fuel sensor)

1-LED ON Download write mode (system administrator only function) Download write state

2-LED OFF

Normal operation mode

*1: Blink types and blink times Fast blink: Blinks in about 1-second cycle Slow blink: Blinks in about 4-second cycle


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SEN03935-02 2. a

Contents of 7-segment and dot displays for CPU The LED display should be checked with the starting switch turned ON.

No.

7

8

LED

7 segments

Dot

Name/function

Number of unsent mails, satellite capture state

GPS positioning status

Display (*2)

Description

The number indicates the number of unsent mails. (10 or more 0 to 9 unsent mails are indicated by “9”.) Light-on indicates that the displayed machine is in process of capturing the satellite. The number indicates the number of unsent mails. (10 or more 0 to 9 unsent mails are indicated by “9”.) Fast blink indicates that the fast blink satellite is not captured. ON

GPS positioning was completed. (The position can be confirmed. *3)

OFF

GPS positioning was not completed. (The position cannot be confirmed. *3)

*2: Blink types and blink times Fast blink: Blinks in about 0.5-second cycle Slow blink: Blinks in about 2.0-second cycle *3: Supplementary explanation of GPS positioning status One or more minute may be taken until GPS positioning is completed after the starting switch was turned ON even in an outdoor service area. GPS positioning will fail in a weak signal or non-service area.

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SEN03935-02

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SEN03935-02



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SEN03936-01





30

130 Testing and adjusting, Part 3 Adjusting machine monitor.............................................................................................................................. 2 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor.............................. 3 Special functions of machine monitor (EMMS) ............................................................................................... 5 Pm clinic inspection chart ............................................................................................................................. 60


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SEN03936-01

130 Testing and adjusting, Part 3 Adjusting machine monitor

Adjusting machine monitor

1

Layout of rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)

q q

Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the machine monitor. The switches shown in the figure are set as when the monitor is delivered.

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130 Testing and adjusting, Part 3 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor

SEN03936-01

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor 1.

1

Items to be set when sensor or controller is replaced, reassembled or added a If any of the following components and parts is replaced or reassembled, initialize the sensors, solenoids, etc. with the machine monitor. a Adjust the items in alphabetical order (A –) with the machine monitor. Replaced, reassembled, or added component or option

Adjustment item

Machine monitor

A, B, C

HST controller

A, B

Change of tire size

B

Addition or removal of option

B

Adjustment item

Contents of adjustment

Description No.

A

Selection of machine model

12 (*1)

B

Selection of option

10 (*1)

C

Inputting of machine serial No.

11 (*1)

*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”


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SEN03936-01 2.

130 Testing and adjusting, Part 3 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor

Adjustment for user's needs If the user makes the following indications or requests, change or adjust the items shown below with the machine monitor. Contents of indication/request

Adjustment item

Change indication unit of speedometer (*2)

D

Turn ECO lamp OFF

E

Change interval of fan automatic reverse operation (Automatic reverse fan specification)

F

Change continuance of fan automatic reverse operation (Automatic reverse fan specification)

G

Travel speed is indicated too quickly/slowly

H

Turn engine speed/travel speed on character display OFF

J

ECSS operates at high or low travel speed

K

Change display of major indication in engine speed (*3)

L

Adjustment item

Contents of change/adjustment

Description No. (*1)

D

Setting of option/Selection of speed unit (*2)

10

E

Setting of option/Selection of indication of ECO lamp

10

F

Adjustment of sensor/Adjustment of interval of fan automatic reverse operation

7–1

G

Adjustment of sensor/Adjustment of continuance of fan automatic reverse operation

7–2

H

Setting of option/Change of tire size

10

J

Setting of option/Change of indication of engine speed or travel speed on normal screen of character display

10

M

Adjustment of ECSS operation travel speed

7–5

L

Travel speed/engine speed display/non-display select

No. 10 of "Operator mode"

*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)” *2: Change of the indication unit of the speedometer of the specification for the SI unit countries cannot be set. *3: When selecting “NO ADD” in optional select, cannot change travel speed/engine speed.

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130 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)

SEN03936-01

Special functions of machine monitor (EMMS) a

EMMS: Equipment Management Monitoring System

1. 2. 3.

Machine monitor mode change switch 1 Machine monitor mode change switch 2 Character display


1

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SEN03936-01

Normal functions and special functions of machine monitor The machine monitor is equipped with the normal functions and special functions. Various items of data are displayed on the character display in the middle of the machine monitor. Depending on the internal setting of the machine monitor, the display items are divided into automatic display items and items displayed when the machine monitor switches are operated. 1) Normal functions: Operator mode Functions for which the content is normally displayed or which can be displayed and operated by the operator operating the switches. a See the Operation and maintenance manual for details of the operator mode. 2) Special functions: Service mode Functions which the serviceman can display and operate with the special switches to carry out inspection, maintenance, and troubleshooting. No. (*1)

No. (*1)

Operator mode

Service mode

1

Service meter display function

2

Electrical system fault history display function

2

Traction level selection function

3

Mechanical system fault history display function

3

HST function selection function

4

Real-time monitoring function

4

Odometer display function

5

Engine cylinder cut-out function

5

Maintenance monitoring function

6

No injection cranking function

6

Telephone number input function

7

Adjustment function

7

Language selection function

8

Maintenance monitoring function

8

Monitor brightness adjustment function

9

Operating information display function

9

Travel speed/engine speed display selecting function (*2)

10

Optional device selecting function

10

Function of turning ON/OFF travel speed/ engine speed display on character display (*3)

11

Machine serial number input function

11

Action code display function

12

Model selection function

12

Failure code display function

13

Initialize function

⇔

14: Item that refers to SERVICE NEWS (*4) *1: No. shows an item number in this document. *2: q Not displayed if “SI unit specification” is set when delivered. q Not displayed if “RPM OPT” is turned NO ADD by selecting an optional device in the service mode. *3: Not displayed if “Travel speed/Engine speed on character display” is turned NO ADD by selecting an optional device in the service mode. *4: Not include “Service mode”

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SEN03936-01

Functions and flow of service mode Note: Some items may not be used, depending on the setting and specification, although they are displayed on the monitor. (For details, see the text.)


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SEN03936-01

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SEN03936-01

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SEN03936-01 Operator mode a a

The operator mode is outlined below. For details of the operator mode, see “Structure, function and maintenance standard” or “Operation and Maintenance Manual”.

1.

Service meter display function If the starting switch is turned ON, the service meter is displayed on the above line and the engine speed is displayed on the lower line. a If the engine speed is displayed at the center of the monitor, the travel speed is displayed.

2.

3.

HST function selection function While the speed range selector switch is in the 3rd or 4th gear speed position, the reverse speed range can be set to 2 levels. a For details, see Operation and Maintenance Manual, Operation, “Other functions of machine monitor”.

4.

Odometer display function The odometer is displayed. a For details, see Operation and Maintenance Manual, Operation, “Other functions of machine monitor”.

Traction level selection function Press [U] switch on the ordinary service meter display screen, and the screen to set the traction level selection function is displayed. a If the traction control is turned ON with the traction control switch, the traction can be set to 3 levels. a For details, see Operation and Maintenance Manual, Operation, “Other functions of machine monitor”.

a a

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For items 3 and after, display a desired screen with [<] or [>] switch on the “Traction level selection function” screen. Each time [<] or [>] switch is pressed, the screen changes in order. Repeat either switch until a desired screen is displayed.

10



5.

Maintenance monitoring function 1) Filter, oil replacement time display (automatic display) As the filter or oil replacement time draws close, the machine monitor automatically displays its information to alert operator's attention. 2) Resetting replacement time (selection menu) As maintenance operation for a filter or oil is completed, the machine monitor allows resetting the time interval through the switch operation. a For details, see the “Other functions of machine monitor” of the “Operation” section in the Operation and maintenance manual.

6.

Telephone number input function Telephone numbers are entered through the switch operation. And modification or cancellation of the phone numbers in the machine monitor is also available through the switch operation. a When action code [E03] is displayed, a phone number is displayed along with [CALL]. a For details, see the “Other functions of machine monitor” of the Operation section in the Operation and maintenance manual.


SEN03936-01 7.

Language selection function Switch operation allows selecting a display language of the machine monitor. a Functions of the service mode are constantly displayed in English since they are exempted from the display selection function. a A desired language is selectable from English, Japanese, German, French, Italian, Spanish and Swedish. a For details, see the “Other functions of machine monitor” of the Operation section in the Operation and maintenance manual.

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SEN03936-01 8.

Monitor brightness adjustment function Brightness of the machine monitor is adjustable in seven levels through the switch operation. a Adjustment of brightness is available in two approaches – adjustment of the monitor alone and separate adjustment of the monitor and liquid crystal. a For details, see the “Other functions of machine monitor” of the Operation section in the Operation and maintenance manual.

9.

Travel speed/engine speed display selecting function A unit to be used for the machine monitor speed display is selectable from km/h and MPH. It is also possible to turn on or off the display of the travel speed and engine speed. a For details, see the “Other functions of machine monitor” of the Operation section in the Operation and maintenance manual.

10. Travel speed/engine speed display/non-display selecting function A unit for the machine monitor speed display is selectable from km/h and MPH. It is also possible to turn on or off display of the travel speed and engine speed. a For details, see the “Other functions of machine monitor” of the Operation section in the Operation and maintenance manual.

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SEN03936-01

11. Action code display function If a trouble occurs, the machine monitor displays an action code corresponding to the seriousness of the trouble to alert the operator for appropriate actions. a The figure below shows an example of the screen on which action code [E03] and [CALL + Telephone number] are alternately displayed. a When action code [E01] or [E02] is displayed, [CALL + Telephone number] is not displayed.

a

Action codes and actions alerted to operator Action code

CALL + Telephone number

E01

Not displayed

• Do necessary testing and/or servicing as the current work is over or at shift of the operator.

E02

Not displayed

• When an overrun-related item is displayed: Slow down the engine or machine speed. • When an overheat-related item is displayed: Stop the machine and run the engine at mid speed with no load.

E03

Displayed


Actions recommended to operator

• Stop the engine and machine immediately and contact a serviceman.

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SEN03936-01 12. Failure code display function Pressing [>] switch once while an action is displayed on the machine monitor displays the failure code corresponding to the failure currently warned. a The failure codes detected in the past are divided into failures of the electrical system and the mechanical system and are recorded as fault history. (For details, see “Service mode”.) a When two or more failures are involved, pressing [>] switch displays further codes. a If [>] switch is pressed again after it was pressed to display every involved failure code, the service meter display screen will be restored. Pressing [>] switch one more time displays the failure codes from the first. If [>] switch is not touched for 30 seconds, the action code display screen is automatically displayed.

a

The service code display function displays the following information. A: Failure code B: Controller code MON: Machine monitor HST: HST controller ENG: Engine controller C: The system where failure occurred

a

For details of a displayed failure code, see “Failure code list”. If any switch operation is not done for 30 seconds or more on the failure code display screen, the action code display screen is automatically turned on.

a

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Service mode 1.

Procedure for switching to Service mode and screen display Reference: The service meter is displayed in English, regardless of language selection in the operator mode. When using Service mode, carry out the following special operation to switch the screen display. 1-1. Checking screen display Make sure that the machine monitor is set to the operator mode and any of “Service meter”, “Action code” or “Failure code” is displayed on the screen. 1-2. Displaying ID input initial screen Hold down [t] switch and [<] switch simultaneously for 5 seconds minimum to open ID input initial screen. a Holding down the two switches for 5 seconds or more makes the entire screen blank. As this state is recognized, release the buttons.

SEN03936-01 (*1): When the cursor is located at the leftmost position, pressing the switch restores the normal screen (Operator mode). When the cursor is at a location other than the leftmost position, pressing the switch returns the cursor to the leftmost position. If any switch operation is not done for 60 seconds or more from ID input screen, the normal screen is automatically turned on.

1-4. Displaying menu initial screen a After settling 4-digit ID, turn on the menu initial screen of Service mode. a Once entered and settled, an ID remains effective until the starting switch is turned off.

1-3. Inputting and confirming ID Operate the buttons to input the ID. q ID: 6491 1) Cursor (C) is positioned at the highestorder digit. Pressing [<] and [>] switches changes the value of this digit in the range of 0 – 9. 2) Press [U] switch when the intended value appeared to specify it. a The cursor moves to the 2nd digit. 3) Set the value in the same order and then press [U] switch. a When you have entered a wrong value to a position except the highest-order digit, move to the highest-order digit using [t] switch to repeat the procedure from the first. In this case, values that had been entered remain as they are until modified. When the cursor is at the highest-order digit, it can move to the higher layer using [t] switch. (*1).


1-5. Selecting service mode menu a Pressing [<] and [>] switches from the menu screen displays Service mode menus endlessly in the following order. a The menus are displayed in the field indicated with [*] mark. [1] ELECTRIC FAULT: Electrical system fault history display function [2] MACHINE FAULT: Mechanical system fault history display function [3] REAL-TIME MONITOR: Real-time monitoring function 30-130

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SEN03936-01

a

[4] CYLINDER CUT-OUT: Engine reduced-cylinder function [5] NO INJECTION: No injection cranking function [6] TUNING: Adjustment function [7] MAINTENANCE MONITOR: Maintenance monitoring function [8] OPERATION INFO: Operating information display function [9] OPTIONAL SELECT: Optional device selecting function [10] MACHINE No. SET: Machine serial number input function [11] MACHINE: Model selection function [12] INITIALIZE: Initialize function (Function specialized for plant) The menu is indicated in the parts of [*].

2.

Electrical system fault history display function (ELECTRIC FAULT) The machine monitor records the past failures in the electric system as the failure codes. The failure codes are displayed from the following operations. 2-1. Selecting the menu Select the ELECTRIC FAULT from the menu screen of Service mode. a [**] field displays total number of the fault history currently recorded (up to 20 cases).

2-2. Displaying fault history Press [U] button while the menu is selected to display the recorded fault history.

1-6. Completion of mode and function Either of the following procedures ends a mode or function independent of the function being selected and the layer in which it is used. 1) When the operation is to be continued using another mode or function: Press [t] switch to return to the mode screen or menu screen to be used next. a Note, however, that [t] switch functions as an execution key on [YES/NO] screen. a When the normal screen (Operator mode) was inadvertently turned on, repeat above steps from 1) (input of the ID is not necessary). 2) When ending an operation completely: Turn the starting switch off from the current state.

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2-3. Displayed fault history The electric system fault history display function displays the following information. A: Record number B: Failure code (Location code in four digits + Problem code in two digits) C: Number of occurrences (number of occurrences of same code in past) D: Elapsed time 1 (Elapsed time on service meter from the first occurrence) E: Elapsed time 2 (Elapsed time on service meter from the last occurrence) a The code of a failure currently occurring is indicated in flashing.



a a

a

For details of a displayed failure code, see “Failure code list” of the failure code display function. Note that part of the information displayed from the electrical system fault history display function and the failure code display function is not identical. When the requested fault history is not recorded, [–] is indicated in the display space.

SEN03936-01 2-6. Deleting all fault history 1) Press [<] or [>] switch while the fault history is on the screen to display the ALL CLEAR menu screen.

2) 3) a 2-4. Switching fault history display Pressing [<] or [>] switch while a set of fault history is on the screen displays another set of recorded fault history. 2-5. Deleting individual fault history 1) Press [U] switch while the target fault history of deletion is on the screen to turn on CLEAR screen. 2) Select “YES” or “NO” using [<] or [>] switch. a The selected cursor will start flashing. If “Y ES” i s s ele cted and [t] s witc h i s pressed, the information will be deleted. If “NO” is selected and [t] switch is pressed, deletion is cancelled and the “Maintenance interv al c hange item” screen is restored. a By default, the cursor is set to NO (cancel) to prevent resetting error. a Information of the currently occurring failure is not deletable.


a a

Press [U] switch to display the ALL CLEAR screen. Select “YES” or “NO” using [<] or [>] switch. The selected cursor will start flashing. If “ YE S” is s elec ted a nd [t] s witc h is pressed, the information will be deleted. If “NO” is selected and [t] switch is pressed, deletion is cancelled and the “ Maintenance interval change item” screen is restored. By default, the cursor is set to NO (cancel) to prevent resetting error. Information of the currently occurring failure is not deletable.

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SEN03936-01 3.

Mechanical system fault history display function (MACHINE FAULT) The machine monitor records the past failures in the mechanical system as the failure codes. The failure codes are displayed from the following operations. 3-1. Selecting the menu a Select MACHINE FAULT from the menu screen of Service mode. a [**] field displays total number of the fault history currently recorded.

3-3. Displayed fault history The mechanical system fault history display function displays the following information. A: B:

Record number Failure code (Location code in four digits + Problem code in two digits) C: Number of occurrences (number of occurrences of same code in past) D: Occurrence time 1 (Time on service meter at the first occurrence) E: Occurrence time 2 (Time on service meter at the last occurrence) a The code of a failure currently occurring is indicated in flashing. a For details of a displayed failure code, see “Failure code list” of next page. a Note that part of the information displayed from the mechanical system fault history display function and the failure code display function is not identical. a When the requested fault history is not recorded, [–] is indicated in the display space.

3-2. Displaying fault history Press [U] switch while the menu is selected to display the recorded fault history.

3-4. Switching fault history display Pressing [<] or [>] switch while a set of fault history is on the screen displays another set of recorded fault history. 3-5. Deleting fault history (Not available) The fault history of the mechanical system is not deletable.

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SEN03936-01

Failure codes table Failure code

Troubled part/item

Trouble

Controller

Action code

Category of record

2G40ZG Brake

Oil pressure reduction

MON

E03

Mechanical system

6091NX

HST filter

Clogging

MON

E01

Mechanical system

989FN1

Travel speed

Overrun alarm

MON

E02

Mechanical system

AA1ANX Air cleaner

Clogging

MON

E01

Mechanical system

AB00L6

Hot short

MON

E01

Electrical system

AB00MA Alternator R system

Ground fault/Disconnection/Low charge level

MON

E03

Electrical system

B@BAZG Engine


ENG

E03

Mechanical system

B@BAZK Engine oil

Low oil level

MON

E01

Mechanical system

B@BCNS Engine

Overheat

ENG

E02

Mechanical system

B@BCZK Engine

Low coolant level

MON

E01

Mechanical system

B@C6NS Front brake

High oil temperature

MON

E02

Mechanical system

B@CRNS HST


MON

E02

Mechanical system

Alternator R system

CA111

Engine controller

Internal abnormality

ENG

E03

Electrical system

CA115

Engine NE, Bkup speed sensor

Abnormality

ENG

E03

Electrical system

CA122

Charge pressure sensor

Abnormally high level

ENG

E03

Electrical system

CA123


Abnormally low level

ENG

E03

Electrical system

CA131

Throttle sensor


ENG

E03

Electrical system

CA132

Throttle sensor


ENG

E03

Electrical system

CA144

Coolant temperature sensor


ENG

E01

Electrical system

CA145

Coolant temperature sensor


ENG

E01

Electrical system

CA153

Charge temperature sensor


ENG

E01

Electrical system

CA154

Charge temperature sensor


ENG

E01

Electrical system

CA155

Charge temperature

Abnormally high speed derate

ENG

E03

Electrical system

CA187

Sensor power supply 2


ENG

E03

Electrical system

CA221

Ambient pressure sensor


ENG

E01

Electrical system


30-130

19


SEN03936-01

Failure code

Troubled part/item

Trouble

Controller

Action code

Category of record

CA222



ENG

E01

Electrical system

CA227



ENG

E03

Electrical system

CA234

Engine

Overspeed

ENG

E02

Mechanical system

CA238

Ne speed sensor power supply

Abnormality

ENG

E03

Electrical system

CA271

IMV (IMA)

Short circuit

ENG

E03

Electrical system

CA272

IMV (IMA)

Disconnection

ENG

E03

Electrical system

CA322

Injector #1 system

Disconnection/Short circuit

ENG

E03

Electrical system

CA323

Injector #5 system


ENG

E03

Electrical system

CA324

Injector #3 system


ENG

E03

Electrical system

CA325

Injector #6 system


ENG

E03

Electrical system

CA331

Injector #2 system


ENG

E03

Electrical system

CA332

Injector #4 system


ENG

E03

Electrical system

CA342

Engine controller

Data mismatching

ENG

E03

Electrical system

CA351

Injector drive circuit

Abnormality

ENG

E03

Electrical system

CA352



ENG

E03

Electrical system

CA386



ENG

E03

Electrical system

CA428

Water sensor


ENG

E01

Electrical system

CA429

Water sensor


ENG

E01

Electrical system

CA431

Idle validation switch

Abnormality

ENG

E01

Electrical system

CA432


Abnormal remedy

ENG

E03

Electrical system

CA435

Engine oil pressure switch

Abnormality

ENG

E01

Electrical system

CA441

Power supply voltage


ENG

E03

Electrical system

CA442



ENG

E03

Electrical system

CA449

Common rail pressure

Abnormally high pressure 2

ENG

E03

Electrical system

CA451



ENG

E03

Electrical system

30-130

20



Failure code

SEN03936-01

Troubled part/item

Trouble

Controller

Action code

Category of record

CA452



ENG

E03

Electrical system

CA488

Charge temperature

Abnormally high torque derate

ENG

E03

Electrical system

CA553



ENG

E03

Electrical system

CA559

Supply pump

Low rail pressure 1

ENG

E03

Electrical system

CA689

Engine Ne speed sensor

Abnormality

ENG

E03

Electrical system

CA731

Engine Bkup speed sensor

Abnormal phase

ENG

E03

Electrical system

CA757

Engine controller

Loss of all data

ENG

E03

Electrical system

CA778


Abnormality

ENG

E03

Electrical system

CA1633

KOMNET

Abnormality

ENG

E03

Electrical system

CA2185

Throttle sensor power supply


ENG

E03

Electrical system

CA2186

Throttle sensor power supply


ENG

E03

Electrical system

CA2249

Supply pump

Low rail pressure 2

ENG

E03

Electrical system

CA2311

IMV (IMA) solenoid

Abnormality

ENG

E03

Electrical system

CA2555

Intake air heater relay

Disconnection

ENG

E01

Electrical system

CA2556


Short circuit

ENG

E01

Electrical system

D160KY

Backup lamp/buzzer relay

Hot short

MON

E01

Electrical system

D192KY

ECSS solenoid relay

Hot short

MON

E01

Electrical system

D1B0KA HST safety relay

Disconnection

HST

E03

Electrical system

D1B0KB HST safety relay

Ground fault

HST

E01

Electrical system

D1B0KY HST safety relay

Hot short

HST

E03

Electrical system

D5ZHL6

Ground fault/Disconnection

MON

E01

Electrical system

DAF3KK UNSW power supply


MON

E01

Electrical system

DAFRKR Monitor panel CAN-NET signal

Disconnection

HST

E03

Electrical system

DAJ0KK

HST controller power supply

Low voltage

HST

E03

Electrical system

DAJ0KT

HST controller memory (EEPROM)

Abnormality

HST

E01

Electrical system

IGN C system


30-130

21


SEN03936-01

Failure code

Troubled part/item

Trouble

Controller

Action code

Category of record

DAJ1L4

HST controller main power line

Disconnection/Ground fault

HST

E01

Electrical system

DAJ1L6


Hot short

HST

E01

Electrical system

DAJ2KK

Controller solenoid power supply Low voltage

HST

E03

Electrical system

DAJ2L3

HST controller load power supply Hot short holding line

HST

E01

Electrical system

DAJ2L4

HST controller load power supply Disconnection/Ground fault holding line

HST

E01

Electrical system

DAJ5KX

Sensor 5V power supply

Out of input range

HST

E03

Electrical system

(DAJ9KQ) HST controller

Disagreement in model selection

MON

E03

—

DAJRKR HST controller CAN-NET

Disconnection in signal line

MON

E03

Electrical system

Disagreement in option selection

MON

E03

—

DB2RKR Engine controller CAN-NET


HST

E03

Electrical system

DD1NL4 Fan auto reverse switch signal

Abnormality

HST

E01

Electrical system

DD1NLD Fan reverse switch signal

Abnormality

HST

E01

Electrical system

DDB6KA Parking brake reminder signal

Disconnection/Hot short

HST

E01

Electrical system

DDB6KB Parking brake indicator signal

Ground fault

HST

E01

Electrical system

(DAJRMA) HST controller

DDB6KZ

Parking brake indicator signal or Trouble parking brake reminder signal

MON

E03

Electrical system

DDB6L0

Parking brake reminder signal

Ground fault

HST

E01

Electrical system

DDB6L4

Parking brake indicator signal


HST

E03

Electrical system

DDD7KX Travel speed control dial


HST

E01

Electrical system

DDD7KY Travel speed control dial

Hot short

HST

E01

Electrical system

Disconnection

MON

E01

Electrical system

DDK3KA Right direction switch


HST

E03

Electrical system

DDK3KB Right direction switch

Ground fault

HST

E03

Electrical system

DDK6KA FNR lever


HST

E03

Electrical system

DDK6KY FNR lever

Hot short

HST

E03

Electrical system

DDS5L6

Steering

Low oil pressure (Operation of emergency steering)

MON

E03

Mechanical system

DF10KA



HST

E01

Electrical system

DDE5MA

30-130

Emergency steering operation switch

22



Failure code

SEN03936-01

Controller

Action code

Category of record

Hot short

HST

E01

Electrical system

DGH1KX HST oil temperature sensor

Ground fault

MON

E01

Electrical system

DGR2KB Brake oil temperature sensor

Ground fault

MON

E01

Electrical system

DGR2KZ Brake oil temperature sensor


MON

E01

Electrical system

DHH1KX HST oil pressure sensor


HST

E03

Electrical system

DHH1KY HST oil pressure sensor

Hot short

HST

E03

Electrical system

DHTCL6 HST filter clogging sensor

Functional defect

MON

E01

Electrical system

DJF1KA

Fuel level sensor


MON

E01

Electrical system

DLT3KX

Travel speed sensor B

Abnormality

HST

E03

Electrical system

DLT4KX

Travel speed sensor A

Abnormality

HST

E03

Electrical system

DLT4LC

Travel speed sensor A & B

Abnormality

HST

E03

Electrical system

DV00KY Alarm buzzer

Hot short

MON

E01

Electrical system

DW26KA Motor 2 solenoid


HST

E01

Electrical system

DW26KY Motor 2 solenoid

Hot short

HST

E01

Electrical system

DW7BKY Fan reverse solenoid circuit

Hot short

HST

E01

Electrical system

DW7BKZ Fan reverse solenoid circuit


HST

E01

Electrical system

DX16KA Fan EPC solenoid

Disconnection

HST

E01

Electrical system

DX16KB Fan EPC solenoid

Ground fault

HST

E01

Electrical system

DX16KY Fan EPC solenoid

Hot short

HST

E01

Electrical system

DX19KA Motor 1 solenoid

Disconnection

HST

E03

Electrical system

DX19KB Motor 1 solenoid

Ground fault

HST

E03

Electrical system

DX19KY Motor 1 solenoid

Hot short

HST

E03

Electrical system

DX20KA Clutch EPC solenoid

Disconnection

HST

E03

Electrical system

DX20KB Clutch EPC solenoid

Ground fault

HST

E03

Electrical system

DX20KY Clutch EPC solenoid

Hot short

HST

E03

Electrical system

DF10KB

Troubled part/item Travel speed range selector switch


Trouble

30-130

23


SEN03936-01

Failure code

Troubled part/item

Trouble

Controller

Action code

Category of record

DXH7KB Reverse solenoid

Ground fault

HST

E03

Electrical system

DXH7KZ Reverse solenoid


HST

E03

Electrical system

DXH8KB Forward solenoid

Ground fault

HST

E03

Electrical system

DXH8KZ Forward solenoid


HST

E03

Electrical system

J141N1

Steering pump

Overrun alarm

HST

E02

Mechanical system

M100N1

HST pump

Overrun alarm

HST

E02

Mechanical system

M400N1

Motor 1

Overrun alarm

HST

E02

Mechanical system

a

a

a a a

Failure codes: The failure code table is written in alphabetical order and also starting from small number. The failure code in parentheses is not recorded in the failure history for both electrical system and mechanical system. Applicable controller: Applicable controller indicates in which controller system the failure has occurred. MON : machine monitor system ENG : Engine controller system HST : HST controller system Action codes: Action codes indicate what is displayed in the operator mode when a failure is detected. History classification: History classification indicates in which system, either electrical system or mechanical system in the failure history display function, a failure has been recorded. Note: Optional equipments are also included in the table.

30-130

24



4.

Real-time monitoring function (REAL-TIME MONITOR) The machine monitor checks state of the machine on real-time basis referencing signals of the sensors being installed in various parts of the machine. The real-time monitoring functions displays following two types of information. q 1 item independent display (for each controller) q 2 items simultaneous display (code input) 4-1. Selecting the menu Select REAL-TIME MONITORING from the menu screen of Service mode.

SEN03936-01 4-3. Selecting sub menu a Press [<] or [>] switch from the sub menu screen to display the sub menus endlessly in the following order. a The sub menus are displayed in the field indicated with [*] mark. [1] MONITOR PANEL: Machine monitor system [2] HST: HST controller system [3] ENGINE: Engine controller system [4] 2 ITEMS: 2 items display

4-4. Setting the 1 item individual monitoring 1) Select the target controller system of monitoring from the sub menu screen. 4-2. Displaying sub menu Press [U] switch while the menu is selected to display the sub menu initial screen.

2)


Press [U] switch while the sub menu is selected to display the MONITOR PANEL screen.

30-130

25

SEN03936-01 3) a a a

Press [<] or [>] switch to select a monitoring item. The monitoring items are scrolled according to the internally set order. Holding down [U] switch turns on highspeed scrolling. Holding and cancelling the monitoring data: Pressing [U] switch while the monitoring is in progress holds the monitoring data and [U] mark starts flashing.Pressing [U] switch again restores the active state.


4-5. Setting 2 items simultaneous monitoring 1) Select 2 ITEMS from the sub menu screen. 2) Press [U] switch while the sub menu is selected to display the monitoring code input screen.

1]

2] 4)

30-130

Display data for 1 item individual monitoring The 1 item individual monitoring screen displays the following information. A: Item display B: Monitoring codes (5 digits) 1: Monitoring data (including the unit used) a See the “Real-time monitoring code list” for details.

26

a 3] a

This cursor (C) is located at the highest-order digit. Pressing [<] or [>] switch changes the value of this digit in the range of 0 – 9. Press [U] switch when the intended value appeared to specify it as the set value. The cursor moves to the 2nd position. Set the value in the same order and then press [U] switch. When you have entered a wrong value to a position except the highestorder digit, the cursor can move to the highest-order digit using [t] switch and repeat the procedure from the first. In this case, values that had been entered remain as they are until modified. When the cursor is at the highest-order digit, it can move to the higher layer using [t] switch.



3) a

4) a

a

SEN03936-01

As both monitoring codes are settled, the 2 ITEMS screen will be turned on. Holding and cancelling the monitoring data: Pressing [U] switch while the monitoring is in progress holds the monitoring data and [U] mark starts flashing.Pressing [U] switch again restores the active state.

Display data for 2 items simultaneous monitoring The 2 items simultaneous monitoring screen displays the following information. A: Monitoring code 1 1: Monitoring data 1 (including the unit used) B: Monitoring code 2 2: Monitoring data 2 (including the unit used) See the “Real-time monitoring code list” for details.


30-130

27


SEN03936-01 Real-time monitoring codes table a Use this page in next page and a spread.

MONITOR PANEL [Machine monitor system] Monitoring item (*1)

Displayed item (*2)

Data display range (*3)

No.

Monitoring code

1

20200

Monitor software No.

VERSION

2

20221

Application version No.

VERSION (APP)

Numerals

3

20222

Data version No.

VERSION (DATA)

Numerals

4

01001

Engine speed

ENG SPEED

0 – 4000

5

40012

Travel speed

SPEED

0.0 – 50.0

6

04202

Fuel level

FUEL SENSOR

0 – 100

7

04200

Fuel level

FUEL SENSOR

0.00 – 5.00

8

04103

Coolant temperature

COOLANT TEMP

–40 – 210

9

04408

HST oil temperature

HST OIL TEMP

24 – 131

10

04409

HST oil temperature

HST OIL TEMP

0.00 – 5.00

11

30201

Front brake oil temperature

F BRAKE OIL

24 – 131

12

30204

Front brake oil temperature

F BRAKE OIL

0.00 – 5.00

13

04302

Charge level

ALTERNATOR R

0.0 – 30.0

14

40200

Small lamp voltage

SMALL LAMP

0.0 – 30.0

15

06001

Boom angle

BOOM ANG

-----

16

06003

Boom angle

BOOM ANG

-----

17

40400

Boom bottom pressure

BOOM BTM PRESS

-----

18

40402

Boom bottom pressure

BOOM BTM PRESS

-----

30-130

28

Alphanumerals



a

SEN03936-01

Use this page in front page and spread. MONITOR PANEL [Machine monitor system] Contents of display in normal state

Unit (*4)

Remarks

As per software No.

Condition display

As per software application version No.

Condition display

As per software data version

Condition display

Low idle : 800 – 850 rpm High idle: 2,200 – 2,300 rpm

rpm

Data are obtained from HST controller.

F1/R1: 4.0 – 7.6 km/h F2/R2: 13.0 – 18.7 km/h F3/R3: 18.7 – 23.6 km/h F4/R4: 38.0 – 44.6km/h

km/h

• Shown value is max. speed in each speed range. • Value of F1/R1 is speed when travel speed control dial is at min. speed position.

3rd – 10th digits from right of part No. are displayed.

0 – 100% (Depends on fuel level)

%

Gauge FULL (100%, 10 z): 0.31 V Gauge 1/2 (50%, 31.1 z): 0.86 V Gauge 1/4 (25%, 46.8 z): 1.17 V Caution (80 z): 1.75 V Gauge EMPTY (0%, 85 z): 1.82 V

V

When sensor is disconnected or has hot-short: Gauge EMPTY When sensor has ground fault: Gauge FULL

Depends on machine condition (°C)

°C

Engine coolant temperature: Max. 102°C Data are obtained from engine controller.


°C

Overheat: 105°C

Gauge enters red range(105°C): 2.07 V (80°C): 2.91 V

V

When sensor is disconnected or has hot-short: Gauge MIN When sensor has ground fault: Gauge MAX


°C

(120°C): 1.62 V 1(80°C): 2.91 V

V

Depends on machine condition (0.0 – 30 V)

V

Depends on machine condition (0.0 – 30 V)

V

-----

deg (°)

-----

V a No use these items.

-----

MPa

-----

V


30-130

29


SEN03936-01 a

Use this page in next page and a spread. MONITOR PANEL [Machine monitor system] Monitoring item (*1)

Displayed item (*2)


No.

Monitoring code

19

40500

Boom head pressure

BOOM HEAD PRES

-----

20

40501

Boom head pressure

BOOM HEAD PRES

-----

21

40600

Calibration pressure

CAL PRESS

-----

22

40800

Weight calculated by load meter

MES LOAD

-----

23

30802

Rotary switch setting condition

SW1, SW2, SW3

24

30904

DIP switch setting condition

SW5-1, SW5-2

ON/OFF, ON/OFF

25

30905


SW5-3, SW5-4

ON/OFF, ON/OFF

26

30906


SW6-1, SW6-2

ON/OFF, ON/OFF

27

30907


SW6-3, SW6-4

ON/OFF, ON/OFF

28

40900

Input signal D_IN_0-7

D-IN--0------7

See separate table.

29

40901


D-IN--8------15

See separate table.

30

40902


D-IN--16------23

See separate table.

31

40903


D-IN--24------31

See separate table.

32

40904


D-IN--32------39

See separate table.

37

40925

Output signal D_OUT_0-3

D-OUT-0--3

See separate table.

F, F, F

*1: All items, including ones for which sensors are not installed on some models and optional components, are displayed. *2: Abbreviated as number of characters is limited. *3: A number out of the display range is displayed as “-----”. *4: If a unit is necessary, the SI unit is used.

30-130

30



a

SEN03936-01

Use this page in front page and spread. MONITOR PANEL [Machine monitor system] Contents of display in normal state

Unit (*4)

-----

MPa

-----

V

Remarks

a No use these items. -----

MPa

-----

t Condition display

a Do not move from initial position.

Condition display


Condition display


Condition display


Condition display


Condition display Condition display Condition display Condition display Condition display Condition display


30-130

31


SEN03936-01

MONITOR PANEL [Machine monitor system] No.

Monitoring code

1

2

3

4

40900

40901

40902

40903

Input/Output signal

Displayed item

Contents of ON/OFF switch

D-IN-0

Headlamp

Headlamp lighting = ON (24 V)/OFF (OPEN)

D-IN-1

Cooling fan reverse switch

Switch = ON (24 V)/OFF (OPEN)

D-IN-2

Starting switch C

Starting motor operation = ON (24 V)/OFF (OPEN)

D-IN-3

—

—

D-IN-4

—

—

D-IN-5

—

—

D-IN-6

Multi-coupler solenoid (Machine with optional multi-coupler spec.)

Multi-coupler solenoid = ON (24 V)/OFF (OPEN)

D-IN-7

—

—

D-IN-8

ECSS switch (Machine with optional ECSS spec.)

ECSS switch = ON (24 V)/OFF (OPEN)

D-IN-9

Cooling fan automatic reverse switch

Cooling fan automatic reverse setting = ON (24 V)/ OFF (OPEN)

D-IN-10

—

—

D-IN-11

—

—

D-IN-12

Right winker

Right winker lighting = ON (GND)/OFF (OPEN)

D-IN-13

Left winker

Left winker lighting = ON (GND)/OFF (OPEN)

D-IN-14

U switch

Pressing switch = ON (24 V)/OFF (OPEN)

D-IN-15

t switch


D-IN-16

Brake oil pressure

Normal oil pressure = ON (GND)/OFF (OPEN)

D-IN-17

—

—

D-IN-18

—

—

D-IN-19

—

—

D-IN-20


No clogging = ON (GND)/OFF (OPEN)

D-IN-21

—

—

D-IN-22

—

—

D-IN-23

—

—

D-IN-24

HST filter clogging

Clogging detection = ON (GND)/OFF (OPEN)

D-IN-25

—

—

D-IN-26

Parking brake

Resetting parking brake = ON (GND)/OFF (OPEN)

D-IN-27

Engine coolant level

Normal coolant level = ON (GND)/OFF (OPEN)

D-IN-28

Omission of applying parking brake


D-IN-29

Engine oil level

Normal oil level = ON (GND)/OFF (OPEN)

D-IN-30

Normal emergency steering (Machine with optional emergency steering)

Low emergency steering pressure = ON (GND)/OFF (OPEN)

D-IN-31

—

—

*: “1” is displayed when ON and “0” is displayed when OFF.

30-130

32



SEN03936-01

MONITOR PANEL [Machine monitor system] No.

5

6

Monitoring code

40904

40925

Input/Output signal

Displayed item


D-IN-32

—

—

D-IN-33

—

—

D-IN-34

High beam (Dimmer switch)

High beam = ON (GND)/OFF (OPEN)

D-IN-35

Omission of applying parking brake (dummy)


D-IN-36

Parking brake (dummy)


D-IN-37

[>] switch

Pressing switch = ON (GND)/OFF (OPEN)

D-IN-38

[<] switch


D-IN-39

Low steering pressure (Machine with optional emergency steering spec.)

Oil pressure reduction = ON (GND)/OFF (OPEN)

D-OUT-0

Alarm buzzer

Output ON = ON (24 V)/OFF (OPEN)

D-OUT-1

—

—

D-OUT-2

Backup alarm/lamp relay


D-OUT-3

ECSS solenoid relay (Machine with optional ECSS spec.)


*: “1” is displayed when ON and “0” is displayed when OFF.


30-130

33


SEN03936-01 a

Use this page in next page and a spread. HST [HST controller system]

No.

Monitoring code

1

20201

Software No.

VERSION

2

20223

Application version No.

VERSION (APP)

3

20224

Data version No.

VERSION (DATA)

4

40977


D-IN--0------7

See separate table.

5

40978


D-OUT-0------7

See separate table.

6

40979


D-OUT-8-----15

See separate table.

7

40980


D-OUT-16----23

See separate table.

8

41600

Engine mode

ENGINE MODE

0/2

9

32600

HST oil pressure

HST PRESS

0.0 – 500.0

10

32601

HST oil pressure

HST PRESS

0.001 – 5.000

11

80000

Motor 1 output command value

MOTOR SOL DIR

0 – 1000

12

81000

Clutch output command value

CLUTCH SOL DIR

0 – 1000

13

41400

Fan output command value

FAN EPC DIR

0 – 1000

14

93400

Fan reverse switch input

FAN REVERSE SW

15

40013

Travel speed

SPEED (HST)

0 – 50.00

16

31400

Output shaft speed

T/M SPEED : OUT

0 – 32767

17

31404

Output shaft speed

T/M SPEED : OUT2

0 – 32767

18

95400

Throttle correction command output

THROTTLE MOD

–100 – 100

19

44200

Throttle quantity upper limit value output

THROT LIMIT UP

0.0 – 100.0

20

44201

Throttle quantity lower limit value output

THROT LIMIT LO

0.0 – 100.0

21

43504

Automatic warm-up cancel flag

WARM-UP CANCEL

30-130

34

Real-time monitoring item (*1)

Displayed item (*2)


0/2/1

0/1



a

SEN03936-01

Use this page in front page and spread. HST [HST controller system] Contents of display in normal state

Unit (*4)

As per software No.

Condition display

As per software application version No.

Condition display

As per software data version

Condition display

Remarks

Condition display Condition display Condition display Condition display 0 Low-pressure relief pressure: 2.5 – 2.8 High-pressure cutoff pressure: 43.1 – 46.6 Low-pressure relief pressure: 0.667 – 0.687 High-pressure cutoff pressure: 3.373 – 3.607

Condition display “0” is always displayed. MPa V

Above 10.5 km/h in 3rd or 4th gear speed: 0 mA Other than above: 100 – 600 mA (Depends on control)

mA

When clutch is engaged: 670 mA When clutch is disengaged (Above 10.5 km/h in 3rd or 4th gear speed): 0 mA

mA

0 – 1000 mA • Fan rotation direction is being reversed: 800 mA • Fan is rotating in reverse: 0 mA

mA

Switch position, forward: 0 Switch position, automatic reverse: 2 Manual reverse switch is being operated: 1

Condition display

Depends on travel speed.

km/h

Not used

0 km/h = 0 min-1 10 km/h = 754 min-1 20 km/h = 1509 min-1 30 km/h = 2264 min-1 40 km/h = 3019 min-1

min-1

“min-1” is SI unit of rotation speed. (1 min-1 = 1 rpm)

0%

%

Ordinary: 100% Forward travel in S mode: 50 – 100%

%

0%

%

Directional lever in N, stopped: 0 (OFF) Other than above: 1 (ON)


“0%” is always displayed.

“0%” is always displayed.

Condition display

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35


SEN03936-01 a

Use this page in next page and a spread. HST [HST controller system]

No.

Monitoring code

22

99100

Parking brake switch signal

PARKING A/B

11/00/10/01

23

04302

Alternator R voltage signal

ALTERNATOR

0.0 – 30.0

24

99200

Travel speed control dial

SPEED POT

0.0 – 50.0

25

99201


SPEED POT

0.001 – 5.000

26

80200

Traction level setting

TRACTION

0 – 100

27

99101

Forward-Reverse selector switch FNR signal

MULTI FNR

100/010/001

28

99300

Machine status

HST STATUS

0–6

29

99301

Clutch status

CLUTCH STATUS

0–4

30

99302

Forward-Reverse recognition

TRAVEL F/R

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36

Real-time monitoring item (*1)

Displayed item (*2)


F/R



a

SEN03936-01

Use this page in front page and spread. HST [HST controller system] Contents of display in normal state

Parking brake position (High): 00 (Middle): 10 (Low): 11 0 – 30 V

Unit (*4)

Remarks

Condition display

V

4.0 – 13.0 km/h (Depends on travel speed control dial position)

km/h

0.9 – 4.1 V (Depends on travel speed control dial position)

V

Traction level setting (When stopped) • When traction level A is set: 84% • When traction level B is set: 74% • When traction level C is set: 64%

%

100: F, 010: N, 001: R ON/OFF refers to each bit.

Condition display

Stopped: 0 Forward travel (Directional lever in F): 1 Reverse travel (Directional lever in R): 2 Forward travel, lever in R: 3 Reverse travel, lever in F: 4 Forward travel, lever in N: 5 Reverse travel, lever in N: 6

Condition display

Clutch condition • Engaged o Being prepared for disengaging: 0 • Disengaged (During high-speed travel in 3rd, 4th speed range): 1 • Disengaged o Engagement is being modulated (During deceleration in 3, 4th speed range): 2 • Completion of engagement (During low-speed travel in 1st, 2nd speed range or 3rd, 4th speed range) • Being disengaged: 4

Condition display

Forward travel: F Reverse travel: R

Condition display

Display is as shown at left, regardless of traction control switch position.

Previous condition is displayed while machine is stopped

*1: All items, including ones for which sensors are not installed on some models and optional components, are displayed. *2: Abbreviated as number of characters is limited. *3: A number out of the display range is displayed as “-----”. *4: If a unit is necessary, the SI unit is used.


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37


SEN03936-01

HST [HST controller system] No.

Monitoring codes

1

2

3

4

Input/Output signal

Displayed item


D-IN-0

FNR (Directional) lever F (Forward)

F (Forward) = ON (24 V)/OFF (OPEN)

D-IN-1

FNR (Directional) lever N (Neutral)

N (Neutral) = ON (24 V)/OFF (OPEN)

D-IN-2

FNR (Directional) lever R (Reverse)

R (Reverse) = ON (24 V)/OFF (OPEN)

D-IN-3

Right FNR (directional) switch selector switch


D-IN-4

Traction control switch


D-IN-5

—

—

D-IN-6

—

—

D-IN-7

—

—

D-OUT-0

—

—

D-OUT-1

—

—

D-OUT-2

—

—

D-OUT-3

—

—

D-OUT-4

—

—

D-OUT-5

—

—

D-OUT-6

—

—

D-OUT-7

—

—

D-OUT-8

—

—

D-OUT-9

—

—

D-OUT-10

—

—

D-OUT-11

—

—

D-OUT-12

—

—

D-OUT-13

—

—

40977

40978

40979

D-OUT-14

VIS Self-holding relay

Output ON = ON (GND)/OFF (OPEN)

D-OUT-15

HST safety relay


D-OUT-16

Motor 2 solenoid relay


D-OUT-17

Fan reverse solenoid relay


D-OUT-18


HST pump F solenoid = ON (24 V)/OFF (OPEN)

D-OUT-19

HST pump R solenoid (Reverse)

HST pump R solenoid = ON (24 V)/OFF (OPEN)

40980 D-OUT-20

—

—

D-OUT-21

—

—

D-OUT-22

—

—

D-OUT-23

—

—

“1” is displayed when ON and “0” is displayed when OFF.

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SEN03936-01

ENG [Engine controller system] No.

Monitoring code

Monitoring items (*1)

Displayed items (*2)

1

20400

Hardware serial No.

2

03200

Battery voltage

POWER SUPPLY

3

01002

Engine speed

ENG SPEED

ECM S/N


Unit (*4)

Arabic numerals

Status display

0.0 – 480.0

V

0 – 4000

rpm

4

04104


COOLANT TEMP

–40 – 210

°C

5

04105

Engine coolant temperature sensor voltage

COOLANT TEMP

0.00 – 5.00

V

6

36400


RAIL PRESS

0 – 400

MPa

7

36402

Common rail pressure sensor voltage

RAIL PRESS

0.00 – 5.00

V

8

37400

Atmospheric pressure

AMBIENT PRESS

–99.9 – 999.9

kPa

9

37402

Atmospheric pressure sensor voltage

AMBIENT PRESS

0.00 – 5.00

V

10

18500

Boost temperature

CHG TEMP

–50 – 200

°C

11

18501

Boost temperature sensor voltage

CHG TEMP

0.00 – 5.00

V

12

36500

Boost pressure

CHG PRESS-A

–99.9 – 999.9

kPa

13

36502

Boost pressure sensor voltage

CHG PRESS-A

0.00 – 5.00

V

14

18700

Engine output torque

OUTPUT TORQUE

–24000 – 24000

Nm

15

36700

Equivalent torque

TORQUE RATIO

0 – 100

%

16

31706

Final accelerator position

FINAL THROTTLE

17

37300

Momentary fuel consumption

FUEL RATE

18

18600

Final injection volume command (in weight)

INJECT COMMAND

19

36300

Final injection timing command TFIN

INJECT TIMING

20

31701

Accelerator pedal position

21

31707

Accelerator pedal sensor voltage

22

18300

Idle validation signal

23

18301

24

0 – 100

%

0.0 – 999.9

1/h

Remarks

0 – 1000

mg

–180.0 – 180.0

CA

THROTTLE POS

0 – 100

%

THROTTLE POS

0.00 – 5.00

V

IVS 1

ON/OFF

Status display

Idle validation signal

IVS 2

ON/OFF

Status display

18900

Engine controller internal temperature

ECM IN TEMP

–40 – 210

°C

25

36200

Final common rail pressure command PFIN

PRESS COMMAND

0 – 400

MPa

26

17500

Selection of engine mode

POWER MODE

0–4

Status display

27

18800

WIF sensor stats

WATER IN FUEL

ON/OFF

Status display

MACHINE ID (H)

Incoming value is displayed as is (Upper 8 digits of 16 characters)

Status display

Status display

28

00400

Name of selected model (upper 8 digits)

29

00401

Name of selected model (lower 8 digits)

MACHINE ID (L)

Incoming value is displayed as is (Lower 8 digits of 16 characters)

30

20216

Build version

BUILD VER

Incoming value is displayed as is (8 characters)

Status display

31

20217

Calibration data version

CAL VER

Incoming value is displayed as is (8 characters)

Status display

*1: All items are displayed including those for which sensors are not provided depending on the given model or option. *2: Abbreviated expression is employed because of number of characters usable is restricted. *3: A number out of the display range is displayed as “-----”. *4: SI units alone are employed whenever a unit is needed. WA320, 320PZ-6 (KA SPEC.)

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SEN03936-01 5.

Engine reduced-cylinder function (CYLINDER CUT-OUT) The engine reduced-cylinder function denotes setting the injector of a single cylinder or two or more cylinders to electrically no injection state and turns on the operation on reduced-cylinder condition. When any cylinders of the engine were suspected for abnormal output (combustion), this approach is used to single out the failed cylinder. 1) Selecting the menu Display the CYLINDER CUT-OUT screen from the menu screen of Service mode.

2)

3)

a a

Displaying sub menu Press [U] switch while the menu i s selected to display the sub menu. a

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Selecting a cylinder to be reduced Using [<] or [>] switch, select a cylinder to be reduced from No. 1 – No. 6 cylinders and then settle the selected cylinder using [U] switch. The cylinder to be reduced is selectable while the engine is run. Any number of cylinders can be reduced – a single unit or two or more units. q [>] switch: Advances the cursor rightward q [<] switch: Advances the cursor leftward q [U] switch: Settles the cylinder to be reduced (the cursor starts flashing after the settlement) q [t] switch: Restores the CYLINDER CUT-OUT screen

40

As the reduced-cylinder command is issued from the engine controller to the cylinder to be reduced, the bottom of the stopped cylinder number turns to black.



4)

Cancelling a reduced cylinder Using [<] or [>] switch, select the currently stopped cylinder and then press [U] switch to cancel the reduced-cylinder command from the engine controller. The black display will disappear.

SEN03936-01 2) a

a 6.

No injection cranking function The machine monitor is equipped with the function capable of lubricating the engine through no injection cranking. When a machine has been stored for a long time, this function is used to lubricate the engine prior to its restart in order to prevent its wear or damages out of oil. The no injection cranking must be set up while the engine is stopped. 1) Selecting menu Display the NO INJECTION screen from menu screen of Service mode.


a

Pressing [U] switch sets up the no injection cranking. If this screen does not appear as [U] switch is hit, a communication error should be suspected.

If the no injection cranking is selected as the engine is running, the engine stop instruction screen will appear. In such case, stop the engine once and then do the set up again.

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SEN03936-01 7.

Adjustment function (TUNING) The machine monitor implements initial setting after disassembly or replacement of the transfer, or after replacement or addition of sensor, HST pump, HST motor and EPC valve or controller. Through the initial setting, the machine monitor corrects and adjusts the installation error or manufacturing variations of individual parts. a Adjustment function Item Code No. No.

Adjustment item

7-1

03

Adjustment of interval of fan automatic reverse operation

7-2

04

Adjustment of continuance of fan automatic reverse operation

7-3

05

Adjustment of lift arm angle sensor (upper) (for load meter) (*)

7-4

06

Adjustment of lift arm angle sensor (lower) (for load meter) (*)

7-5

07

Adjustment of ECSS operation travel speed

7-1. Adjustment of interval of fan automatic reverse operation a This function is used to change the interval of the forward and reverse operations of the fan when the fan automatic reverse operation is selected. a The interval of the fan automatic reverse operation is adjustable in the range from 0.1 h (6 minutes) to 200 h. It must be set to at least twice the continuance of the fan automatic reverse operation, however, and cannot be set shorter than twice. a When the machine is delivered, the interval of fan automatic reverse operation is set to 2.0 h. a When the machine is delivered, the continuance of the fan automatic reverse operation is set to 2 minutes. 1) On the service mode menu screen, display the TUNING screen.

* This menu is displayed but it is not used.

a

The items which prohibit use The setting of following items (code: 01, 02) are not changed because of prohibition of use.

2)

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42

Hold down the [U] switch for at least 5 seconds to display the next screen. a Do not use this item.



3)

With the [<] and [>] switches, select 03: FAN REV PD screen.

4)

Press the [U] switch to settle. a If the [U] switch is pressed, the screen to adjust the interval of fan automatic reverse operation is displayed. With the [<] and [>] switches, select an interval in the range from “0.1” to “200” (Unit: h). Press the [t] switch to settle the setting. a The selected interval of fan automatic reverse operation is not changed to a value less than twice the continuance of the fan automatic reverse operation.

5)

6)

SEN03936-01 7-2. Adjustment of continuance of fan automatic reverse operation a This function is used to change the continuance of the reverse operation when the fan automatic reverse operation is selected. a The continuance of the fan automatic reverse operation is adjustable in the range from 0.5 minutes to 10 minutes. It must be set to below 1/2 of the interval of the fan automatic reverse operation, however, and cannot be set longer than 1/2. a When the machine is delivered, the continuance of fan automatic reverse operation is set to 2.0 minutes. a When the machine is delivered, the interval of the fan automatic reverse operation is set to 2.0 h. 1) On the service mode menu screen, display the TUNING screen.

2)



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43


SEN03936-01 3)

With the [<] and [>] switches, select 04: FAN REV PD screen.

4)

Press the [U] switch to settle. a If the [U] switch is pressed, the screen to adjust the continuance of fan automatic reverse operation is displayed. With the [<] and [>] switches, select a continuance in the range from “0.5” to “10” (Unit: minute). Press the [t] switch to settle the setting. a The selected continuance of fan automatic reverse operation is not changed to a value longer than 1/2 of the interval of the fan automatic reverse operation.

5)

6)

7-5. Adjustment of ECSS operation travel speed (if equipped) a This function is used to adjust the ECSS operation/reset travel speed. a The initial ECSS operation travel speed is 5 km/h (3.1 MPH). a The ECSS reset travel speed is the ECSS operation travel speed minus 1 km/h (0.6 MPH). Example: q If the ECSS operation travel speed is 5 km/h (3.1 MPH), the ECSS reset travel speed is 4 km/h (2.5 MPH). q If the ECSS operation travel speed is 8 km/h (5.0 MPH), the ECSS reset travel speed is 7 km/h (4.4 MPH). 1) Display the “TUNING” screen from the menu screen of Service mode.

2)


7-3. Adjustment of lift arm angle sensor (upper) (Load meter specification) a This item is not used. 7-4. Adjustment of lift arm angle sensor (lower) (Load meter specification) a This item is not used.

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3)

Select “07: ECSS SPEED” with [<] or [>] switch.

4)

Press [U] switch to settle. a If the selection is settled, the ECSS operation travel speed adjustment screen appears.

SEN03936-01 8.

Maintenance monitoring function The maintenance function offers the following capabilities in the maintenance of filters and oils. q Change of maintenance interval time q Selection between enabling or disabling timer by item q Setting of a default value q Selection between enabling or disabling timer for items 8-1. Changing maintenance interval time 1) Display the MAINTENANCE MONITOR screen from the menu screen of Service mode.

2) a a 5)

6)

7)

To increase the ECSS operation travel speed, press [>] switch. a The operation travel speed is increased 1 km/h (0.6 MPH) by 1 operation of the switch. a The operation travel speed can be adjusted to a maximum of 8 km/h (5.0 MPH). To decrease the ECSS operation travel speed, press [<] switch. a The operation travel speed is decreased 1 km/h (0.6 MPH) by 1 operation of the switch. a The operation travel speed can be adjusted to a minimum of 5 km/h (3.1 MPH). If the operation travel speed is set to a desired value, press [t] switch to finish setting.


3)

Press [U] switch to display 01: ENG OIL screen. The lower left side space indicates the time remained up to the replacement. The lower right side space indicates the cumulative replacement frequencies. Using [<] or [>] switch, select the item for which the maintenance interval is to be changed from the following.

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SEN03936-01 List of maintenance items Item

ID No.

Indication of items on the character display

Replacement interval time (H)

Engine oil

01

ENG OIL

500

Engine oil filter

02

ENG FILT

500

Fuel pre-filter

41

FUEL P FILT

500

Fuel filter

03

FUEL FILT

1000

Corrosion resistor

06

CORR RES

1000

Transfer oil

25

TRANSF OIL

1000

HST oil filter

26

HST FILT

1000

Hydraulic oil filter

04

HYD FILT

2000

Hydraulic oil

10

HYD OIL

2000

Axle oil

15

AXLE OIL

2000

4)

Settle the target items of interval change by use of [U] switch.

5)

Maintenance interval time change procedure 1] This cursor is located at the highestorder digit. Pressing [<] or [>] switch changes the value of this digit in the range of 0 – 9. 2] Press [U] switch when the intended value appeared to specify it as the set value. a The cursor moves to the 2nd digit. 3] Set the values up to the lowest-order digit in the same order and then press [U] switch. q When the input interval time is within the setting range: The screen changes to the check screen. q When the entered interval time is out of the setting range: The entered interval time does not replace the current value and the input screen will be restored. The shortest interval time value is 50 h.

a

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46

a

When you have entered a wrong value to a position except the highest-order digit, move to the highest-order digit using [t] switch and repeat the procedure from the first. In this case, the value that had been entered remains as it is until modified. When the cursor is at the highest-order digit, move to the higher layer using [t] switch.



6) a

a a

q

Select “YES” or “NO” using [<] or [>] switch. The selected cursor will start flashing. If “Y ES” i s s ele cted and [t] s witc h i s pressed, the information will be deleted. If “NO” is selected and [t] switch is pressed, deletion is cancelled and the maintenance interval change item screen is restored. By default, the cursor is set to NO (cancel) to prevent resetting error. When an interval time is changed, the timer remaining time is changed as shown below. Timer remaining time = Interval time being set – Elapsed time from the last replacement

8-2. Selection between enabling or disabling timer by item 1) Pressing [<] or [>] switch from 8-1-3) Interval time change screen displays the “Selection between enabling or disabling timer by item” screen. a When “Timer by item” is enabled, the order of display is ON o OFF.


SEN03936-01 a a

When “Timer by item” is disabled, the order of display becomes OFF o ON. The default display is ON.

2) a

Press [U] switch from this state. If “Timer by item” is disabled, OFF will be displayed in the upper column.

a

If “Timer by item” is enabled, ON will be displayed in the upper column.

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SEN03936-01 3) a

a a

q

Select “YES” or “NO” using [<] or [>] switch. The selected cursor will start flashing. If “Y ES” i s s ele cted and [t] switc h i s pressed, the information will be deleted. If “NO” is selected and [t] switch is pressed, deletion is cancelled and the maintenance interval change item screen is restored. By default, the cursor is set to NO (cancel) to prevent resetting error. An interval time is changed, the timer remaining time is changed as shown below. Timer remaining time = Interval time being set – Elapsed time from the last replacement

3) 4) a

a

Press [U] switch from this state. Select “YES” or “NO” using [<] or [>] switch. The selected cursor will start flashing. If “YE S” is s elec ted a nd [ t] s witc h is pressed, the change will be enabled If “NO” is selected and [t] switch is pressed, the change will not be implemented and the maintenance monitoring screen will be restored. By default, the cursor is set to NO (cancel) to prevent resetting error.

8-3. Changing set default value. 1) Press [U] switch from the MAINTENANCE MONITOR screen of Service mode to display 01: ENG OIL screen.

a

a a

2)

Using [<] or [>] switch, select the INITIALIZE screen from the following table.

a

If the default value setting is executed, all the currently changed interval times are returned to the default values. It is executed on every item independent of whether or not the function is enabled for a specific item. Timer remaining time shall be Default value – E lapsed time s ince the l ast replacement. Executing the default value setting does not affect the reset frequency. Namely, it remains the same as before this operation was executed. Set enable for enable or disable of individual items.

8-4. Selection between timer stop for all items and enable by item 1) Press [U] switch from the MAINTENANCE MONITOR screen of Service mode to display 01: ENG OIL screen.

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2)

3)

Using [<] or [>] switch, select the ALL ITEMS OFF OR ON screen from the following table.

SEN03936-01 5) a

Press [U] switch to display the ALL ITEMS o OFF screen. a

6) a

a 4)

Press [U] switch from the ALL ITEMS o OFF screen or the ALL ITEMS o ON screen. When [U] switch is pressed from the ALL ITEMS o OFF screen, OFF will be is displayed in the upper space.

Press [<] or [>] switch when selecting the ALL ITEMS o ON.


When [U] switch is pressed from the ALL ITEMS o ON screen, ON will be is displayed in the upper space. Select “YES” or “NO” using [<] or [>] switch. The selected cursor will start flashing. If “ YE S” is s elec ted a nd [t] s witc h is pressed, the information will be deleted. If “NO” is selected and [t] switch is pressed, deletion is cancelled and the maintenance interval change item screen is restored. By default, the cursor is set to NO (cancel) to prevent resetting error.

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SEN03936-01 7) a a a

8) a

a a a a

9.

As the timer stop for all items is executed: The timer function for all items is stopped a n d t h e M A I N TE N A N CE M O NI TO R screen is restored. Setting for individual items is also disabled. If cancelled: The operation is cancelled a n d t h e M A I N TE N A N CE M O NI TO R screen is restored. When timer enable for all items is executed: Interval time being set for all items is executed to the set value before disabled i nd e p e nd e n t o f wh e th e r o r n ot i t i s enabled or disabled for a specific item. The timer remaining time is reset. (The reset frequency remains the same as before the resetting.) The MAINTENANCE MONITOR screen is restored. Setting for individual items is also enabled. If cancelled: The operation is cancelled a n d t h e M A I N TE N A N CE M O NI TO R screen is restored.

Operating information display function It is a fuel consumption-related function and displays the following information. q Fuel consumption ratio and average fuel consumption q Cumulative fuel consumption and travel distance q Cumulative fuel consumption and elapsed time 1) Selecting menu Display the OPERATION INFO screen from the menu screen of Service mode.

3)

Using [<] or [>] switch, select the item to be displayed from 1] – 4] on the fuel consumption ratio and average fuel consumption screen. 1] Fuel consumption ratio and average fuel consumption screen a The upper column displays fuel consumption [L/km or L/mile] per 1 km (or 1 mile) from the last resetting. q Above value is computed from the fuel consumption ratio and travel distance (odometer distance). a The lower column displays the average fuel consumption [L/h] from the last resetting. a Calculation is done only for the duration in which the engine is run.

2] a

q

a

q

q

a

2)

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Cumulative fuel consumption and travel distance The upper column displays the cumulative fuel consumption [L] from the last resetting. The counting is stopped at 99999.9, the upper limit. The lower column displays the travel distance [km or mile] from the last resetting. The unit km or mile shall be selected depending on that used on the odometer. The counting is stopped at 99999.9, the upper limit. Calculation is done only for the duration in which the engine is run.

Press [U] switch to display the fuel consumption ratio and average fuel consumption screen.

50



SEN03936-01 4) a a a

3] a

q

a

q

a

Cumulative fuel consumption and elapsed time The upper column displays the cumulative fuel consumption [L] from the last resetting. The counting is stopped at 99999.9, the upper limit. The lower column displays the elapsed time [h] from the last resetting. The counting is stopped at 99999.9, the upper limit. Calculation is done only for the duration in which the engine is run.

5) a a

Deleting display data Data on screens 3) – 1] to 3] allow deletion. Select a desired item and then delete it using [U] switch. Use [t] switch when canceling deletion of data.

Setting gain correction Gain correction denotes the function of correcting gain to cumulative fuel consumption. Gain correction is reflected 3) – 1] to 3]. 1] After deleting data (RESET screen), press [<] or [>] switch to display the current set value.

2] a a

3] 4] 5] a 6]


Pressing [U] switch displays the correction screen. Default value: 0.0% This setting allows correcting the cumulative fuel consumption in the range of –50.0 to +50.0. Move the cursor to [+] or [–]. Pressing [<] or [>] switch alternately displays [+] and [–]. Press [U] switch to settle [+] or [–]. The cursor moves to the highestorder digit of the set value. Pressing [<] or [>] switch changes the value of this digit in the range of 0 – 9.

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51

SEN03936-01 7] a 8] a a

a

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52


Press [U] switch when the intended value appeared to specify it as the set value. The cursor moves to the 2nd digit. Set the values up to the lowest digit in the same order as above and then press [U] switch to settle. As the selection is settled, the preceding screen is restored. If [t] switch is pressed before finishing entering, the cursor moves to the [+] and [–] position. In this case, the value remains unchanged. Pressing [t] switch again restores the preceding screen. If the value is not in the –50 – +50 range, pressing [U] switch at the lowest digit just moves the cursor the [+] and [–] position and the value remains as it is.



SEN03936-01

10. OPTIONAL SELECT function a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and the option is effective. a Before setting an option, check that the machine model has been selected. (Select the machine model before setting the option.) Optional device installation setting table

No.

Item

Display in English

Setting at monitor delivery Contents of selection For SI

For non-SI

1

Tire type

TIRE TYPE

20.5

20.5

2

Emergency steering

EMERG S/T

NO ADD

NO ADD

If equipped, select “ADD”.

3

Right FNR (directional) switch

FNR

NO ADD

NO ADD

If equipped, select “ADD”.

Keep “20.5”

4

ECO lamp operation

ECO LAMP

ADD

ADD

• Keep to “ADD” normally. • “NO ADD” is selected, ECO lamp in machine monitor is kept turned OFF.

5

ECSS

E. C. S. S.

ADD

ADD

If not installed optionally, select “NO ADD”.

6

Reverse fan

REVERSE FAN

ADD

ADD

If fan reverse function is not installed, select “NO ADD”.

7

Parking brake

PKG BRAKE

MECHA

MECHA

9

Tire size correction

11 Travel speed unit

Selection of travel 12 speed/engine speed display on main screen

Selection of engine speed/travel speed on 13 normal screen of character display or non-display

TIRE SIZE

SPEED (UNIT)

RPM OPT

RPM/SPEED

0%

—

— (*1)

ADD

0%

MPH

NO ADD

ADD

Remarks

If electric parking brake is installed, MECHA: Mechanical select “ELEC”. ELEC: Electric • Keep to “0” normally. • If number other than “0” is selected, only travel speed display in machine monitor increases or decreases according to selected number. • Can be changed in only nonMPH: Display in mile SI specification. For contents km/h: Display in kilomeof change, see “Remarks” colter umn. • Can be changed in only nonSI specification. For contents of change, see “Remarks” column. • To change travel speed display to engine speed display in operator mode, select “ADD”. Note: Do not select “ADD” in region where display of travel speed is obliged by law.

NO ADD: (*2) ADD: (*3) ADD o NO ADD: (*4) NO ADD o ADD: (*5)

• Keep to “ADD” normally. • If “NO ADD” is selected, “Engine speed or travel speed” are not displayed on character display.

ADD: (*6) NO ADD: (*7) ADD o NO ADD: (*8) NO ADD o ADD: (*9)

Reference: Item Nos. 8 and 10 are missing. *1: Fixed to “NO ADD (km/h)” internally, although not displayed. *2: “Selection of speed/engine speed” is not displayed in operator mode. *3: “Selection of speed/engine speed” is displayed in operator mode (Tachometer can be displayed as main item).


30-130

53

SEN03936-01 *4: *5: *6: *7: *8: *9:


Fixed to speedometer. Setting at previous ADD or initial setting. “Travel speed/rpm on character display: Displayed/Not displayed” is displayed in operator mode. “Travel speed/rpm on character display: Displayed/Not displayed” is not displayed in operator mode. Not displayed. Setting at previous ADD or initial setting.

30-130

54



1)

Display the OPTIONAL SELECT screen from the menu screen of Service mode.

2)

Hold down [U] switch for 5 seconds or longer. The 1: TIRE TYPE screen will appear. a If the [t] switch is pressed, the screen returns to the OPTIONAL SELECT screen.

3)

a

Be sure to start setting of each option o n 1 : T IR E T Y P E s c r e e n . A ft e r changing or settling the option, set other items in order on the next 2: EMERG S/T screen and the following screens.


SEN03936-01 10-1. Option setting/not setting selection a Among the items included in the list of installed optional devices and their setting, the option setting/not setting selection applies to the following items. a If the options are not selected, the option nonselection screen (NO ADD) is displayed.

a

If the options are selected, the option selected screen (ADD) is displayed.

a

[U] switch allows alternately displaying the option non-selection screen and the optionselected screen.

Reference: Details of the main items are shown below.

30-130

55


SEN03936-01 10-2. Selection of optional tire type a Select “1: TIRE TYPE” from “Optional device installation setting table”. Reference: This screen appears first when the screen is changed from the “OPTIONAL SELECT” screen. a Each time [U] switch is pressed, the tire type changes from small to large. Selectable size: 20.5 a Select only “20.5” (Do not change) a If the tire type is changed, the operation acceptance tone (peep) sounds.

10-4. Setting tire deflection option a Select 9: TIRE SIZE from the list of installed optional devices and their setting. a Pressing [U] switch sequentially displays [@@]% in the following order. a The display progresses from +00 through –10. Pressing [U] switch at this point returns the display to +00. Order No.1

No.2

No.3

No.4

No.5

No.6

No.7

@@

+02

+04

+06

+08

+10

+12

+00

Order No.8 @@

a

10-3. Selection of optional parking brake a Select “7: PKG BRAKE” from “Optional device installation setting table”. a Each time [U] switch is pressed, the parking brake type changes. S e l e c ta b l e i t e m : M E C H A ( M e c h a n i c a l : Default), ELEC (Electric) a If the parking brake type is changed, the operation acceptance tone (peep) sounds.

30-130

56

–02

No.9 No.10 No.11 No.12 No.13 No.14 –4

–6

–8

–10

–12

+00

As the display is switched, the sound (beep) indicating acceptance of the operation will be generated.

10-5. Selection of optional travel speed unit a If the SI unit specification is selected when delivered, this menu is not displayed. (Unit is fixed to km/h.) a Select “11: SPEED UNIT” from “Optional device installation setting table”. a Each time [U] switch is pressed, the speed unit changes. Selectable item: MPH (default), km/h a If the unit is changed, the operation acceptance tone (peep) sounds.



10-6. Storing option selection 1) When the option selection was changed, turn off the starting switch once to stop the controller operation completely. (After turning off the starting switch, wait for 15 seconds without doing any switch operation.) 2) The specified option selection is enabled as the starting switch is turned on. a Whenever an option selection is made, turn off the starting switch once and then turn it on again in approximately 15 seconds.

SEN03936-01 11. Machine serial number input function 1) Display the MACHINE No. SET screen from the menu screen of Service mode.

2) 3)


Press [U] switch to display the MACHINE No. screen. Enter the serial number according to the following procedure. a The cursor is positioned at the highest-order digit. 1] Pressing [<] or [>] switch increases or decreases the value at the cursor position. Select a desired value using these switches. 2] Press [U] switch to settle the selection. a The cursor moves to the digit situated immediately on the right hand. 3] Set the values up to the lowest digit in the same order as above and then press [U] switch to settle. a As the selection is settled, the immediately preceding screen is restored. a Pressing [t] switch while entry is taking place will move the cursor the highestorder digit. In this case, repeat entry from the highest-order digit. a If [t] switch is pressed while the cursor is at the highest-order digit, the immediately preceding screen will be restored.

30-130

57


SEN03936-01 12. Machine model select function (MACHINE WA***) a The setting of the machine model of the machine monitor can be changed with the machine model select function. a If the machine monitor is initialized, perform the machine model select operation first. a If the machine model select operation is performed, the setting of options is reset. Accordingly, start with the option select operation and select all the options.

3)

12-1. Implementing the model change 1) Display the MACHINE screen from the menu screen of Service mode. a The currently selected machine model is displayed on the lower line.

a

a

4) a

a

2)

Hold down [U] switch for 5 seconds to display the model selection screen.

With the [<] and [>] switches, select the machine model. a Selectable models q WA100 q WA150 q WA200 q WA250 q WA270 q WA320 a If wrong model and tire are set, machine does not work correctly. Press [t] switch when stopping the model selection. As the operation is stopped, the sound (beep) indicating acceptance of the operation will be generated, restoring the MACHINE screen. With the [U] switch, settle the changed machine model and tire size. As the selection is settled, the sound (beep) indicating acceptance of the operation will be generated, restoring the MACHINE screen. Check that the desired machine model is displayed on the machine model select screen.

12-2. Storing model change 1) When the model change was done, turn off the starting switch once to stop the controller operation completely. (After turning off the starting switch, wait for 15 seconds without doing any switch operation.) 2) The model being selected as the starting switch is turned on is validated. a Whenever a model change was done, turn off the starting switch once and then turn it on again in approximately 15 seconds. 13. Initialize function This function is used only in the factory. It is, therefore, not used for a service purpose.

30-130

58



SEN03936-01

14. Item that refers to SERVICE NEWS Refer to SERVICE NEWS for the following items. q Setting of service meter when machine monitor is exchanged. q Setting of odometer when machine monitor is exchanged.


30-130

59

130 Testing and adjusting, Part 3 Pm clinic inspection chart

SEN03936-01

Pm clinic inspection chart

WA320-6 Serial No. 70001 and up

1

Machine serial No. Hours inspection

Work order No.

Engine serial No.

Date of execution Year:

Month:

SAA6D107E-1 #

Service Meter

Serviceman

Day:

h

Questions asked to operator, walk around inspection Ambient temperature Max. °C

Was there any abnormality before inspection started?

Max. coolant temp. (During operation) Segment color

a

W G G G G R R 1 2 3 4 5 6 7

Segment color

Conditions

Unit

High idle Engine speed Engine

G G G G G R R 1 2 3 4 5 6 7

rpm

HST stall

800 – 850

800 – 850

Measurement results

Pass

Fail

2,110 – 2,310 2,010 – 2,300

1,830 – 2,160 1,730 – 2,260 kPa {mmH2O}

At rated output High idle

Oil pressure

Service limit value

2,050 – 2,250 1,950 – 2,300

Full stall (HST stall + hydraulic stall) Blow-by pressure


2,200 – 2,300 2,200 – 2,300

Hydraulic stall

SAE15W-40 Low idle

HST

m

Max. HST oil temp. (During operation)

Low idle

k

°C

Altitude

If the machine is cold, warm it up fully. <>: Reference value Item

a

Min.

MPa {kg/cm2}

Max. 0.98 {Max. 100}

1.96 {200}

Min. 0.29 {Min. 3.0}

0.25 {2.5}

Min. 0.10 {Min. 1.0}

0.07 {0.7}

Before starting the inspection, check that the machine does not move when the directional lever is placed in position. When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel safety at a speed of more than 10 km/h. High-pressure cut-off pressure

Directional lever: F Speed selector switch: 2nd Traction control switch: ON

42.9 – 45.3 {438 – 462}

41.1 – 45.3 {420 – 460}

Low-pressure relief pressure (work equipment PPC circuit basic pressure)

Directional lever: N

3.0 – 3.2 {31 – 33}

2.9 – 3.2 {30 – 33}

Engine: Full throttle Directional lever: N Hydraulic Brake: released oil temp.: 45 – 55°C Directional lever: N Brake: pressed

3.0 – 3.2 {31 – 33}

2.9 – 3.2 {30 – 33}

Max. 0.6 {Max. 6}

Max. 0.6 {Max. 6}

Directional lever: Forward and reverse Gear speed selector switch: 1st Travel speed control dial: Min. side Measure while driving at full throttle (Approx. 5 km/h).

3.0 – 3.2 {31 – 33}

2.8 – 3.2 {29 – 33}

Directional lever: F Speed selector switch: 3rd or 4th

3.0 – 3.2 {31 – 33}

2.9 – 3.2 {30 – 33}

Servo piston control pressure

• •

Servo piston actuation pressure

Transfer clutch control pressure

30-130

60

Hydraulic oil temp.: 45 – 55°C

MPa {kg/cm2}


130 Testing and adjusting, Part 3 Pm clinic inspection chart

SEN03936-01 WA320-6 Serial No. 70001 and up <>: Reference value

Steering

Item Steering wheel operating time

Conditions Engine low idle

Unit

sec.

Engine high idle

Steering relief pressure

MPa {kg/cm2}

Engine high idle

Brake

Service brake

Lining thickness

Front left Rear right

mm

Rear left Relief pressure Work equipment

Service limit value

3.3 – 4.1

Max. 4.8

3.4 – 4.0

2.7 – 4.7

20.1 – 21.6 {205 – 220}

18.6 – 22.6 {190 – 230}

0.9 – 1.1

Max. 0.6

0.9 – 1.1

Max. 0.6

0.9 – 1.1

Max. 0.6

Measurement results

Pass

Fail

Lock frame with frame lock bar

Front right

Lift arm speed

0.9 – 1.1

Max. 0.6

20.2 – 21.0 {206 – 214}

18.6 – 22.6 {190 – 230}

Raising time

5.2 – 6.2

Max. 8.6

Lowering time

3.0 – 4.0

Max. 5.3

0.9 – 1.5

Max. 1.8

0.9 – 1.5

Max. 2.0

Bucket relief

Engine high idle

Dumping time Bucket speed

Hydraulic drift Axle


MPa {kg/cm2}

sec.

Tilting-back time (At full stroke) Engine stopped

Check differential oil visually

Bucket cylinder Lift cylinder Front axle Rear axle

mm/15 min. —

Max. 17

Max. 26

Max. 20

Max. 30

Must be no excessive metal particles

MEMO


30-130

61

SEN03936-01



30-130

62

SEN03937-01




40 Troubleshooting

40

100 Failure code table and fuse locations Failure codes table.......................................................................................................................................... 2 Fuse locations................................................................................................................................................. 8


40-100

1

100 Failure code table and fuse locations Failure codes table

SEN03937-01

Failure codes table Failure code

1

Troubled part

Trouble

Controller

Action code

Category of Reference record document No.

2G40ZG Brake


MON

E03

Mechanical system

6091NX

HST filter

Clogging

MON

E01

Mechanical system

989FN1

Travel speed

Overrun alarm

MON

E02

Mechanical system

AA1ANX Air cleaner

Clogging

MON

E01

Mechanical system

AB00L6

Hot short

MON

E01

Electrical system

AB00MA Alternator R system

Ground fault/Disconnection/Low charge level

MON

E03

B@BAZG Engine


ENG

E03

B@BAZK Engine oil

Low oil level

MON

E01

B@BCNS Engine

Overheat

ENG

E02

Mechanical system

B@BCZK Engine

Low coolant level

MON

E01

Mechanical system

B@C6NS Front brake


MON

E02

Mechanical system

B@CRNS HST


MON

E02

Mechanical system

Alternator R system

Troubleshooting by failure code (Display Mechanical of code), Part 1 system SEN03939-00 Mechanical system Electrical system

CA111

Engine controller

Internal abnormality

ENG

E03

Electrical system

CA115

Engine NE, Bkup speed sensor

Abnormality

ENG

E03

Electrical system

CA122



ENG

E03

Electrical system

CA123



ENG

E03

Electrical system

CA131

Throttle sensor


ENG

E03

Electrical system

CA132

Throttle sensor


ENG

E03

Electrical system

CA144

Coolant temperature sensor Abnormally high level

ENG

E01

Electrical system

CA145

Coolant temperature sensor Abnormally low level

ENG

E01

Electrical system

CA153

Charge temperature sensor Abnormally high level

ENG

E01

Electrical system

CA154

Charge temperature sensor Abnormally low level

ENG

E01

Electrical system

CA155

Charge temperature

Abnormally high speed derate

ENG

E03

Electrical system

CA187



ENG

E03

Electrical system

CA221



ENG

E01

Electrical system

40-100

2

Troubleshooting by failure code (Display of code), Part 2 SEN03940-00



Failure code

Troubled part

SEN03937-01

Trouble

Controller

Action code


CA222



ENG

E01

Electrical system

CA227



ENG

E03

Electrical system

CA234

Engine

Overspeed

ENG

E02

Mechanical system

CA238

Ne speed sensor power supply

Abnormality

ENG

E03

Electrical system

CA271

IMV (IMA)

Short circuit

ENG

E03

Electrical system

CA272

IMV (IMA)

Disconnection

ENG

E03

Electrical system

CA322

Injector #1 system


ENG

E03

Electrical system

CA323

Injector #5 system


ENG

E03

Electrical system

CA324

Injector #3 system


ENG

E03

Electrical system

CA325

Injector #6 system


ENG

E03

Electrical system

CA331

Injector #2 system


ENG

E03

Electrical system

CA332

Injector #4 system


ENG

E03

Electrical system

CA342

Engine controller

Data mismatching

ENG

E03

Electrical system

CA351

Injector drive circuit

Abnormality

ENG

E03

Electrical system

CA352



ENG

E03

Electrical system

CA386



ENG

E03

Electrical system

CA428

Water sensor


ENG

E01

Electrical system

CA429

Water sensor


ENG

E01

Electrical system

CA431


Abnormality

ENG

E01

Electrical system

CA432


Abnormal remedy

ENG

E03

Electrical system

CA435

Engine oil pressure switch

Abnormality

ENG

E01

Electrical system

CA441



ENG

E03

Electrical system

CA442



ENG

E03

Electrical system

CA449



ENG

E03

Electrical system

CA451

Common rail pressure senAbnormally high level sor

ENG

E03

Electrical system




40-100

3


SEN03937-01

Failure code

Troubled part

Trouble

Controller

Action code


ENG

E03

Electrical system

CA452

Common rail pressure sensor Abnormally low level

CA488

Charge temperature

Abnormally high torque derate

ENG

E03

Electrical system

CA553



ENG

E03

Electrical system

CA559

Supply pump

Low rail pressure 1

ENG

E03

Electrical system

CA689

Engine Ne speed sensor

Abnormality

ENG

E03

Electrical system

CA731

Engine Bkup speed sensor Abnormal phase

ENG

E03

Electrical system

CA757

Engine controller

Loss of all data

ENG

E03

Electrical system

CA778


Abnormality

ENG

E03

Electrical system

CA1633

KOMNET

Abnormality

ENG

E03

Electrical system

CA2185

Throttle sensor power supply Abnormally high level

ENG

E03

Electrical system

CA2186

Throttle sensor power supply Abnormally low level

ENG

E03

Electrical system

CA2249

Supply pump

Low rail pressure 2

ENG

E03

Electrical system

CA2311

IMV (IMA) solenoid

Abnormality

ENG

E03

Electrical system

CA2555


Disconnection

ENG

E01

Electrical system

CA2556


Short circuit

ENG

E01

Electrical system

D160KY

Backup lamp/buzzer relay

Hot short

MON

E01

Electrical system

D192KY

ECSS solenoid relay

Hot short

MON

E01

Electrical system

D1B0KA HST safety relay

Disconnection

HST

E03

Electrical system

D1B0KB HST safety relay

Ground fault

HST

E01

Electrical system

D1B0KY HST safety relay

Hot short

HST

E03

Electrical system

D5ZHL6


MON

E01

Electrical system


MON

E01

Electrical system

Disconnection

HST

E03

Electrical system

IGN C system

DAF3KK UNSW power supply DAFRKR

Monitor panel CAN-NET signal

DAJ0KK

HST controller power supply Low voltage

HST

E03

Electrical system

DAJ0KT

HST controller memory (EEPROM)

HST

E01

Electrical system

40-100

4

Abnormality





Failure code

SEN03937-01

Troubled part

Trouble

Controller

Action code


DAJ1L4



HST

E01

Electrical system

DAJ1L6


Hot short

HST

E01

Electrical system

DAJ2KK

Controller solenoid power supply

Low voltage

HST

E03

Electrical system

DAJ2L3

HST controller load power supply holding line

Hot short

HST

E01

Electrical system

DAJ2L4

HST controller load power supply holding line


HST

E01

Electrical system

DAJ5KX

Sensor 5V power supply

Out of input range

HST

E03

Electrical system

(DAJ9KQ) HST controller

Disagreement in model selection

MON

E03

—

DAJRKR HST controller CAN-NET


MON

E03

Electrical system

Disagreement in option selection

MON

E03

—


HST

E03

Electrical system

HST

E01

Electrical system

Abnormality

HST

E01

Electrical system

(DAJRMA) HST controller DB2RKR Engine controller CAN-NET DD1NL4

Fan auto reverse switch sigAbnormality nal

DD1NLD Fan reverse switch signal DDB6KA



HST

E01

Electrical system

DDB6KB


Ground fault

HST

E01

Electrical system

Trouble

MON

E03

Electrical system

Ground fault

HST

E01

Electrical system

Parking brake indicator DDB6KZ signal or parking brake reminder signal DDB6L0


DDB6L4



HST

E03

Electrical system

DDD7KX Travel speed control dial


HST

E01

Electrical system

DDD7KY Travel speed control dial

Hot short

HST

E01

Electrical system

MON

E01

Electrical system

DDE5MA

Emergency steering operaDisconnection tion switch

DDK3KA Right direction switch


HST

E03

Electrical system

DDK3KB Right direction switch

Ground fault

HST

E03

Electrical system

DDK6KA FNR lever


HST

E03

Electrical system

DDK6KY FNR lever

Hot short

HST

E03

Electrical system

DDS5L6

Low oil pressure (Operation of emergency steering)

MON

E03

Mechanical system

Steering




40-100

5


SEN03937-01

Failure code

Troubled part

Trouble

Controller

Action code


DF10KA



HST

E01

Electrical system

DF10KB


Hot short

HST

E01

Electrical system

MON

E01

Electrical system

DGH1KX HST oil temperature sensor Ground fault DGR2KB


Ground fault

MON

E01

Electrical system

DGR2KZ



MON

E01

Electrical system

DHH1KX HST oil pressure sensor


HST

E03

Electrical system

DHH1KY HST oil pressure sensor

Hot short

HST

E03

Electrical system

DHTCL6 HST filter clogging sensor

Functional defect

MON

E01

Electrical system

DJF1KA

Fuel level sensor


MON

E01

Electrical system

DLT3KX

Travel speed sensor B

Abnormality

HST

E03

Electrical system

DLT4KX

Travel speed sensor A

Abnormality

HST

E03

Electrical system

DLT4LC

Travel speed sensor A & B

Abnormality

HST

E03

Electrical system

DV00KY Alarm buzzer

Hot short

MON

E01

Electrical system

DW26KA Motor 2 solenoid


HST

E01

Electrical system

DW26KY Motor 2 solenoid

Hot short

HST

E01

Electrical system

DW7BKY Fan reverse solenoid circuit Hot short

HST

E01

Electrical system

DW7BKZ Fan reverse solenoid circuit


HST

E01

Electrical system

DX16KA Fan EPC solenoid

Disconnection

HST

E01

Electrical system

DX16KB Fan EPC solenoid

Ground fault

HST

E01

Electrical system

DX16KY Fan EPC solenoid

Hot short

HST

E01

Electrical system

DX19KA Motor 1 solenoid

Disconnection

HST

E03

Electrical system

DX19KB Motor 1 solenoid

Ground fault

HST

E03

Electrical system

DX19KY Motor 1 solenoid

Hot short

HST

E03

Electrical system

DX20KA Clutch EPC solenoid

Disconnection

HST

E03

Electrical system

DX20KB Clutch EPC solenoid

Ground fault

HST

E03

Electrical system

DX20KY Clutch EPC solenoid

Hot short

HST

E03

Electrical system

40-100

6





Failure code

Troubled part

SEN03937-01

Trouble

Controller

Action code


DXH7KB Reverse solenoid

Ground fault

HST

E03

Electrical system

DXH7KZ Reverse solenoid


HST

E03

Electrical system

DXH8KB Forward solenoid

Ground fault

HST

E03

Electrical system

DXH8KZ Forward solenoid


HST

E03

J141N1

Steering pump

Overrun alarm

HST

E02

M100N1

HST pump

Overrun alarm

HST

E02

Mechanical system

M400N1

Motor 1

Overrun alarm

HST

E02

Mechanical system

a

a

a a a

Troubleshooting by failure Electrical code (Display system of code), Part 7 Mechanical SEN03945-00 system

Failure codes: The failure code table is written in alphabetical order and also starting from small number. The failure code in parentheses is not recorded in the failure history for both electrical system and mechanical system. Applicable controller: Applicable controller indicates in which controller system the failure has occurred. MON : machine monitor system ENG : Engine controller system HST : HST controller system Action codes: Action codes indicate what is displayed in the operator mode when a failure is detected. History classification: History classification indicates in which system, either electrical system or mechanical system in the failure history display function, a failure has been recorded. Note: Optional equipments are also included in the table.


40-100

7

100 Failure code table and fuse locations Fuse locations

SEN03937-01

Fuse locations

1

Connection table of fuse box and slow blow fuse a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuse box and slow blow fuse to see if the power is supplied normally. Fuse box: FS1 Type of power supply (Power source)

Fuse No. Fuse capacity

Unswitched power supply (Slow blow fuse [50 A])

Destination of power (*)

1

20A

Starting switch B

2

10 A

Hazard lamp

3

15 A

HST controller

4

30 A

Engine controller

5

10 A

Machine monitor Tachograph Buzzer

6

10 A

Radio Auto-grease Room lamp

7

10 A

Unswitched power supply for optional devices

8

10 A

Headlamp (left)

9

10 A

Headlamp (right)

10

10 A

Turn signal lamp

11

10 A

Stop lamp relay Stop lamp switch Stop lamp

12

15 A

VIS power supply holding relay HST controller

13

10 A

Detent active relay ECSS switch Quick coupler Boom kick-out relay PPC solenoid Bucket leveler relay Proximity switch

14

20 A

Front/Rear wiper Wiper timer Window washer

15

10 A

Radio Auto-grease Cigarette lighter

Accessory power supply (Slow blow fuse [80 A])

*: Optional devices are included. Devices which are not set may be included.

40-100

8



SEN03937-01

Fuse box: FS2 Type of power supply (Power source)

Fuse No. Fuse capacity

Accessory power supply (Slow blow fuse [80A])

ACC signal (ACC switch)

Destination of power (*)

1

20 A

Air conditioner blower

2

5A

Air conditioner compressor

3

20 A

Beacon Working lamp (Front: For addition) Rotary lamp

4

20 A

Glass heater

5

10 A

Load meter, air cleaner clogging relay

6

20 A

Key ON power for optional device

7

10 A

DC converter

8

10 A

Parking brake

9

10 A

Horn Air suspension seat

10

10 A

Small lamp (right)

11

10 A

Small lamp (left)

12

10 A

Working lamp (front)

13

10 A

Working lamp (rear)

14

10 A

Machine monitor (Starting switch ACC signal) Backup lamp Backup alarm

15

5A

Engine controller (Starting switch ACC signal)

*: Optional devices are included. Devices which are not set may be included. Location q Inside of cover (1) at rear of console in cab


Fuse No.

40-100

9


SEN03937-01 Slow blow fuse Type of power supply (Power source) Accessory power supply (Battery) Unswitched power supply (Battery)

Fuse capacity 80 A

Fuse box FS1 No.8 – 15 Fuse box FS2 No.1 – 15

120A

Engine intake air heater relay

50 A

Fuse box FS1 No.1 – 7

Location Remove plate (2) on left side of engine compartment and remove cover (3).

40-100

10

Destination of power

Arrangement of slow blow fuse




SEN03937-01

40-100

11

SEN03937-01



40-100

12

SEN03938-02




40 Troubleshooting

40

200 General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting ........................................................................................................... 3 Testing before troubleshooting........................................................................................................................ 4 Classification and procedures of troubleshooting ........................................................................................... 5 Information contained in troubleshooting table ............................................................................................... 8 Connection table for connector pin numbers ................................................................................................ 10 T- branch box and T- branch adapter table ................................................................................................... 46


40-200

1

SEN03938-02

Points to remember when troubleshooting k k k k k k

200 General information on troubleshooting Points to remember when troubleshooting

1

Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 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 coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a shortcut 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.

4.

5.

6.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q 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 1) 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) Are abnormal symptoms detected in the machine? 2) Make checks before starting day's work. 3) Make checks of other items. 4) Check other maintenance items which can be visually checked and are considered necessary. Confirming failure Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a problem of handling, operation, etc. a 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 table or flowchart (matrix) to find out the failure part exactly. a 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 immediate failure is repaired, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.

40-200

2


200 General information on troubleshooting Sequence of events in troubleshooting

SEN03938-02

Sequence of events in troubleshooting

1

(Rev. 2007.12)


40-200

3

200 General information on troubleshooting Testing before troubleshooting

SEN03938-02

Testing before troubleshooting

Hydraulic and mechanical equipment

Electrical parts

Lubricating oil and coolant

Item

Criteria

Remedy

1.

Check of level and type of fuel

—

Add fuel

2.

Check for foreign matter in fuel Check fuel filter and fuel pre-filter for clogging

—

Clean or drain

3.

Check of fuel filter for clogging

—

Replace

4.

Check of level and type of oil in engine oil pan

Between H and L

Add oil

5.

Check of coolant level

Between FULL and LOW

Add coolant

6.

Check of air cleaner for clogging

No red

Clean or replace

7.

Check of level and type of hydraulic oil

Between H and L

Add oil

8.

Check of level and type of HST oil

Between H and L

Add oil

9.

Check of engine oil filter for clogging

—

Replace

10. Check of hydraulic oil filter for clogging

—

Replace

11. Check of HST oil filter for clogging

—

Replace

12. Check of battery terminal cables for looseness and corrosion

—

13. Check of alternator terminal cables for looseness and corrosion 14. Check of starting motor terminal cables for looseness and corrosion

— —

Retighten or replace Retighten or replace Retighten or replace

15. Check of operation of instruments

—

Repair or replace

16. Check for abnormal noise and smell

—

Repair

17. Check for oil leakage

—

Repair

18. Bleeding air

—

Bleed air

19. Check of effect of brake

—

Repair or adjust

20 – 30 V

Charge or replace

Between U.L and L.L

Add or replace

22. Check wires for discoloration, burn, and removal of cover

—

Replace

23. Check for removed wire clamp and drooping wire

—

Repair

—

Disconnect and dry connectors

—

Replace

After several-minute operation: 27.5 – 29.5 V

Repair or replace

—

Replace

20. Check of battery voltage (with engine stopped) 21. Check of battery electrolyte level Electrical equipment

1

24. Check wiring for wetting with water (Check connectors and terminals for wetting with water, in particular) 25. Check of slow-blow fuses and fuses for disconnection and corrosion 26. Check of alternator voltage (with engine at medium speed or higher) 27. Check of operating sound of battery relay (Starting switch OFF o ON)

40-200

4


200 General information on troubleshooting Classification and procedures of troubleshooting

SEN03938-02

Classification and procedures of troubleshooting

1

Classification of troubleshooting Mode Display of code

Contents Troubleshooting by failure code (Display of code)

E-mode

Troubleshooting of electrical system

H-mode

Troubleshooting of hydraulic and mechanical system

S-mode

Troubleshooting of engine

Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.

Procedure for troubleshooting to be taken when action code is displayed on machine monitor: If an action code is displayed on the machine monitor, display the failure code in the failure code display mode (for the electrical system and the mechanical system) of the machine monitor (EMMS). Carry out troubleshooting in [Display of failure code] according to the displayed failure code. a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code “lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may not have been repaired (Some troubles can be detected by simply turning the starting switch ON). a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble corresponding to it has been repaired (For the method of reproducing the failure code, see the troubleshooting in [Display of code]).

2.

Procedure for troubleshooting to be taken when failure code is recorded: If an action code is not displayed on the machine monitor, check for a failure code in the failure code display mode (for the electrical system and the mechanical system) of the machine monitor (EMMS). If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code. a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code “lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may not have been repaired (Some troubles can be detected by simply turning the starting switch ON). a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble corresponding to it has been repaired (For the method of reproducing the failure code, see the troubleshooting in [Display of code]).

3.

Procedure of troubleshooting to be taken when action code is not displayed and failure code is not recorded: If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out troubleshooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.


40-200

5


SEN03938-02

Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.

Phenomena looking like trouble

Code display

E-mode

H-mode

S-mode

Phenomena related to action codes and failure codes 1 Action codes are displayed on machine monitor 2 If failure code display function is checked, failure codes are displayed

Check failure code q

Phenomena related to engine 3 Engine does not start easily (Starting performance is poor) Engine does not turn

4 5

Engine does not start

6

S-1 E-1

S-2 a)

Engine turns but no exhaust smoke comes out

S-2 b)

Exhaust smoke comes out but engine does not start (Fuel is injected)

S-2 c)

7 Engine does not pick up smoothly

S-3

8 Engine stops during operation

H-4

9 Engine does not rotate smoothly

S-4 S-5

10 Engine lacks output (or lacks power)

S-6

11 Exhaust smoke is black (Incomplete combustion)

S-7

12 Oil consumption is excessive (or exhaust smoke is blue)

S-8

13 Oil becomes contaminated quickly

S-9

14 Fuel consumption is excessive

S-10

15 Oil is in coolant (or coolant spurts back or coolant level goes down)

S-11

16 Oil pressure drops

S-12

17 Oil level rises (Entry of coolant or fuel)

S-13

18 Coolant temperature becomes too high (overheating)

S-14

19 Abnormal noise is made

S-15

20 Vibration is excessive

S-16

21 Preheater does not operate normally

E-2 Phenomena related to power train

22 The machine does not start

H-1

23 The travel speed is low

E-3 a), b)

24 The travel speed is high

E-3 c)

H-2

25 The traction force is weak

H-3

26 Engine stalls when traveling or engine speed drops excessively

H-4

27 Shift range is not shifted

H-5

28 Travel direction selection system does not function

E-9

Phenomena related to steering 29 The steering wheel does not turn

H-6

30 The steering wheel is heavy

H-7

31 Steering wheel shakes or jerks

H-8

32 Machine deviates naturally to one side when traveling

H-9

Phenomena related to brake 33 The brake does not work or does not work well

H-10

34 The brake is not released or is dragged

H-11

40-200

6



SEN03938-02

Phenomena related to work equipment 35 The lift arm does not rise or lower

H-12

36 The lift arm moves slowly or the lift arm rising force is insufficient

H-13

37 When rising, the lift arm comes to move slowly at specific height

H-14

The lift arm cylinder cannot hold down the bucket (The bucket rises in 38 the air)

H-15

39 Hydraulic drifts of the lift arm occur often

H-16

40 The lift arm wobbles during operation

H-17

When the control lever is switched from "HOLD" to "RAISE," the lift 41 arm falls temporarily

H-18

42 The bucket does not tilt back

H-19

43 The bucket moves slowly or the tilting-back force is insufficient

H-20

44 The bucket comes to operate slowly in the midst of tilting-back

H-21

45 The bucket cylinder cannot hold down the bucket

H-22

46 Hydraulic drifts of the bucket occur often

H-23

47

The bucket wobbles during travel with load (The work equipment valve is set to "HOLD")

H-24

48

When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily

H-25

49

The control levers of the lift arm and bucket do not move smoothly and heavy

H-26

50 The ECSS does not operate and machine pitches and bounces

E-4

51 ECCS keeps operating

E-5

52 Defective boom kick-out function and cancellation

E-6

53 Defective bucket positioner function and cancellation

E-7

54 Defective lift arm FLOATING holding function and cancellation

E-8

H-27

Others 55

Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)

H-28

56 Fan does not reverse

E-10

57 Fan keeps rotating in reverse

E-11

58 Wiper does not operate

E-12

59 Windshield washer does not operate

E-13

60 Headlamp, clearance lamp and tail lamp do not light up or go off

E-14

61 Working lamp does not light up or go off

E-15

62 Turn signal lamp and hazard lamp do not light up or go off

E-16

63 Brake lamp does not light or it keeps lighting up

E-17

64 Backup lamp does not light or it keeps lighting up

E-18

65 Backup alarm does not sound or it keeps sounding

E-19

66 Horn does not sound or it keeps sounding

E-20

67 Alarm buzzer does not sound or it keeps sounding

E-21

68 Air conditioner does not operate or stop

E-22

69 The KOMTRAX system does not work properly

E-23


40-200

7

200 General information on troubleshooting Information contained in troubleshooting table

SEN03938-02

Information contained in troubleshooting table Action code

Failure code

Monitor display

Monitor display

Contents of trouble Action of controller Problem that appears on machine Related information

Action taken by machine monitor or controller to protect system or devices when engine controller detects trouble Problem that appears on machine as result of action taken by machine monitor or controller (shown above) Information related to detected trouble or troubleshooting

1

40-200

8

Problem that appears on machine

State where the monitor panel or controller detects the trouble

Cause

Possible causes and standard value in normal state

Trouble

1

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge assumed cause (good or not) • Remarks required to judge whether the cause is good

• Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to ground (earth) circuit comes into contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes 2 into contact with the power (24 V) circuit. • Short circuit Possible causes of trouble A harnesses of an independent circuit abnormally comes is assumed to be detected into contact with one of another circuit. (The order number indicates a serial number, not a priority sequence.) (1) Method of indicating connector number and handling Tbranch For troubleshooting, insert or connect T-branch adapter 3 as shown below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T-branch adapter in both the male and female. • When “male” and “female” is indicated for a connector number, disconnect the connector, and insert the T-branch adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. 4 • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.


200 General information on troubleshooting Information contained in troubleshooting table

SEN03938-02

Related circuit diagram

This is the excerpted circuit diagram related to trouble • Connector No.: Indicates (Model – No. of pins) (Color) • “Connector No. and pin No.” from each branching/ merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (io): Roughly shows the location on the machine.


40-200

9

SEN03938-02

Connection table for connector pin numbers a

200 General information on troubleshooting Connection table for connector pin numbers

(Rev. 2009.04)

The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

40-200

10




SEN03938-02

40-200

11

SEN03938-02

40-200

12





SEN03938-02

40-200

13

SEN03938-02

40-200

14





SEN03938-02

40-200

15

SEN03938-02

40-200

16





SEN03938-02

40-200

17

SEN03938-02

40-200

18





SEN03938-02

40-200

19

SEN03938-02

40-200

20





SEN03938-02

40-200

21

SEN03938-02

40-200

22





SEN03938-02

40-200

23

SEN03938-02

40-200

24





SEN03938-02

40-200

25

SEN03938-02

40-200

26





SEN03938-02

40-200

27

SEN03938-02

40-200

28





SEN03938-02

40-200

29

SEN03938-02

40-200

30





SEN03938-02

40-200

31

SEN03938-02

40-200

32





SEN03938-02

40-200

33

SEN03938-02

40-200

34





SEN03938-02

40-200

35

SEN03938-02

40-200

36





SEN03938-02

40-200

37

SEN03938-02

40-200

38





SEN03938-02

40-200

39

SEN03938-02

40-200

40





SEN03938-02

40-200

41

SEN03938-02

40-200

42





SEN03938-02

40-200

43

SEN03938-02

40-200

44





SEN03938-02

40-200

45

200 General information on troubleshooting T- branch box and T- branch adapter table

SEN03938-02

T- branch box and T- branch adapter table

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.

q

q

q q

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification symbol

799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

a

(Rev. 2009.03)1

q

799-601-2600 T-box (for ECONO)

21

799-601-3100 T-box (for MS)

37

q

799-601-3200 T-box (for MS)

37

q q

799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)

24

MS-24P

q

799-601-3420 Adapter for BENDIX (MS)

24

MS-24P

q


17

MS-17P

q


17

MS-17P

q


5

MS-5P

q


10

MS-10P

q


5

MS-5P

q


17

MS-17P

q


19

MS-19P

q


14

MS-14P

q

799-601-2710 Adapter for MIC

5

MIC-5P

q q

q


13

MIC-13P

q q

q


17

MIC-17P

q q q

q q

q


21

MIC-21P

q q q

q q

q


9

MIC-9P

q q q

q

q

799-601-3470 Case

799-601-2750 Adapter for ECONO

2

ECONO2P

q q


3

ECONO3P

q q


4

ECONO4P

q q


8

ECONO8P

q q


12 ECONO12P q q

799-601-2810 Adapter for DLI

8

DLI-8P

q q


12

DLI-12P

q q


16

DLI-16P

q q

799-601-2840 Extension cable (ECONO type)

12 ECONO12P q q

799-601-4350 T-box (for DRC 60, ECONO)

q

q

799-601-2850 Case

q

60

q

799-601-4360 Case q

q

X2P

q q q

q

3

X3P

q q q

q

4

X4P

q q q

q

6

SW6P

q q q q q q

799-601-7010 Adapter for X (T-adapter)

1

799-601-7020 Adapter for X

2

799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP

8

SW8P


12

SW12P


14

SW14P


16

SW16P

799-601-7080 Adapter for M (T-adapter)

1

q

q


2

M2P

q q q

q


3

M3P

q q q

q

40-200

46

q q

q q



SEN03938-02

8

S8P

q q q

q

799-601-7150 Adapter for S (White)

10

S10P

q q q

q

799-601-7160 Adapter for S (Blue)

12

S12P

q q q q q q

16

S16P


16

S16PW


12

S12PW

Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

q

799-601-7140 Adapter for S

799-601-7170 Adapter for S (Blue)

799-601-9100

M8P

799-601-9000

8

799-601-8000 q


799-601-7500

q

q q q

799-601-7400

q q q

M6P

799-601-7100

M4P

6

799-601-7000

4


799-601-2800


Part name

799-601-2700


Part No.

799-601-2500

Number of pins

T-adapter kit

q q q

799-601-7180 Adapter for AMP040

8

A8P

q


12

A12P

q

q


16

A16P

q q q

q


20

A20P

q q q

q

799-601-7230 Short connector for X

2

—

q q q

q

q q

799-601-7240 Case

q

799-601-7270 Case 799-601-7510 Adapter for 070

10

07-10

q

799-601-7520 Adapter for 070

12

07-12

q

799-601-7530 Adapter for 070

14

07-14

q

799-601-7540 Adapter for 070

18

07-18

q

799-601-7550 Adapter for 070

20

07-20

q


5

REL-5P

q


6

REL-6P

q

799-601-7380 Adapter for JFC

2

—

799-601-9010 Adapter for DTM

2

DTM2

q

q

799-601-9020 Adapter for DT

2

DT2

q

q


3

DT3

q

q


4

DT4

q

q


6

DT6

q

q

799-601-9060 Adapter for DT (Gray)

8

DT8GR

q

q

q

799-601-9070 Adapter for DT (Black)

8

DT8B

q

q

799-601-9080 Adapter for DT (Green)

8

DT8G

q

q

799-601-9090 Adapter for DT (Brown)

8

DT8BR

q

q

799-601-9110 Adapter for DT (Gray)

12

DT12GR

q

q

799-601-9120 Adapter for DT (Black)

12

DT12B

q

q

799-601-9130 Adapter for DT (Green)

12

DT12G

q

q

799-601-9140 Adapter for DT (Brown)

12

DT12BR

q

q

799-601-9210 Adapter for HD30-18

8

D18-8

q q

799-601-9220 Adapter for HD30-18

14

D18-14

q q

799-601-9230 Adapter for HD30-18

20

D18-20

q q

799-601-9240 Adapter for HD30-18

21

D18-21

q q

799-601-9250 Adapter for HD30-24

9

D24-9

q q

799-601-9260 Adapter for HD30-24

16

D24-16

q q

799-601-9270 Adapter for HD30-24

21

D24-21

q q

799-601-9280 Adapter for HD30-24

23

D24-23

q q

799-601-9290 Adapter for HD30-24

31

D24-31

q q

799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)


24

q q q q

q q

q

q q

q

40-200

47


Out of kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800


799-601-2700

Part name

T-adapter kit 799-601-2500

Part No.

Number of pins

SEN03938-02

q

799-601-9330 Case

q

799-601-9340 Case 799-601-9350 Adapter for DRC

40

DRC-40

q q

799-601-9360 Adapter for DRC

24

DRC-24

799-601-9410* Socket for engine (CRI-T2)

2

G

Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor

3

A3

q q

2

P

q q

799-601-9440* Socket for engine (CRI-T2)

3

1,2,3

q

795-799-5520* Socket for engine (HPI-T2)

2

S

q

Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor

2

C

q q

2

A

q q

799-601-9430*

795-799-5540*

Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV

Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM

q

795-799-5460 Cable for engine (HPI-T2)

3

—

q


3

—

q


3

—

799-601-4110 Adapter for engine (140-T3) PIM

4

ITT3N

q q

799-601-4130 Adapter for engine (CRI-T3) NE, CAM

3

FCIN

q q

Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure

3

FCIG

q q

799-601-4150 Adapter for engine (CRI-T3) POIL

3

FCIB

q q

Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch

2

4160

q q

799-601-4180 Adapter for engine (CRI-T3) PEVA

3

4180

q q

q

799-601-4190*

Socket for engine (CRI-T3) Commonrail pressure

3

1,2,3L

q q

799-601-4230*

Socket for engine (CRI-T3) Air intake pressure/temperature

4

1,2,3,4C

q q

799-601-4240* Socket for engine (CRI-T3) PAMB

3

1,2,3A

q q

799-601-4250* Socket for engine (CRI-T3) PIM

3

1,2,3B

q q

799-601-4330* Socket for engine (CRI-T3) G

3

1,2,3,G

q q q q

799-601-4340*

Socket for engine (CRI-T3) Pump actuator

2

2,PA

799-601-4380*

Socket for engine (CRI-T3)(95) Air intake pressure/temperature

4

1,2,3,4T

q q q

799-601-4260 Adapter for controller (ENG)

4

DTP4


50

DRC50

q


60

DRC60

q q

799-601-4390* Socket for controller (95 ENG)

60

—

799-601-4280* Box for controller (PUMP)

121

—

q

799-601-9720 Adapter for controller (HST)

16

HST16A

q


16

HST16B

q


26

HST26A

q

2, 3, 4,

—

q

799-601-9890

Multi-adapter for DT2 – 4 and DTM2

“ * ” Shows not T-adapter but socket.

40-200

48




SEN03938-02

40-200

49

SEN03938-02



40-200

50

SEN03939-00




40 Troubleshooting

40

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [2G40ZG] Brake: Oil pressure reduction.................................................................................... 2 Failure code [6091NX] HST filter: Clogging .................................................................................................... 4 Failure code [989FN1] Travel speed: Overrun alarm...................................................................................... 6 Failure code [AA1ANX] Air cleaner: Clogging................................................................................................. 8 Failure code [AB00L6] Alternator R system: Hot short ................................................................................. 10 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 12 Failure code [B@BAZG] Engine: Oil pressure reduction .............................................................................. 14 Failure code [B@BAZK] Engine oil: Low level .............................................................................................. 15 Failure code [B@BCNS] Engine: Overheat .................................................................................................. 16 Failure code [B@BCZK] Engine: Low coolant level...................................................................................... 18 Failure code [B@C6NS] Front brake: High oil temperature.......................................................................... 20 Failure code [B@CRNS] HST: High oil temperature..................................................................................... 21


40-310

1

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [2G40ZG] Brake: Oil pressure reduction

SEN03939-00

Failure code [2G40ZG] Brake: Oil pressure reduction Action code

Failure code

E03

2G40ZG

Contents of trouble

Trouble

Brake: Oil pressure reduction (Machine monitor system)

• While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pressure was below 4.4 MPa {45 kg/cm2} (circuit is open).

• Turns central warning lamp and caution buzzer ON. • Turns brake oil pressure caution lamp ON. Action of • Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the machine monitor engine starts, but no failure codes are displayed. • if cause of failure disappears, system resets itself. Problem that appears on machine Related information

• If machine is used as it is, brake may not work. • Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function (Monitoring code: MONITOR PANEL – 40902 – D-IN-16). Causes

Standard value in normal state/Remarks on troubleshooting

1 Brake oil pressure reduction

System is normal. a Carry out troubleshooting for hydraulic and mechanical systems. a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

2

Defective brake oil pressure sensor (Internal defect)

T12 (male)

Between (1) – (2) Possible causes and standard value in normal state

Oil pressure

Resistance

Min. 5.88 MPa {60 kg/cm2}

Max. 1 z

Max. 3.92 MPa {40 kg/cm2}

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring Wiring harness between T12 (female) (1) – 3 or defective contact in con- L26 (female) (1) nector) Wiring harness between T12 (female) (2) – ground

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L26 4 Defective machine monitor Between (1) – ground

40-310

2

Oil pressure

Voltage

Min. 5.88 MPa {60 kg/cm2}

Max. 1 V

Max. 3.92 MPa {40 kg/cm2}

20 – 30 V


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [2G40ZG] Brake: Oil pressure reduction

SEN03939-00



40-310

3

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [6091NX] HST filter: Clogging

SEN03939-00

Failure code [6091NX] HST filter: Clogging Action code

Failure code

E01

6091NX

Contents of trouble

Trouble

HST filter: Clogging (Machine monitor system)

• When HST oil temperature was above 50°C, HST oil filter clogging sensor signal circuit was closed (in contact with GND).

Action of • Turns HST clogging caution lamp ON. machine monitor • if cause of failure disappears, system resets itself. Problem that appears on machine Related information

• If machine is used as it is, foreign matter may enter HST circuit. The input state from the HST oil filter clogging sensor can be checked with monitoring function (Monitoring code: MONITOR PANEL – 40903 – D-IN-24) Causes 1 Clogged HST oil filter

Standard value in normal state/Remarks on troubleshooting System is normal. a Check HST oil filter directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2


Defective HST oil filter clogging sensor (Internal defect)

T13

Filter condition

Resistance

Between T13 – ground

Not clogged (Normal)

Min. 1 Mz

Clogged

Max. 1 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between T13 – L26 (female) 3 or defective contact in con- (5) nector) Wiring harness between HST oil filter clogging sensor body – ground

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor

L26 Between (5) – ground

Filter condition

Voltage

Not clogged (Normal)

20 – 30 V

Clogged

Max. 1 V


40-310

4


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [6091NX] HST filter: Clogging


SEN03939-00

40-310

5

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [989FN1] Travel speed: Overrun alarm

SEN03939-00

Failure code [989FN1] Travel speed: Overrun alarm Action code

Failure code

E02

989FN1

Contents of trouble

Trouble

Travel speed: Overrun alarm (Machine monitor system)

• Travel speed exceeded 45 km/h. • Auto-decelerator does not work at speed higher than 40 km/h.

Action of • Turns central warning lamp and caution buzzer ON. machine monitor Problem that appears on machine Related information

• If machine is used as it is, brake etc. may be damaged.

• If [DW26KA] or [DW26KY] is displayed, carry out troubleshooting for it first.

Causes Possible causes and standard value in normal state

40-310

6


1 Overrun

System is normal (when machine is used as it overruns by accelerating on sharp downhill road etc.) a Check using condition and teach operator correct using method. a Check related components for damage.

2 Defective machine monitor

• If alarm is turned ON while travel speed is below limit, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [989FN1] Travel speed: Overrun alarm


SEN03939-00

40-310

7

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AA1ANX] Air cleaner: Clogging

SEN03939-00

Failure code [AA1ANX] Air cleaner: Clogging Action code

Failure code

E01

AA1ANX


Trouble

1

Air cleaner: Clogging (Machine monitor system)

• When the engine is started, the air cleaner clogging sensor circuit is OPEN. • Turns the air cleaner clogging caution lamp ON. • If problem is removed, system is returned to normal operating state. • The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is black. • The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring function (Code: MONITOR PANEL, 40902, D-IN-20). • Method of reproducing failure code: Start engine Causes 1 Clogged air cleaner

2

Defective dust indicator (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting The air cleaner may be clogged. Check it directly. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace the dust indicator

If the condition becomes normal, the trouble is attributable to defective indicator.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L112 (Male) Resistance Defective dust indicator relay Between (1) and (2) 200 – 400 z (L112) 3 a Prepare with starting switch OFF, then start engine and carry out (Internal disconnection or troubleshooting. short circuit)


When dust indicator relay (L112) is replaced with a relay of the same type (5-pin type), if the condition becomes normal, the exchange relay is defective. Disconnection in wiring harness 4 (Disconnection or defective contact in connector)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harnesses between L112 (female) (6) – L26 (female) (3)

Resistance

Max. 1 z

Wiring harnesses between L112 (female) (3) – chassis ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring harwithout turning starting switch ON. 5 ness Resis(Contact with ground circuit) Wiring harness between L112 (female) (6) Min. 1 Mz – L26 (female) (3) and chassis ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. L26 6 Defective machine monitor Between (3) and chassis ground

40-310

8

Dust indicator

Voltage

Normal (Air cleaner is normal)

Max. 1 V

Defective (Air cleaner is clogged)

20 – 30 V


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AA1ANX] Air cleaner: Clogging

SEN03939-00

Circuit diagram related to dust indicator


40-310

9

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00L6] Alternator R system: Hot short

SEN03939-00

Failure code [AB00L6] Alternator R system: Hot short Action code

Failure code

E01

AB00L6

Contents of trouble

Trouble

Alternator R system: Hot short (Machine monitor system)

• When engine is stopped, alternator terminal R input voltage is above 12 V.

Action of • Turns the charge circuit error caution lamp ON. machine monitor Problem that appears on machine Related information

• After the engine is started, just turning on the starting switch runs the service meter. • The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring code: HST – 04302 – ALTERNATOR R). • Method of reproducing failure code: Turn the starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

1


2

Defective alternator (Internal trouble)

Hot short in wiring harness (Contact with 24V circuit)

Alternator

Engine

Voltage

Wiring harness between E02 (female) (1) – ground

Running (Throttle: Above 1/2)

27.5 – 29.5 V

Holds in position

Max. 1.5 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harnesses between E02 (female) (1) – L25 (female) (18), – circuit branch end and ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3 Defective machine monitor

L25 Between (18) and ground

40-310

10

Engine

Voltage


27.5 – 29.5 V

Holds in position

Max. 1.5 V


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00L6] Alternator R system: Hot short

SEN03939-00



40-310

11

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage

SEN03939-00

Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/ Low charge voltage Action code

Failure code

E03 Contents of trouble

AB00MA

Trouble

Alternator R system: Ground fault/Disconnection/Low charge voltage (Machine monitor system)

• While the engine is running, the alternator terminal R input voltage is below 5 V.

Action of • Turns the charge circuit failure caution lamp ON. machine monitor • Turns the centralized warning lamp and alarm buzzer ON. Problem that appears on machine Related information

• Deterioration of battery or insufficient charging • Engine does not start. • The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring code: HST – 04302 – ALTERNATOR R). • Method of reproducing failure code: Start engine Causes 1 The battery is deteriorated.

Standard value in normal state/Remarks on troubleshooting The battery may be deteriorated. Check it directly. a Prepare with starting switch OFF, then start engine and carry out troubleshooting.

2


Defective alternator (Internal trouble)

Disconnection in wiring harness 3 (Disconnection or defective contact in connector)

Alternator

Engine

Voltage

Wiring harness between E02 (female) (1) – ground


27.5 – 29.5 V

Holds in position

Max. 1.5 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harnesses between E02 (female) (1) – L25 (female) (18)

Resistance

Max. 1 z

a Prepare by turning starting switch OFF and then start engine to carry out troubleshooting. Grounding fault in wiring har4 ness Wiring harness between E02 (female) (1) – Resis(Contact with ground circuit) L25 (female) (18) – circuit branch end and Min. 1 Mz tance ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective machine monitor

L25 Between (18) and ground

40-310

12

Engine

Voltage


27.5 – 29.5 V

Holds in position

Max. 1.5 V


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage

SEN03939-00



40-310

13

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BAZG] Engine: Oil pressure reduction

SEN03939-00

Failure code [B@BAZG] Engine: Oil pressure reduction Action code

Failure code

E03

B@BAZG

Contents of trouble

Trouble

Engine: Oil pressure reduction (Engine controller system)

• While engine is run, engine oil pressure became lower than operating range.

Action of • Limits output and continues operation (Limits fuel injection rate and engine speed). machine monitor • Turns the centralized warning lamp and alarm buzzer ON. Problem that appears on machine Related information

• Engine output lowers.

• Method of reproducing failure code: Start engine

Causes 1



Low engine oil pressure Engine oil has potentially gone low. Check the pressure and if it is (When the system is normal) below the specified level, locate and eliminate the cause.

Defective engine oil pressure 2 switch (Internal trouble)

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. OIL PRESSURE SWITCH

Resistance

Between terminals

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harnesses between EC1 (female) ResisMin. 1 Mz (17) – OIL PRESSURE SWITCH and ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective engine controller

EC1

Resistance

Between (17) and ground

Min. 1 Mz


40-310

14


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BAZK] Engine oil: Low level

SEN03939-00

Failure code [B@BAZK] Engine oil: Low level Action code

Failure code

E01

B@BAZK

Contents of trouble

Action of controller Problem that appears on machine Related information

Trouble

1

Engine oil: Low level (Machine monitor system)

• While engine is stopped, the engine oil level sensor circuit was detected to have remained in OPEN condition for more than 2 seconds. (This error, however, is not detected for 5 minutes from the engine stop) • An error being detected at stopping the engine remains as the error after the engine is started again until the normal condition is recovered. • Turns the engine oil level caution lamp ON. • If problem is removed, system is returned to normal operating state. • The engine oil level is low (The engine may be broken). • The input state (ON/OFF) from the engine level sensor can be checked with the monitoring function (Code: MONITOR PANEL, 40903, D-IN-29). • Method of reproducing failure code: Turn the starting switch ON. Causes 1 Low engine oil level

Standard value in normal state/Remarks on troubleshooting The engine oil level may be low. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective engine oil level 2 sensor (Internal disconnection) Possible causes and standard value in normal state

Disconnection in wiring harness 3 (Disconnection or defective contact)

E26 (male) Between (1) and chassis ground

Engine oil level

Resistance

Oil level is normal

Max. 1 z

Oil level is insufficient (low level)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harnesses between L27 (female) (11) – E26 (female) (1)

Resistance

Max. 1 z


L27 (female)

Engine oil level

Voltage

Wiring harness between (11) – chassis ground

Oil level is normal

20 – 30 V

Oil level is insufficient (low level)

Max. 1 V



40-310

15

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BCNS] Engine: Overheat

SEN03939-00

Failure code [B@BCNS] Engine: Overheat Action code

Failure code

E02

B@BCNS

Contents of trouble

Trouble

Engine: Overheat (Engine controller system)

• While engine was running, engine coolant temperature sensor signal circuit detected engine coolant overheat.

Action of • Limits fuel injection until coolant temperature lowers to operating range. machine monitor • Turns central warning lamp and caution buzzer ON. Problem that appears on machine Related information

• Engine output decreases. • Engine coolant temperature can be checked with monitoring function. (Monitoring code: ENGINE – 04104 – COOLANT TEMP (°C)) Causes


1

Engine coolant overheat (when system is normal)

Engine coolant may be overheating. Remove cause of overheat.

2

Defective engine coolant temperature sensor system

If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].

3 Defective engine controller

40-310

16


If causes 1 and 2 are not detected, engine controller may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BCNS] Engine: Overheat


SEN03939-00

40-310

17

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BCZK] Engine: Low coolant level

SEN03939-00

Failure code [B@BCZK] Engine: Low coolant level Action code

Failure code

E01

B@BCZK

Contents of trouble

Trouble

Engine: Low coolant level (Machine monitor system)

• Radiator coolant level switch signal circuit was opened (disconnected from GND) for 30 seconds.

Action of • Turns radiator coolant level caution lamp ON. machine monitor Problem that appears on machine Related information

• If machine is used as it is, engine may overheat. • Operation of radiator coolant level switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40903 – D-IN-27) Causes 1

Low radiator sub-tank coolant level

Standard value in normal state/Remarks on troubleshooting System is normal. a Radiator sub-tank coolant level may be low. Check and add coolant, if necessary. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2

Defective radiator coolant level switch (Internal defect)

B05 (male)

Between (1) – (2) Possible causes and standard value in normal state

Sub-tank coolant level

Resistance

Above low level (Normal)

Max. 1 z

Below low level

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between L27 (female) (10) – 3 or defective contact in con- B05 (female) (1) nector) Wiring harness between B05 (female) (2) – ground

Resistance

Max. 1 z

Resistance

Max. 1 z



40-310

18

Sub-tank coolant level

Voltage

Above low level (Normal)

Max. 1 V

Below low level

20 – 30 V


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BCZK] Engine: Low coolant level

SEN03939-00



40-310

19

310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@C6NS] Front brake: High oil temperature

SEN03939-00

Failure code [B@C6NS] Front brake: High oil temperature Action code

Failure code

E02

B@C6NS

Contents of trouble

Trouble

Front brake: High oil temperature (Machine monitor system)

• Front brake (axle) high oil temperature was detected (Details are as follows). • Oil temperature above 130°C (when travel speed was below 35 km/h) or above 125°C (when travel speed was above 35 km/h) was detected for 5 seconds continuously.

Action of • Turns central warning lamp and caution buzzer ON. machine monitor • Turns brake oil temperature caution lamp ON. Problem that appears on machine

Related information

• If machine is used as it is, brake may be damaged. • If temperature above 120°C is detected for 5 seconds continuously, only caution lamp is turned ON as preliminary warning. • Brake oil temperature can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)) (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)) Causes


20

System is normal. a Front brake (Axle) oil may be overheated. Remove cause of overheat.

1

Front brake (Axle) high oil temperature

2

If cause 1 is not detected, brake oil temperature sensor system may Defective brake oil temperabe defective. Carry out troubleshooting for failure codes [DGR2KB] ture sensor and [DGR2KZ].


40-310


If causes 1 and 2 are not detected, machine monitor may be defective. Carry out troubleshooting for failure codes [DGR2KB] and [DGR2KZ].


310 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@CRNS] HST: High oil temperature

SEN03939-00

Failure code [B@CRNS] HST: High oil temperature Action code

Failure code

E02

B@CRNS

Contents of trouble

Trouble

HST: High oil temperature (Machine monitor system)

• HST oil temperature higher than 105°C was detected for 10 seconds continuously.

Action of • Turns central warning lamp and caution buzzer ON. machine monitor • Turns HST oil temperature caution lamp ON. Problem that appears on machine Related information

• If machine is used as it is, hydraulic system equipments may be damaged. • HST oil temperature can be checked with monitoring function. (Monitoring code: MONITO PANEL – 04408 – HST OIL TEMP (°C)) (Monitoring code: MONITO PANEL – 04409 – HST OIL TEMP (V)) Causes


1 HST high oil temperature

Standard value in normal state/Remarks on troubleshooting System is normal. a HST oil may be overheated. Remove cause of overheat.

Defective HST oil temperature sensor

If cause 1 is not detected, HST oil temperature sensor system may be defective. Carry out troubleshooting for failure code [DGH1KX].


If causes 1 and 2 are not detected, machine monitor may be defective. Carry out troubleshooting for failure code [DGH1KX].

2


40-310

21

SEN03939-00



40-310

22

SEN03940-00




40 Troubleshooting

40

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA111] Abnormality in engine controller ................................................................................... 3 Failure code [CA115] Engine Ne or Bkup speed sensor error ........................................................................ 4 Failure code [CA122] Charge pressure sensor high error .............................................................................. 6 Failure code [CA123] Charge pressure sensor low error................................................................................ 8 Failure code [CA131] Throttle sensor high error........................................................................................... 10 Failure code [CA132] Throttle sensor low error ............................................................................................ 12 Failure code [CA144] Coolant sensor high error........................................................................................... 14 Failure code [CA145] Coolant sensor low error ............................................................................................ 16 Failure code [CA153] Charge temperature sensor high error....................................................................... 18 Failure code [CA154] Charge temperature sensor low error ........................................................................ 20 Failure code [CA155] Derating of speed by abnormally high charge temperature ....................................... 22 Failure code [CA187] Sensor power supply 2 low error................................................................................ 24 Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 26 Failure code [CA222] Atmospheric sensor low error .................................................................................... 28 Failure code [CA227] Sensor power supply 2 high error .............................................................................. 30 Failure code [CA234] Engine overspeed ...................................................................................................... 31 Failure code [CA238] Ne speed sensor power supply error ......................................................................... 32 Failure code [CA271] IMV (IMA) Short circuit ............................................................................................... 33 Failure code [CA272] IMV (IMA) Disconnection ........................................................................................... 34 Failure code [CA322] Injector #1 open/short error........................................................................................ 36 Failure code [CA323] Injector #5 open/short error........................................................................................ 38 WA320, 320PZ-6 (KA SPEC.)

40-320

1

SEN03940-00

320 Troubleshooting by failure code (Display of code), Part 2

Failure code [CA324] Injector #3 open/short error ........................................................................................ 40 Failure code [CA325] Injector #6 open/short error ........................................................................................ 42 Failure code [CA331] Injector #2 open/short error ........................................................................................ 44 Failure code [CA332] Injector #4 open/short error ........................................................................................ 46 Failure code [CA342] Calibration code inconsistency................................................................................... 48 Failure code [CA351] Injectors drive circuit error .......................................................................................... 50 Failure code [CA352] Sensor power supply 1 low error................................................................................ 52 Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54

40-320

2


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA111] Abnormality in engine controller

SEN03940-00

Failure code [CA111] Abnormality in engine controller Action code

Failure code

E03

CA111

Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state

Trouble

1

Abnormality in engine controller (Engine controller system)

• Abnormality occurred in memory of engine controller or power supply circuit. • Turns the centralized warning lamp and alarm buzzer ON.

• The engine does not start.


Causes



Possible defect in engine controller (Troubleshooting cannot be carried out.)


40-320

3

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA115] Engine Ne or Bkup speed sensor error

SEN03940-00

Failure code [CA115] Engine Ne or Bkup speed sensor error Action code

Failure code

E03

CA115


40-320

4

Trouble

1

Engine Ne or Bkup speed sensor error (Engine controller system)

• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit. • Turns the centralized warning lamp and alarm buzzer ON. • Engine stops. • The engine does not start. • Method of reproducing failure code: Start engine

Causes 1


Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directly for defecsor connector tive connection (wrong connection).


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA115] Engine Ne or Bkup speed sensor error


SEN03940-00

40-320

5

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA122] Charge pressure sensor high error

SEN03940-00

Failure code [CA122] Charge pressure sensor high error Action code

Failure code

E03

CA122

Contents of trouble Action of controller Problem that appears on machine

Related information

Trouble

1

Charge pressure sensor high error (Engine controller system)

• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor. • Fixes charge pressure (boost pressure) and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Engine output drops. • The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A). • The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A). • Method of reproducing failure code: Turn the starting switch ON. Causes 1


Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out troubleply 2 system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective boost pressure BOOST PRESS & IMT Voltage sensor and temperature sen2 Voltage 4.75 – 5.25 V sors [pressure signal system] Between (2) and (4) (Internal trouble) Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.


a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (44) – ness BOOST PRESS & IMT (female) (1) and Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harnesses between EC1 (female) 4 ness (with another wiring harness) (44) – BOOST PRESS & IMT (female) (1) and EC1 (female) (47) – BOOST PRESS & IMT (female) (4).

5

Defective wiring harness connector

Resistance

Min. 100 kz

Connecting parts among boost pressure sensor/temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock and broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


EC1 Between (37) and (47)

40-320

6

Voltage Power supply

4.75 – 5.25 V


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA122] Charge pressure sensor high error

SEN03940-00



40-320

7

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA123] Charge pressure sensor low error

SEN03940-00

Failure code [CA123] Charge pressure sensor low error Action code

Failure code

E03

CA123


Related information

Trouble

1

Charge pressure sensor low error (Engine controller system)

• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor. • Fixes charge pressure (boost pressure) and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Engine output drops. • The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A). • The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A). • Method of reproducing failure code: Turn the starting switch ON. Causes 1



Defective boost pressure sensor or temperature sen2 sor [pressure signal circuit] (Internal trouble)


BOOST PRESS & IMT Between (2) and (4)

Power supply

Voltage 4.75 – 5.25 V

Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring har3 ness Wiring harness between EC1 (female) (44) – ResisMin. (Contact with ground circuit) BOOST PRESS & IMT (female) (1) and tance 100 kz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harnesses between EC1 (female) 4 ness (with another wiring harness) (44) – BOOST PRESS & IMT (female) (1), EC1 (female) (47) – BOOST PRESS & IMT (female) (4)

5


Resistance

Min. 100 kz

Connecting parts among boost pressure sensor/temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock and broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



40-320

8


4.75 – 5.25 V


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA123] Charge pressure sensor low error

SEN03940-00



40-320

9

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA131] Throttle sensor high error

SEN03940-00

Failure code [CA131] Throttle sensor high error Action code

Failure code

E03

CA131


Related information

Trouble

1

Throttle sensor high error (Engine controller system)

• High voltage was detected in the throttle sensor signal circuit. • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not reach full throttle. • The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the monitoring function (Code: ENGINE, 31701, THROTTLE POS). • The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code: ENGINE, 31707, THROTTLE POS). • Method of reproducing failure code: Turn the starting switch ON.

1

Causes


Defective throttle sensor power supply system

If failure code [CA2185] is indicated simultaneously, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective accelerator pedal 2 (Internal trouble)

PD1

Accelerator pedal

Voltage

Between (1) and (3)

All range (Power supply)

4.75 – 5.25 V

When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V

Between (2) and (3)

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for another cause of trouble before judgment


a Prepare with starting switch OFF, then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. 3 5V, 24V circuit) in wiring harWiring harness between EC2 (female) (9) – ness Voltage Max. 1 V PD1 (female) (2) and ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har4 ness Wiring harness between EC2 (female) (9) – ResisMin. (with another wiring harness) PD1 (female) (2), EC2 (female) (22) – PD1 tance 100 kz (female) (1)

5


Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


EC2

Accelerator pedal

Voltage

Between (22) and (23)


4.75 – 5.25 V

When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V


40-320

10


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA131] Throttle sensor high error

SEN03940-00



40-320

11

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA132] Throttle sensor low error

SEN03940-00

Failure code [CA132] Throttle sensor low error Action code

Failure code

E03

CA132


Related information

Trouble

1

Throttle sensor low error (Engine controller system)

• Low voltage was detected in the throttle sensor signal circuit. • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not reach full throttle. • The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the monitoring function (Code: ENGINE, 31701, THROTTLE POS). • The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code: ENGINE, 31707, THROTTLE POS). • Method of reproducing failure code: Turn the starting switch ON.

1

Causes


Defective throttle sensor power supply system

If failure code [CA2186] is indicated simultaneously, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective accelerator pedal 2 (Internal trouble)

PD1

Accelerator pedal

Voltage

Between (1) and (3)


4.75 – 5.25 V

When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V

Between (2) and (3)

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for another cause of trouble before judgment


a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 3 (Short circuit with ground cir- Wiring harness between EC2 (female) (9) – ResisMin. cuit) PD1 (female) (2) and ground tance 100 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har4 ness Wiring harness between EC2 (female) (9) – ResisMin. (with another wiring harness) PD1 (female) (2), EC2 (female) (23) – PD1 tance 100 kz (female) (3)

5


Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


EC2

Accelerator pedal

Voltage



4.75 – 5.25 V

When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V


40-320

12


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA132] Throttle sensor low error

SEN03940-00



40-320

13

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA144] Coolant sensor high error

SEN03940-00

Failure code [CA144] Coolant sensor high error Action code

Failure code

E01

CA144


Related information

Trouble

1

Coolant sensor high error (Engine controller system)

• High voltage is detected in coolant temperature sensor signal circuit. • Fixes engine coolant temperature and continues operation. • Exhaust smoke becomes white • Overheat prevention function does not function. • The input state (temperature) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04104, COOLANT TEMP). • The input state (voltage) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04105, COOLANT TEMP). • Method of reproducing failure code: Turn the starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective coolant tempera1 ture sensor (Internal trouble)

COOLANT TEMP (male)

Between (A) and (B)

Disconnection in wiring harness 2 (Disconnection or defective contact in connector) Possible causes and standard value in normal state

Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (15) – COOLANT TEMP (female) (B)

Resistance

Max. 10z

Wiring harness between EC1 (female) (38) – COOLANT TEMP (female) (A)

Resistance

Max. 10z


Short circuit in wiring harWiring harness among all pins between EC1 3 ness (with another wiring harness) (female) (15) – EC1 (female) (With all connectors of wiring harness disconnected)

4


Resistance

Min. 100 kz

Connecting parts among coolant temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EC1 (female)

5 Defective engine controller Between (15) and (38)

40-320

14

Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA144] Coolant sensor high error

SEN03940-00



40-320

15

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA145] Coolant sensor low error

SEN03940-00

Failure code [CA145] Coolant sensor low error Action code

Failure code

E01

CA145


Related information

Trouble

1

Coolant sensor low error (Engine controller system)

• Low voltage is detected in coolant temperature sensor signal circuit. • Fixes engine coolant temperature and continues operation. • Exhaust smoke becomes white • Overheat prevention function does not function. • The input state (temperature) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04104, COOLANT TEMP). • The input state (voltage) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04105, COOLANT TEMP). • Method of reproducing failure code: Turn the starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. COOLANT TEMP (male)

Defective coolant tempera1 ture sensor (Internal trouble)


Between (A) and (B)

Between (B) and ground

Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

All range

Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 2 (Short circuit with ground cir- Wiring harness between EC1 (female) (15) – ResisMin. cuit) COOLANT TEMP (female) (B) and ground tance 100 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring har3 ness Wiring harness among all pins between EC1 (with another wiring harness) (female) (15) – EC1 (female) (With all connectors of wiring harness disconnected)

4

40-320

16


Resistance

Min. 100 kz

Connecting parts among coolant temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA145] Coolant sensor low error

Causes

SEN03940-00

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EC1 (male)





Coolant temperature

Resistance

0°C

30 – 37 kz

25°C

9.3 – 10.7 kz

50°C

3.2 – 3.8 kz

80°C

1.0 – 1.3 kz

95°C

700 – 800 z

All range

Min. 100 kz



40-320

17

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA153] Charge temperature sensor high error

SEN03940-00

Failure code [CA153] Charge temperature sensor high error Action code

Failure code

E01

CA153


Related information

Trouble

1

Charge temperature sensor high error (Engine controller system)

• High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor. • Fixes charge temperature and continues operation. • Exhaust smoke becomes white. • Boost temperature-based engine protection function does not function. • The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP). • The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP). • Method of reproducing failure code: Turn the starting switch ON. Causes


Defective temperature signal circuit of boost pressure 1 and temperature sensor (Internal trouble)

BOOST PRESS & IMT (male)

Between (3) and (4)


Charge temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (23) – BOOST PRESS & IMT (female) (3)

Resistance

Max. 10z

Wiring harness between EC1 (female) (47) – BOOST PRESS & IMT (female) (4)

Resistance

Max. 10z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness Wiring harness among all pins between EC1 ResisMin. (with another wiring harness) (female) (23) – EC1 (female) (With all contance 100 kz nectors of wiring harness disconnected)

4


Connecting parts among boost pressure sensor/temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EC1 (female)

5 Defective engine controller Between (23) and (47)

40-320

18

Charge temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 z


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA153] Charge temperature sensor high error

SEN03940-00



40-320

19

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA154] Charge temperature sensor low error

SEN03940-00

Failure code [CA154] Charge temperature sensor low error Action code

Failure code

E01

CA154


Related information

Trouble

1

Charge temperature sensor low error (Engine controller system)

• Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor. • Fixes charge temperature and continues operation. • Exhaust smoke becomes white. • Boost temperature-based engine protection function does not function. • The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP). • The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP). • Method of reproducing failure code: Turn the starting switch ON. Causes


BOOST PRESS & IMT (male) Defective temperature signal circuit of boost pressure 1 sensor and temperature sensor Between (2) and (1) (Internal trouble) Between (2) and ground Possible causes and standard value in normal state

Charge temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 z

All range

Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 2 (Short circuit with ground cir- Wiring harness between EC1 (female) (23) – ResisMin. BOOST PRESS & IMT (female) (3) and cuit) tance 100 kz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


4

40-320

20


Resistance

Min. 100 kz

Connecting parts among boost pressure sensor/temperature sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA154] Charge temperature sensor low error

Causes

SEN03940-00



EC1 (female) 5 Defective engine controller



Charge temperature

Resistance

0°C

29 – 36 kz

25°C

9 – 11 kz

40°C

4.9 – 5.8 kz

100°C

600 – 700 z

All range

Min. 100 kz



40-320

21

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA155] Derating of speed by abnormally high charge temperature

SEN03940-00

Failure code [CA155] Derating of speed by abnormally high charge temperature Action code

Failure code

E03

CA155


Related information

Trouble

• Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Engine output drops. • Engine stops • The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP). • The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP). • Method of reproducing failure code: Start engine

22


Cooling performance deterioration of the after cooler is suspected. Inspect the following points directly. Drop in cooling performance 1 • Malfunction of hydraulic drive fan of aftercooler • Lack of cooling air • Clogged aftercooler fin 2

Abnormally high temperature at turbocharger outlet


40-320

Derating of speed by abnormally high charge temperature (Engine controller system)

• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.

Causes


1

Inspect related parts directly. If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA155] Derating of speed by abnormally high charge temperature


SEN03940-00

40-320

23

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA187] Sensor power supply 2 low error

SEN03940-00

Failure code [CA187] Sensor power supply 2 low error Action code

Failure code

E03

CA187


Trouble

1

Sensor power supply 2 low error (Engine controller system)

• Low voltage is detected in sensor power supply 2 circuit. • • • •

Fixes boost pressure and continues operation. Fixes charge temperature and continues operation. Limits output and continues operation. Turns the centralized warning lamp and alarm buzzer ON.

• Engine output drops.

• Method of reproducing failure code: Turn the starting switch ON.

Causes

Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

1

Defective sensor or wiring harness


2



40-320

24

Disconnect devices at right in order. If mark E of failure code disappears after reproduction operation is conducted, that device or wiring harness has a defect in it.

Boost pressure, temperature sensor

BOOST PRESS & IMT


FUEL RAIL PRESS

Bkup sensor

CAM SENSOR

Engine wiring harness

EC1

Connecting parts among each sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)



SEN03940-00



40-320

25

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA221] Atmospheric pressure sensor high error

SEN03940-00

Failure code [CA221] Atmospheric pressure sensor high error Action code

Failure code

E01

CA221


Related information

Trouble

1

Ambient pressure sensor high error (Engine controller system)

• High voltage is detected in atmospheric pressure sensor circuit. • Fixes atmospheric pressure and continues operation. • Engine does not start easily. • Engine output drops. • The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS). • The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring function (Code: ENGINE, 37402, AMBIENT PRESS). • Method of reproducing failure code: Turn the starting switch ON. Causes 1



2


AMBAIR PRESSURE Voltage Defective atmospheric presPower supply 4.75 – 5.25 V sure sensor (Internal trouble) Between (1) and (2) Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (3) – ness AMBAIR PRESSURE (female) (3) and Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harness between EC1 (female) (3) – 4 ness (with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 (female) (33) – AMBAIR PRESSURE (female) (1)

5


Resistance

Min. 100 kz

Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



40-320

26


4.75 – 5.25 V


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA221] Atmospheric pressure sensor high error

SEN03940-00



40-320

27

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA222] Atmospheric sensor low error

SEN03940-00

Failure code [CA222] Atmospheric sensor low error Action code

Failure code

E01

CA222


Related information

Trouble

1

Atmospheric sensor low error (Engine controller system)

• Low voltage is detected in atmospheric pressure sensor circuit. • Fixes atmospheric pressure and continues operation. • Engine does not start easily. • Engine output drops. • The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS). • The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring function (Code: ENGINE, 37402, AMBIENT PRESS). • Method of reproducing failure code: Turn the starting switch ON. Causes 1



2


AMBAIR PRESSURE Voltage Defective atmospheric presPower supply 4.75 – 5.25 V sure sensor (Internal trouble) Between (1) and (2) Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 3 Wiring harness between EC1 (female) (3) – (Short circuit with ground cirResisMin. AMBAIR PRESSURE (female) (3) and cuit) tance 100 kz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harness between EC1 (female) (3) – 4 ness (with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 (female) (38) – AMBAIR PRESSURE (female) (2)

5


Resistance

Min. 100 kz

Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



40-320

28


4.75 – 5.25 V


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA222] Atmospheric sensor low error

SEN03940-00



40-320

29

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA227] Sensor power supply 2 high error

SEN03940-00

Failure code [CA227] Sensor power supply 2 high error Action code

Failure code

E03

CA227


Trouble

Sensor power supply 2 high error (Engine controller system)

• High voltage is detected in sensor power supply 2 circuit. • • • •

Fixes boost pressure and continues operation. Fixes charge temperature and continues operation. Limits output and continues operation. Turns the centralized warning lamp and alarm buzzer ON.




1



Connecting parts among each sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

1


40-320

30


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA234] Engine overspeed

SEN03940-00

Failure code [CA234] Engine overspeed Action code

Failure code

E02

CA234


Trouble

Engine Overspeed (Engine controller system)

• Engine speed is above upper control limit. • Stops injection of injector until engine speed drops to normal level. • Turns the centralized warning lamp and alarm buzzer ON. • Engine speed fluctuates. • Engine speed can be checked by monitoring function (Code: ENGINE, 01001, ENG SPEED). • Method of reproducing failure code: Start engine and running at high idle. Causes


1

1 Use of improper fuel 2

Standard value in normal state/Remarks on troubleshooting Check fuel used directly.

Improper way of speed con- Way of speed control may be improper. Teach proper way of use to trol operator.



If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

40-320

31

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA238] Ne speed sensor power supply error

SEN03940-00

Failure code [CA238] Ne speed sensor power supply error Action code

Failure code

E03

CA238


Trouble

1

Ne speed sensor supply power error (Engine controller system)

• Low voltage is detected in engine Ne speed sensor power supply circuit. • Controls Ne speed sensor with signals of Bkup speed sensor. • Turns the centralized warning lamp and alarm buzzer ON. • Starting performance is poor. • There is hunting from engine. • Method of reproducing failure code: Turn the starting switch ON.

Causes



1

2

Defective sensor or wiring harness


Disconnect devices at right in order. If failure code disappears after reproduction operation is conducted, that device or wiring harness has a defect in it.

Ne speed sensor

CRANK SENSOR


EC1

Connecting parts among each sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


40-320

32


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA271] IMV (IMA) Short circuit

SEN03940-00

Failure code [CA271] IMV (IMA) Short circuit Action code

Failure code

E03

CA271

Trouble

IMV (IMA) Short circuit (Engine controller system)

Contents of trouble

• There is short circuit in supply pump actuator drive circuit.

Action of controller

• Turns the centralized warning lamp and alarm buzzer ON.

Problem that appears on machine Related information

1

• Engine speed does not rise from low idle. • Engine output drops. • Common rail fuel pressure is above command value. • Method of reproducing failure code: Turn the starting switch ON.

Causes


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump actu1 ator CP3 PUMP REGULATOR (male) Resistance Between (1) and ground

Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness 2 Wiring harness between EC1 (female) (2) – (Short circuit with ground cirResisMin. CP3 PUMP REGULATOR (female) (1) and cuit) tance 100 kz ground Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness Wiring harness among all pins between EC1 Min. (with another wiring harness) (female) (2) – EC1 (female) (With all connec- Resistance 100 kz tors of wiring harness disconnected)

4


Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


EC1 (female)

Resistance


Min. 100 kz



40-320

33

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA272] IMV (IMA) Disconnection

SEN03940-00

Failure code [CA272] IMV (IMA) Disconnection Action code

Failure code

E03

CA272


Trouble

1

IMV (IMA) Disconnection (Engine controller system)

• There is disconnection in supply pump actuator drive circuit. • Turns the centralized warning lamp and alarm buzzer ON. • Engine runs, but in unstable condition. • Common rail fuel pressure is above command value. • Method of reproducing failure code: Turn the starting switch ON.

Causes


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump actu1 ator CP3 PUMP REGULATOR (male) Resistance Max. 5 z

Between (1) and (2) Disconnection in wiring harness 2 (Disconnection or defective contact in connector)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (2) – CP3 PUMP REGULATOR (female) (1)

Resistance

Max. 10 z

Wiring harness between EC1 (female) (32) – CP3 PUMP REGULATOR (female) (2)

Resistance

Max. 10 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


3

Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between EC1 (female) (2) – CP3 PUMP REGULATOR (female) (1) and ground

Voltage

Max. 3 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har4 ness Wiring harness among all pins between EC1 Min. (with another wiring harness) (female) (2) – EC1 (female) (With all connec- Resistance 100 kz tors of wiring harness disconnected)

5




40-320

34

EC1 (female)

Resistance


Max. 5 z


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA272] IMV (IMA) Disconnection

SEN03940-00



40-320

35

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA322] Injector #1 open/short error

SEN03940-00

Failure code [CA322] Injector #1 open/short error Action code

Failure code

E03

CA322


Trouble

1

Injector #1 open/short error (Engine controller system)

• There is disconnection or short circuit in drive circuit of injector No. 1. • Turns the centralized warning lamp and alarm buzzer ON. • There is irregular combustion or hunting. • Engine output drops. • Method of reproducing failure code: Start engine

Causes


1 Defective injector No. 1


INJ CYL 1

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (45) – INJ CYL 1 (1)

Resistance

Max. 2 z

Wiring harness between EC1 (female) (53) – INJ CYL 1 (2)

Resistance

Max. 2 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness Resis(Contact with ground circuit) Wiring harness between EC1 (female) (45) – Max. 2 z INJ CYL 1 (1) and ground tance Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness among all pins between EC1 Short circuit in wiring har(female) (45) – EC1 (female) (With all con4 ness nectors of wiring harness disconnected) (with another wiring harness) Wiring harness among all pins between EC1 (female) (53) – EC1 (female) (With all connectors of wiring harness disconnected)

Resistance

Min. 100 kz

Resistance

Min. 100 kz

5


Connecting parts among injector No. 1, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation

6

Defective other cylinder injector or harness

If other failure codes are indicated simultaneously, carry out troubleshooting for them. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-320

36

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

37


SEN03940-00


Failure code

E03

CA323


Trouble

1



Causes




INJ CYL 5

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz


Resistance

Max. 2 z


Resistance

Max. 2 z



Resistance

Min. 100 kz

Resistance

Min. 100 kz

5



6




40-320

38

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

39


SEN03940-00


Failure code

E03

CA324


Trouble

1



Causes




INJ CYL 3

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz


Resistance

Max. 2 z


Resistance

Max. 2 z



Resistance

Min. 100 kz

Resistance

Min. 100 kz

5



6




40-320

40

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

41


SEN03940-00


Failure code

E03

CA325


Trouble

1



Causes




INJ CYL 6

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz


Resistance

Max. 2 z


Resistance

Max. 2 z



Resistance

Min. 100 kz

Resistance

Min. 100 kz

5



6




40-320

42

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

43


SEN03940-00


Failure code

E03

CA331


Trouble

1



Causes




INJ CYL 2

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz


Resistance

Max. 2 z


Resistance

Max. 2 z



Resistance

Min. 100 kz

Resistance

Min. 100 kz

5



6




40-320

44

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

45


SEN03940-00


Failure code

E03

CA332


Trouble

1



Causes




INJ CYL 4

Resistance

Between (1) and (2)

Max. 2 z


Min. 100 kz


Resistance

Max. 2 z


Resistance

Max. 2 z



Resistance

Min. 100 kz

Resistance

Min. 100 kz

5



6




40-320

46

EC1 (female)

Resistance


Max. 2 z


Min. 100 kz



SEN03940-00



40-320

47

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA342] Calibration code inconsistency

SEN03940-00

Failure code [CA342] Calibration code inconsistency Action code

Failure code

E03

CA342



40-320

48

Trouble

1

Calibration code inconsistency (Engine controller system)

• Matching error occurred in engine controller data. • Turns the centralized warning lamp and alarm buzzer ON. • Continues the normal operation. • Engine stops or does not start. • Method of reproducing failure code: Turn the starting switch ON.

Causes


1 Defect in related system

If another code is displayed, carry out troubleshooting for it.


Possible defect in engine controller (Troubleshooting cannot be carried out.)


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA342] Calibration code inconsistency


SEN03940-00

40-320

49

320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA351] Injectors drive circuit error

SEN03940-00

Failure code [CA351] Injectors drive circuit error Action code

Failure code

E03

CA351


Trouble

1

Injectors drive circuit error (Engine controller system)

• Abnormality occurred in injector drive power supply circuit. • Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON. • • • •

Exhaust smoke is black. There is irregular combustion. Engine output drops. The engine does not start.


Causes



If another code is displayed, carry out troubleshooting for it.

Defective fuse No. 4 of fuse 2 box FS1

If the fuse is broken, the circuit probably has a grounding fault, etc. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

L107 (Male) Resistance Defective engine control cutBetween (1) and (2) 200 – 400 z out relay 1 (L107) (Internal 3 a Prepare with starting switch OFF, then turn starting switch ON disconnection or short cirand carry out troubleshooting. cuit) When engine control cut-out relay 1 (L107) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay 1 is defective.


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L108 (male) Resistance Defective engine control cutBetween (1) and (2) 200 – 400 z out relay 2 (L108) (Internal 4 a Prepare with starting switch OFF, then turn starting switch ON disconnection or short cirand carry out troubleshooting. cuit) When engine control cut-out relay 2 (L108) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay 2 is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 5 (Disconnection or defective contact in connector)


40-320

50

Wiring harness between fuse No. 4 of fuse box FS1 – L107, L108 (female) (3)

Resistance

Max. 0.5 z

Wiring harness between L107 (female) (5), L108 (female) (5) – EC3 (female) (3), (4)

Resistance

Max. 0.5 z

Wiring harness between EC3 (female) (1), (2) – ground

Resistance

Max. 10 z

If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in the system, troubleshooting cannot be carried out.)


320 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA351] Injectors drive circuit error

SEN03940-00



40-320

51


SEN03940-00

Failure code [CA352] Sensor power supply 1 low error Action code

Failure code

E03

CA352


Trouble

1

Sensor power supply 1 low error (Engine controller system)

• Low voltage is detected in sensor power supply 1 (5V) circuit. • Fixes atmospheric pressure and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Starting performance is poor. • Engine output drops. • Method of reproducing failure code: Turn the starting switch ON.

Causes


Defective sensor or wiring 1 harness Possible causes and standard value in normal state

52

Atmospheric pressure sensor

AMBAIR PRESSURE


EC1


Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

2

40-320

Disconnect devices at right in order. If failure code disappears after reproduction operation is conducted, that device or wiring harness has a defect in it.



SEN03940-00



40-320

53


SEN03940-00

Failure code [CA386] Sensor power supply 1 high error Action code

Failure code

E03

CA386



Trouble

1

Sensor power supply 1 high error (Engine controller system)

• High voltage is detected in sensor power supply 1 (5V) circuit. • Fixes atmospheric pressure and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Starting performance is poor. • Engine output drops. • Method of reproducing failure code: Turn the starting switch ON.

Causes



Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation


If cause 1 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

1


40-320

54




SEN03940-00

40-320

55

SEN03940-00



40-320

56

SEN03941-01




40 Troubleshooting

40

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA428] Abnormally high level in water sensor.......................................................................... 4 Failure code [CA429] Abnormally low level in water sensor ........................................................................... 6 Failure code [CA431] Idle validation switch error............................................................................................ 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error ........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2 ............................................................................ 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28 Failure code [CA553] Common rail pressure high error 1 ............................................................................ 29 Failure code [CA559] Supply pump pressure very low error ........................................................................ 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 34 Failure code [CA757] All continuous data lost error...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46 Failure code [CA2249] Supply pump pressure very low error 2 ................................................................... 48 WA320, 320PZ-6 (KA SPEC.)

40-330

1

SEN03941-01


Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50 Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54

40-330

2




SEN03941-01

40-330

3

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA428] Abnormally high level in water sensor

SEN03941-01

Failure code [CA428] Abnormally high level in water sensor Action code

Failure code

E01

CA428


Trouble

1

Abnormally high level in water sensor (Engine controller system)

• High voltage occurred in fuel water sensor • None in particular.

• Water separator monitor does not indicate normally.


Causes


1 Defective fuel water sensor


E42 (female)

Resistance

Between (1) and (2)

Max. 10 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (14) – E42 (male) (1)

Resistance

Max. 10 z

Wiring harness between EC1 (female) (47) – E42 (male) (2)

Resistance

Max. 10 z



4


Resistance

Min. 100 kz

Connecting parts among fuel water sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-330

4

EC1 (female)

Resistance


Max. 10 z


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA428] Abnormally high level in water sensor

SEN03941-01



40-330

5

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA429] Abnormally low level in water sensor

SEN03941-01

Failure code [CA429] Abnormally low level in water sensor Action code

Failure code

E01

CA429


Trouble

1

Abnormally low level in water sensor (Engine controller system)

• Low voltage occurred in fuel water sensor • None in particular.

• Water separator monitor does not indicate normally.


Causes


1 Defective fuel water sensor

E42 (female)

Resistance

Between (1) and (2)

Max. 10 z


Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness Wiring harness between EC1 (female) (14) – ResisMin. (Contact with ground circuit) E42 (male) (1) and ground tance 100 kz Possible causes and standard value in normal state


4


Connecting parts among fuel water sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-330

6

EC1 (female)

Resistance


Max. 10 z


Min. 100 kz


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA429] Abnormally low level in water sensor

SEN03941-01



40-330

7

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA431] Idle validation switch error

SEN03941-01

Failure code [CA431] Idle validation switch error Action code

Failure code

E01

CA431


Related information

Trouble

1

Idle validation switch error (Engine controller system)

• Abnormality occurred in idle validation switch circuit • Operates at position of throttle of throttle sensor.

— • The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function (Code: ENGINE, 18300, IVS 1). • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function (Code: ENGINE, 18301, IVS 2). • Method of reproducing failure code: Turn the starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PD1

1

Defective accelerator pedal (Internal trouble)

Signal name

Between (5) and (4)

Signal 1

Between (6) and (4)

Signal 2

Voltage See Fig. 1

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for another cause of trouble before judgment a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Wiring harness between EC2 (female) (11) – PD1 (female) (5)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


40-330

8

Wiring harness among all pins between EC2 (female) (11) – EC2 (female) (PD1 and 2, too, is disconnected.)

Resistance

Min. 100 kz

Short circuit in wiring harWiring harness among all pins between EC2 3 ness (female) (1) – EC2 (female) (PD1 and 2, too, (with another wiring harness) is disconnected.)

Resistance

Min. 100 kz

Between EC2 (female) (11) – EC3 (female) (3), (4) (PD1 and 2, too, is disconnected.)

Resistance

Min. 100 kz

Between EC2 (female) (1) – EC3 (female) (3), (4) (PD1 and 2, too, is disconnected.)

Resistance

Min. 100 kz




4


SEN03941-01

Standard value in normal state/Remarks on troubleshooting Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


5

Defective engine controller

EC2 (female)

Signal name


Signal 1


Signal 2

Voltage See Fig. 1



40-330

9

SEN03941-01


Fig. 1 Throttle: Throttle sensor signal voltage Idle validation: Idle validation switch signal voltage A: Voltage when pedal opened + 0.03 x (Voltage when pedal pressed – Voltage when pedal opened) B: Voltage when pedal opened + 0.1 x (Voltage when pedal pressed – Voltage when pedal opened)

40-330

10




SEN03941-01

40-330

11

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA432] Idle validation action error

SEN03941-01

Failure code [CA432] Idle validation action error Action code

Failure code

E03

CA432

Contents of trouble



Related information

Trouble

1

Idle validation action error (Engine controller system)

• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory) 1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0% after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after the accelerator pedal is ON. 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0% (fix to the low idle). • Turns the centralized warning lamp and alarm buzzer ON. • Engine speed does not rise from low idle. • The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function (Code: ENGINE, 18300, IVS 1). • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function (Code: ENGINE, 18301, IVS 2). • The input state from throttle position sensor can be checked with the monitoring function (Code: ENGINE, 31701/31707, THROTTLE POS) • Method of reproducing failure code: Turn the starting switch ON. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PD1

Signal name

Between (2) and (3)

APS sig.

Between (5) and (4)

IVS 1

Between (6) and (4)

IVS 2

1 Defective accelerator pedal Possible causes and standard value in normal state

Voltage When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V

See Fig. 1

Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for another cause of trouble before judgment a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection or defective contact in connector)

40-330

12


Resistance

Max. 10 z


Resistance

Max. 10 z

Wiring harness between EC2(female) (21) – PD2 (female) (1)

Resistance

Max. 10 z



Causes

SEN03941-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness among all pins between EC2 (female) (22) – EC2 (female) (PD1 and 2, too, is disconnected.)

Short circuit in wiring har3 ness Wiring harness among all pins between EC2 (with another wiring harness) (female) (9) – EC2 (female) (PD1 and 2, too, is disconnected.)


Wiring harness between EC2 (female) (21) – EC2 (female) (PD1 and 2, too, is disconnected.)

4


Resistance

Min. 100 kz

Resistance

Min. 100 kz

Resistance

Min. 100 kz

Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


EC2 (female)

Accelelator pedal


Signal 1


Signal 2



Voltage See Fig. 1

When released

0.50 – 0.80 V

When pressed

3.70 – 4.00 V

40-330

13

SEN03941-01



40-330

14



SEN03941-01

Fig. 1 Throttle: Throttle sensor signal voltage Idle validation: Idle validation switch signal voltage A: Voltage when pedal opened + 0.03 x (Voltage when pedal pressed – Voltage when pedal opened) B: Voltage when pedal opened + 0.1 x (Voltage when pedal pressed – Voltage when pedal opened)


40-330

15

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA435] Engine oil pressure switch error

SEN03941-01

Failure code [CA435] Engine oil pressure switch error Action code

Failure code

E01

CA435

Contents of trouble Action of controller

Trouble

1

Engine oil pressure switch error (Engine controller system)

• Abnormality occurred in engine oil pressure switch signal circuit. • None in particular.


• Engine oil switch-based engine protection function does not function. • Engine oil pressure monitor does not indicate normally.

Related information

• Method of reproducing failure code: Starting switch ON or start engine

Causes


1

Defective engine oil pressure OIL PRESSURE SWITCH (male) switch Between OIL PRESURE SWITCH (male) and body


Resistance Max. 10 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (17) – OIL PRESSURE SWITCH (female)

Resistance

Max. 10 z


4


Connecting parts among engine oil pressure switch, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


EC1 (female)

Resistance


Max. 10 z


40-330

16


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA441] Battery voltage low error

SEN03941-01

Failure code [CA441] Battery voltage low error Action code

Failure code

E03

CA441


Trouble

1

Battery voltage low error (Engine controller system)

• Low voltage (Max. 6 V) occurred in controller power supply voltage circuit. • Turns the centralized warning lamp and alarm buzzer ON. • Engine stops • Starting performance is poor • Method of reproducing failure code: Turn the starting switch ON.

Causes 1

Loose, corroded battery terminal

Standard value in normal state/Remarks on troubleshooting Inspect battery terminal directly for loose and corrosion. a Prepare with starting switch OFF, then turn starting switch OFF and START and carry out troubleshooting.

2 Defective battery voltage

Defective fuse No. 4 of fuse 3 box FS1

Battery (1 piece)

Starting switch

Voltage

Between (+) and (–) terminals

OFF

Min. 12 V

START

Min. 6.2 V

If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L107 (Male)

Resistance

Defective engine control cutBetween (1) and (2) 200 – 400 z 4 out relay (L107) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON connection or short circuit) and carry out troubleshooting. Possible causes and standard value in normal state

When engine control cut-out relay (L107) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay (L107) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L108 (Male)

Resistance

Defective engine control cutBetween (1) and (2) 200 – 400 z 5 out relay (L108) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON connection or short circuit) and carry out troubleshooting. When engine control cut-out relay (L108) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay (L108) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 6 (Disconnection or defective contact in connector)



Resistance

Max. 10 z


Resistance

Max. 10 z


Resistance

Max. 10 z

40-330

17


SEN03941-01

Causes


Ground fault in wiring harWiring harness between fuse No. 4 of fuse 7 ness box FS1 – L107, L108 (female) (3) and (Contact with ground circuit) ground Wiring harness between L107 (female) (5), L108 (female) (5) – EC3 (3), (4) and ground

Resistance

Min. 100 kz

Resistance

Max. 10z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness among pins between EC3 (female) (3), (4) – EC3 (female) (1), (2) (With battery terminal disconnected)


Short circuit in wiring har8 ness Wiring harness among all pins between EC3 (with another wiring harness) (female) (3), (4) – EC2 (female) (With battery terminal disconnected) Wiring harness among all pins between EC3 (female) (1), (2) – EC2 (female) (With battery terminal disconnected)

9


Resistance

Min. 100 kz

Resistance

Min. 100 kz

Resistance

Min. 100 kz

Connecting parts among fuse No. 4 of fuse box FS1, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


40-330

18

EC3 (female)

Starting switch

Voltage

Between (3), (4) and (1), (2)

ON

Min. 24 V

START

Min. 12 V



SEN03941-01



40-330

19

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA442] Battery voltage high error

SEN03941-01

Failure code [CA442] Battery voltage high error Action code

Failure code

E03

CA442


Trouble

1

Battery voltage high error (Engine controller system)

• High voltage (min. 36V) occurred in controller power supply voltage circuit. • Turns the centralized warning lamp and alarm buzzer ON.

• Engine may stop.


Causes




Battery

Voltage

Between (+) and (–) terminals

Less than 32 V

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 2 Defective alternator

E02 (male)

Engine speed

Voltage


Min. medium speed

27.5 – 29.5 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective engine controller

40-330

20

EC3 (female)

Voltage

Between (3), (4) and (1), (2)

Less than 32 V


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA442] Battery voltage high error

SEN03941-01



40-330

21

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA449] Common rail pressure high error 2

SEN03941-01

Failure code [CA449] Common rail pressure high error 2 Action code

Failure code

E03

CA449


Related information

Trouble

Common rail pressure high error 2 (Engine controller system)

• Voltage (2) in common rail circuit is abnormally high. • Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON. • Engine sound becomes larger under no load or light load. • Engine output drops. • The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Start engine Causes




• If another code is displayed, carry out troubleshooting for it.

2 Air in low-pressure circuit

Commingling of air with the low pressure circuit is suspected. Inspect the circuit directly in the following procedure. 1) Remove the pressure pickup plug (outlet side) of the fuel main filter. 2) Operate the feed pump of the fuel pre-filter. 3) Inspect leakage of fuel and air from the pressure pickup plug.

Defective fuel return circuit 3 device

a For check of pressure in fuel return circuit, see Testing and adjusting, “Testing fuel pressure”. Fuel circuit pressure At low idle or cranking

Defective common rail pressure sensor

Monitoring code (Machine monitor) Code: 36400, RAIL PRESS

5 Defective pressure limiter

6 Defective supply pump

Monitoring information Condition when engine stopped

0 – 0.39 MPa {0 – 4 kg/cm2}

For testing of leakage from pressure limiter, see Testing and adjusting, “Testing leakage from pressure limiter and return rate from injector”. Leakage from pressure limiter

22

Max. 0.02 MPa {Max. 0.19 kg/cm2}

a Prepare with starting switch ON, then carry out troubleshooting without turning starting switch OFF. 4

40-330

1

At low idle

0 cc (No leakage)

If causes 1 – 5 are not detected, supply pump may be defective.




SEN03941-01

40-330

23

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA451] Common rail pressure sensor high error

SEN03941-01

Failure code [CA451] Common rail pressure sensor high error Action code

Failure code

E03

CA451


Related information

Trouble

1

Common rail pressure sensor high error (Engine controller system)

• High voltage occurred in common rail pressure sensor. • Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not start. • Engine speed or output drops. • The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Turn the starting switch ON. Causes


Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out trouble1 ply 2 system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective common rail pres2 sure sensor

FUEL RAIL PRESS Between (3) and (1)

Voltage

Power supply

4.75 – 5.25 V



a Prepare with starting switch OFF, then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. 3 5V, 24V circuit) in wiring harWiring harness between EC1 (female) (25) – ness Voltage Max. 1 V FUEL RAIL PRESS (female) (2) and ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harness between EC1 (female) (25) – 4 ness (with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 (female) (37) – FUEL RAIL PRESS (female) (3)

5


Resistance

Min. 100 kz

Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



40-330

24


4.75 – 5.25 V


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA451] Common rail pressure sensor high error

SEN03941-01



40-330

25

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA452] Common rail pressure sensor low error

SEN03941-01

Failure code [CA452] Common rail pressure sensor low error Action code

Failure code

E03

CA452


Related information

Trouble

1

Common rail pressure sensor low error (Engine controller system)

• Low voltage occurred in common rail pressure sensor. • Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not start. • Engine speed or output drops. • The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Turn the starting switch ON. Causes


Defective sensor power sup- If failure code [CA187] is indicated simultaneously, carry out trouble1 ply 2 system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective common rail pres2 sure sensor

FUEL RAIL PRESS Between (3) and (1)

Voltage

Power supply

4.75 – 5.25 V



a Prepare with starting switch OFF, then turn starting switch ON Ground fault in wiring harand carry out troubleshooting. 3 ness ResisMin. (Contact with ground circuit) Wiring harness between EC1 (female) (25) – FUEL RAIL PRESS (female) (2) and ground tance 100 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harWiring harness between EC1 (female) (25) – 4 ness (with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 (female) (37) – FUEL RAIL PRESS (female) (3)

5


Resistance

Min. 100 kz

Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



40-330

26


4.75 – 5.25 V


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA452] Common rail pressure sensor low error

SEN03941-01



40-330

27

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA488] Derating of torque by abnormally high charge temperature

SEN03941-01

Failure code [CA488] Derating of torque by abnormally high charge temperature Action code

Failure code

E03

CA488


Related information

Trouble

• Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Engine output drops. • The input state (boost temperature) from the boost pressure and temperature sensors can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP). • The input state (boost temperature sensor voltage) from the boost pressure and temperature sensors can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP). • Method of reproducing failure code: Start engine

28


Inspect following directly. Drop in cooling performance • Malfunction of hydraulic drive fan 1 of aftercooler • Insufficient cooling air • Clogged aftercooler fin 2

Abnormally high temperature at turbocharger outlet


40-330

Derating of torque by abnormally high charge temperature (Engine controller system)

• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.

Causes


1

Inspect related parts directly. If causes 1 – 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)



SEN03941-01

Failure code [CA553] Common rail pressure high error 1 Action code

Failure code

E03

CA553

Contents of trouble

Trouble

Common rail pressure high error 1 (Engine controller system)

• Voltage (1) in common rail circuit is abnormally high.


• None in particular. • Turns the centralized warning lamp and alarm buzzer ON.


• Engine sound becomes larger under no load or light load. • Engine output drops.

Related information

• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Start engine Causes 1 Defect in related system


1

Standard value in normal state/Remarks on troubleshooting If another code is displayed, carry out troubleshooting for it.

2

Defective connection of ground terminal

Inspect following directly for connection of ground terminal. • Ground terminal (battery (-)) of machine main unit. • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor

3

Broken O-ring of supply pump actuator

Inspect O-ring directly for breakage.


40-330

29

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA559] Supply pump pressure very low error

SEN03941-01

Failure code [CA559] Supply pump pressure very low error Action code

Failure code

E03

CA559


Related information

Trouble

1

Supply pump pressure very low error (Engine controller system)

• No-pressure feed (1) occurred in common rail circuit. • Turns the centralized warning lamp and alarm buzzer ON. • Engine does not start or starting performance is poor • Exhaust smoke is black. • Engine output drops. • The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Start engine Causes 1 Fuel leakage to outside

Standard value in normal state/Remarks on troubleshooting Inspect for fuel leakage directly (visual inspection at engine low idle). a For check of pressure in fuel low-pressure circuit, see Testing and adjusting, “Testing fuel pressure”.

Defective low-pressure cir2 cuit device

3 Defective pressure limiter

Pressure in fuel lowpressure circuit

0.3 – 1.1 MPa {3.1 – 11.3 kg/cm2}

At low idle (When starting is available)

0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

For testing of leakage from pressure limiter, see Testing and adjusting, “Testing leakage from pressure limiter and return rate from injector”. Leakage from pressure limiter


Cranking (When starting is not available)

At low idle

0 cc (No leakage)

a For testing of return rate from injector, see Testing and adjusting, “Testing leakage from pressure limiter and return rate from injector”. Defective injector 4 (High-pressure piping in head included)

Return rate from injector

Cranking (When starting is not available)

Max. 90 cc/min.

At low idle (When starting is available)

Max. 180 cc/min.

a For testing of return rate from supply pump, see Testing and adjusting, Testing leakage-from pressure limiter and return rate from injector. 5 Defective supply pump

40-330

30

Cranking (When starting is not available) Return rate from supply pump At low idle (When starting is available)

Max. 140 cc/min.

Max. 1,000 cc/min.


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA559] Supply pump pressure very low error


SEN03941-01

40-330

31

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Engine Ne speed sensor error

SEN03941-01

Failure code [CA689] Engine Ne speed sensor error Action code

Failure code

E03

CA689

Trouble

Engine Ne speed sensor error (Engine controller system)

Contents of trouble

• Abnormality occurred in signals from engine Ne speed sensor.


• Controls Ne speed sensor with signals of Bkup speed sensor. • Turns the centralized warning lamp and alarm buzzer ON.


1

• There is hunting from engine. • Starting performance is poor • Engine output drops. • Method of reproducing failure code: Start engine

Causes 1

Defective Ne speed sensor power supply system

Standard value in normal state/Remarks on troubleshooting If failure code [CA238] is indicated simultaneously, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

2

Defective engine Ne speed sensor

CRANK SENSOR Between (1) and (2)

Voltage

Power supply

4.75 – 5.25 V

Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Broken engine Ne speed 3 sensor or defective clearance 4 Possible causes and standard value in normal state

Broken rotation sensing flywheel


Inspect engine Ne speed sensor for breakage or clearance.

Inspect it for breakage directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (27) – CRANK SENSOR (female) (3)

Resistance

Max. 10 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 6 ness ResisMin. (Contact with ground circuit) Wiring harness between EC1 (female) (27) – CRANK SENSOR (female) (3) and ground tance 100 kz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5V, 7 24V circuit) in wiring harness Wiring harness between EC1 (female) (27) – Voltage Max. 1 V CRANK SENSOR (female) (3) and ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (27) – Short circuit in wiring harCRANK SENSOR (female) (3), EC1 (female) 8 ness (16) – CRANK SENSOR (female) (1) (with another wiring harness) Wiring harness between EC1 (female) (27) – CRANK SENSOR (female) (3), EC1 (female) (48) – CRANK SENSOR (female) (2)

40-330

32

Resistance

Min. 100 kz

Resistance

Min. 100 kz


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Engine Ne speed sensor error

9 Possible causes and standard value in normal state

SEN03941-01

Causes



Connecting parts among engine Ne speed sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.




4.75 – 5.25 V



40-330

33

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA731] Engine Bkup speed sensor phase error

SEN03941-01

Failure code [CA731] Engine Bkup speed sensor phase error Action code

Failure code

E03

CA731


Trouble

• Controls Ne speed sensor with signals of Bkup speed sensor. • Turns the centralized warning lamp and alarm buzzer ON. • Engine does not start or is difficult to start. • Idle speed is unstable. • Exhaust smoke is black. • Method of reproducing failure code: Start engine

Broken engine Ne speed sensor

Inspect engine Ne speed sensor for breakage directly.

2

Broken engine Bkup speed sensor

Inspect engine Bkup speed sensor for breakage directly. Inspect it for defect or breakage according to the following procedure. 1) Set No. 1 cylinder to compression top dead center (align stamping mark). 2) If tip of Ne speed sensor is aligned with center of oblong hole of rotation sensing flywheel, it is mounted normally.

Inspect it for defect or breakage according to the following procedure. 1) Set No. 1 cylinder to compression top dead center (align stampDefective/broken mount of ing mark). 4 rotation sensing ring on cam2) Remove Bkup speed sensor. shaft side 3) If 2 grooves (1 thread) of rotation sensing ring can be seen through sensor mounting hole, it is mounted normally. 5

6

34


1

Defective/broken mount of 3 rotation sensing flywheel on crankshaft side

40-330

Engine Bkup speed sensor phase error (Engine controller system)

• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.

Causes


1

Defective timing between crankshaft and camshaft

Inspect crankshaft and camshaft for timing directly.

Defective connection of ground terminal

Inspect following directly for connection of ground terminal. • Ground terminal (battery (-)) of machine main unit. • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA757] All continuous data lost error

SEN03941-01

Failure code [CA757] All continuous data lost error Action code

Failure code

E03

CA757


Trouble

1

All continuous data lost error (Engine controller system)

• All data in engine controller are lost. • Turns the centralized warning lamp and alarm buzzer ON. • Engine stops and sometimes cannot be started. • The monitoring function of the machine monitor (engine controller system) sometimes fail to work normally. • Method of reproducing failure code: Turn the starting switch ON.

Causes 1 Defect in related system 2

Loose, corroded battery terminal

Standard value in normal state/Remarks on troubleshooting If another code is displayed, carry out troubleshooting for it. Inspect battery terminal directly for loose and corrosion. a Prepare with starting switch OFF, then carry out troubleshooting with starting switch OFF and START.


4

Defective fuse No. 4 of fuse box FS1

Battery (1 piece)

Starting switch

Voltage

Between (+) – (–) terminals

OFF

Min. 12 V

START

Min. 6.2 V

If the fuse is broken, the circuit probably has a grounding fault, etc. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L107 (male)


Resistance

Defective engine control cutBetween (1) and (2) 200 – 400 z 5 out relay (L107) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON connection or short circuit) and carry out troubleshooting. When engine control cut-out relay (L107) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay (L107) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L108 (male)

Resistance

Defective engine control cutBetween (1) and (2) 200 – 400 z 6 out relay (L108) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON connection or short circuit) and carry out troubleshooting. When engine control cut-out relay (L108) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay (L108) is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 7 (Disconnection or defective contact in connector)



Resistance

Max. 10z


Resistance

Max. 10z


Resistance

Max. 10z

40-330

35


SEN03941-01

Causes



Standard value in normal state/Remarks on troubleshooting Connecting parts among fuse No. 4 of fuse box FS1, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


EC3 (female) Between (3) and (1)

40-330

36

Starting switch

Voltage

ON

Min. 24 V

START

Min. 12 V



SEN03941-01



40-330

37

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA778] Engine Bkup speed sensor error

SEN03941-01

Failure code [CA778] Engine Bkup speed sensor error Action code

Failure code

E03

CA778


Trouble

1

Engine Bkup speed sensor error (Engine controller system)

• Abnormality is detected in signals of engine Bkup speed sensor. • Controls Bkup speed sensor with signals of Ne speed sensor. • Turns the centralized warning lamp and alarm buzzer ON. • Starting performance is poor • Engine output lowers. • Method of reproducing failure code: Start engine

Causes 1



2

Defective engine Bkup speed sensor

CAM SENSOR Between (1) and (2)

Voltage

Power supply

4.75 – 5.25 V

Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. Broken engine Bkup speed 3 sensor or defective clearance

Inspect engine Bkup speed sensor directly for breakage or clearance.

4 Broken rotation sensing ring Inspect it for breakage directly. Possible causes and standard value in normal state


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (26) – CAM SENSOR (female) (3)

Resistance

Max. 10 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 6 ness Wiring harness between EC1 (female) (26) – ResisMin. (Contact with ground circuit) CAM SENSOR (female) (3) and ground tance 100 kz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5V, 7 24V circuit) in wiring harness Wiring harness between EC1 (female) (26) – Voltage Max. 1 V CAM SENSOR (female) (3) and ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (26) – Short circuit in wiring harCAM SENSOR (female) (3), EC1 (female) 8 ness (37) – CAM SENSOR (female) (1) (with another wiring harness) Wiring harness between EC1 (female) (26) – CAM SENSOR (female) (3), EC1 (female) (47) – CAM SENSOR (female) (2)

40-330

38

Resistance

Min. 100 kz

Resistance

Min. 100 kz


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA778] Engine Bkup speed sensor error


SEN03941-01

Causes



Connecting parts among engine Bkup speed sensor, engine wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.




4.75 – 5.25 V



40-330

39

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA1633] KOMNET datalink timeout error

SEN03941-01

Failure code [CA1633] KOMNET datalink timeout error Action code

Failure code

E03

CA1633


Trouble

1

KOMNET datalink timeout error (Engine controller system)

• Engine controller detected a communication error in the KOMNET communication circuit used for the communication between the HST controller and machine monitor. • Continues the operation from the default mode. • Turns the centralized warning lamp and alarm buzzer ON. • If problem is removed, system is returned to normal operating state. • KOMNET communication information may not be transmitted correctly to cause incorrect operation of machine. (Problem depends on failure occurrence location.) • If failure code [DAJRKR] is indicated simultaneously, carry out troubleshooting for it first. • Method of reproducing failure code: Turn the starting switch ON. Causes


1

Defective CAN end point resistance


40

Resistance

Between (A) and (B)

110 – 140 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CAN2 (male)

Resistance

Between (A) and (B)

110 – 140 z



40-330

CAN1 (male)

Wiring harness between EC2 (female) (46), (47) – HST (female) (28), (38)

Resistance

Max. 1 z

Wiring harness between EC2 (female) (46), (47) – L29 (female) (3), (8)

Resistance

Max. 1 z

Wiring harness between EC2 (female) (46), (47) – C140 (female) (28), (38)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between EC2 (female) (46), (47) – CAN1 (female) (A), (B)

Resistance

Max. 1 z


Resistance

Max. 1 z



Causes

SEN03941-01



Wiring harness between EC2 (female) (46), (47) – HST (female) (28), (38) and ground

Resistance

Min. 1 Mz

Wiring harness between EC2 (female) (46), (47) – L29 (female) (3), (8) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between EC2 (female) (46), (47) – CAN1 (female) (A), (B) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring harness Wiring harness between EC2 (female) (46), 3 (Short circuit with ground cir- (47) – C140 (female) (28), (38) and ground cuit) Wiring harness between EC2 (female) (46), (47) – L80 (female) (7), (8) and ground

Defective machine monitor, 4 HST controller, engine controller or KOMTRAX terminal


a If above troubleshootings 1 – 3 have not identified the cause of the trouble, failure on the machine monitor, HST controller, engine controller or KOMTRAX terminal should be suspected. (Since trouble is in system, troubleshooting cannot be carried out.)

40-330

41

SEN03941-01



40-330

42




SEN03941-01

40-330

43

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2185] Throttle sensor supply voltage high error

SEN03941-01

Failure code [CA2185] Throttle sensor supply voltage high error Action code

Failure code

E03

CA2185


Trouble

1

Throttle sensor supply voltage high error (Engine controller system)

• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit. • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not reach full throttle.


Causes



Short circuit in wiring harWiring harness among all pins between EC2 1 ness (female) (22) – EC2 (female) (PD1 and 2, (with another wiring harness) too, is disconnected.) Between EC2 (female) (22) – EC3 (female) (3) (PD1 and 2, too, is disconnected.)

44

Min. 100 kz

Resistance

Min. 100 kz


Connecting parts among accelerator pedal dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation



2

40-330

Resistance


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2185] Throttle sensor supply voltage high error

SEN03941-01



40-330

45

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2186] Throttle sensor power supply low error

SEN03941-01

Failure code [CA2186] Throttle sensor power supply low error Action code

Failure code

E03

CA2186


Trouble

1

Throttle sensor power supply voltage low error (Engine controller system)

• Low voltage occurred in throttle sensor power supply circuit. • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON. • The engine does not reach full throttle.


Causes


a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 ness ResisMin. (Contact with ground circuit) Wiring harness between EC2 (female) (22) – PD1 (female) (1) and ground tance 100 kz


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har2 ness Wiring harness among all pins between EC2 ResisMin. (with another wiring harness) (female) (9) – EC2 (female) (PD1 and 2, too, tance 100 kz is disconnected.)


Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation



3

40-330

46


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2186] Throttle sensor power supply low error

SEN03941-01



40-330

47

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2249] Supply pump pressure very low error 2

SEN03941-01

Failure code [CA2249] Supply pump pressure very low error 2 Action code

Failure code

E03

CA2249


Related information


40-330

48

Trouble

1

Supply pump pressure very low error 2 (Engine controller system)

• No-pressure feed (2) occurred in common rail circuit. • Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON. • Starting performance is poor • Exhaust smoke is black. • Engine output lowers. • The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36400, RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: ENGINE, 36402, RAIL PRESS). • Method of reproducing failure code: Start engine Causes 1

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [CA559].


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2249] Supply pump pressure very low error 2


SEN03941-01

40-330

49

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2311] Abnormality in IMV (IMA) solenoid

SEN03941-01

Failure code [CA2311] Abnormality in IMV (IMA) solenoid Action code

Failure code

E03

CA2311


Trouble

1

Abnormality in IMV (IMA) solenoid (Engine controller system)

• Resistance in supply pump actuator circuit is abnormally high or low. • Turns the centralized warning lamp and alarm buzzer ON.



Causes 1 Defect in related system

Standard value in normal state/Remarks on troubleshooting If another code is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2

Defective supply pump actu- CP3 PUMP REGULATOR (male) ator Between (1) and (2)

Resistance Max. 5 z

Between (1) and ground Disconnection in wiring harness 3 (Disconnection or defective contact in connector) Possible causes and standard value in normal state

Min. 100 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC1 (female) (2) – CP3 PUMP REGULATOR (female) (1)

Resistance

Max. 5 z

Wiring harness between EC1 (female) (32) – CP3 PUMP REGULATOR (female) (2)

Resistance

Max. 5 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har4 ness Wiring harness between EC1 (female) (2) – ResisMin. (Contact with ground circuit) CP3 PUMP REGULATOR (female) (1) and tance 100 kz ground

5




40-330

50

EC1 (female)

Resistance


Max. 5 z


Min. 100 kz


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2311] Abnormality in IMV (IMA) solenoid

SEN03941-01



40-330

51

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2555] Intake heater relay disconnection error

SEN03941-01

Failure code [CA2555] Intake heater relay disconnection error Action code

Failure code

E01

CA2555


Trouble

1

Intake heater relay disconnection error (Engine controller system)

• There is disconnection in intake air heater relay. • None in particular.


• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temperature)

Related information

• The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP) • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or less. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Test relay unit).

1

Defective heater relay (Internal disconnection)

Resistance

Between E06 and ground

300 – 600 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test by replacing relay unit.) When heater relay is replaced with a relay of the same type, if the condition becomes normal, the heater relay is defective.



a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC2 (female) (40) – E06

Resistance

Max. 10 z

Wiring harness between heater relay R90 – R20

Resistance

Max. 10 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness Wiring harness among all pins between EC2 ResisMin. (with another wiring harness) (female) (40) – EC2 (female) (E06, too, is tance 100 kz disconnected.)

4


Connecting parts among heater relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-330

52

EC2 (female)

Resistance


300 – 600 z


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2555] Intake heater relay disconnection error

SEN03941-01



40-330

53

330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2556] Intake heater relay short circuit error

SEN03941-01

Failure code [CA2556] Intake heater relay short circuit error Action code

Failure code

E01

CA2556


Trouble

1

Intake heater relay short circuit error (Engine controller system)

• There is short circuit in intake air heater relay. • None in particular.


• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temperature)

Related information

• The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP) • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or less. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Test relay unit).

1

Defective heater relay (Internal short circuit)

Between E06 and ground

Resistance 300 – 600 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test by replacing relay unit.) When heater relay is replaced with a relay of the same type, if the condition becomes normal, the heater relay is defective.


a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness ResisMin. (Contact with ground circuit) Wiring harness between EC2 (female) (40) – E06 tance 100 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness Wiring harness among all pins between EC2 ResisMin. (with another wiring harness) (female) (40) – EC2 (female) (E06, too, is tance 100 kz disconnected.)

4


Connecting parts among heater relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly. • Loose connector, broken lock, broken seal • Corrosive, bent, broken, forced-in, or extended pin • Humidity in connector, entry of dirt or dust, poor insulation a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-330

54

EC2 (female)

Resistance


300 – 600 z


330 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2556] Intake heater relay short circuit error

SEN03941-01



40-330

55

SEN03941-01



40-330

56

SEN03942-01




40 Troubleshooting

40

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ............................................................. 2 Failure code [D192KY] ECSS solenoid relay: Hot short ................................................................................. 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................... 6 Failure code [D1B0KB] HST safety relay: Ground fault .................................................................................. 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 24 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 32 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 37 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43


40-340

1

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short

SEN03942-01

Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short Action code

Failure code

E01

D160KY

Contents of trouble

Trouble

Backup alarm/lamp relay 1 circuit: Hot short (Machine monitor system)

• Since there is hot short in backup alarm/lamp relay 1 output system, backup lamp relay 1 does not operate.

• Turns output to backup alarm/lamp relay 1 OFF. Action of • If hot short occurs while alarm buzzer is in operation, output is turned OFF. machine monitor • If hot short occurs while ECSS is in operation, output is turned OFF. Problem that appears on machine

Related information

• • • •

Backup lamp is kept ON. Backup alarm is kept ON. Alarm buzzer may not sound. ECSS may not operate.

• Output state (ON/OFF) to backup alarm/lamp relay 1 can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-2) • Operating condition of alarm buzzer can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-0) • Operating condition of ECSS can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-3) • Method of reproducing failure code: Turn starting switch ON + Set FNR (directional) lever or switch to R (Reverse) position. Causes


Condition becomes Replace backup lamp normal. relay (L109) with Defective backup alarm/lamp another relay. Condition does not 1 relay (L109) (Internal defect) become normal.

Resistance

Between L109 (male) (1) – (2)

Hot short (Contact with 5 V, 2 24 V circuit) in wiring harness


2

Relay (L109) is normal



40-340

Relay (L109) is defective.

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Set FNR (directional) lever or switch to R (Reverse) position.) Wiring harness between L24 (female) (12) – L109 (female) (2)

Voltage

Max. 1 V

If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short

SEN03942-01



40-340

3

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D192KY] ECSS solenoid relay: Hot short

SEN03942-01

Failure code [D192KY] ECSS solenoid relay: Hot short Action code

Failure code

E01

D192KY

Contents of trouble

Trouble

ECSS solenoid relay: Hot short (Machine monitor system)

• Since there is hot short in ECSS solenoid relay output system, ECSS solenoid relay does not operate.

• Turns output to ECSS solenoid relay OFF. Action of • If hot short occurs while backup alarm/lamp is in operation, output is turned OFF. machine monitor • If hot short occurs while alarm buzzer is in operation, output is turned OFF. Problem that appears on machine

Related information

• ECSS does not operate. • Backup alarm/lamp may not sound. • Alarm buzzer may not operate. • Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-3) • Operating condition of backup alarm/lamp can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-2) • Operating condition of alarm buzzer can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-0) • This fault is not detected if ECSS is not installed. • Method of reproducing failure code: Travel at speed higher than 5 km/h. Causes


Condition becomes Replace ECSS sole- normal. noid relay (L110) with Defective ECSS solenoid Condition does not another relay. 1 relay (L110) (Internal defect) become normal.

Resistance

Between L110 (male) (1) – (2) Hot short (Contact with 5 V, 2 24 V circuit) in wiring harness


4

Relay (L110) is normal.



40-340


200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness L24 (female) (11) – L110 (female) (2) and ground

Voltage

Max. 1 V

If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D192KY] ECSS solenoid relay: Hot short

SEN03942-01



40-340

5

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KA] HST safety relay: Disconnection

SEN03942-01

Failure code [D1B0KA] HST safety relay: Disconnection Action code

Failure code

E03

D1B0KA

Contents of trouble

Related information

HST safety relay: Disconnection (HST controller system)

• Disconnection was detected in HST safety relay circuit when starting switch is turned ON.

• • Action of • machine monitor • • Problem that appears on machine

Trouble

Turns clutch EPC solenoid output OFF. Turns motor 1 solenoid output OFF. Turns HST safety relay output OFF. Even if trouble disappears, system does not reset itself until starting switch is turned OFF. Turns the centralized warning lamp and alarm buzzer ON.

• Traction force decreases. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) Causes


1

Defective HST safety relay (Internal defect)

Replace HST safety relay (L111) with another relay.

Condition becomes normal.


Condition does not become normal.


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance


200 – 400 z

a Prepare with starting switch OFF, then start engine and carry out troubleshooting.


Defective VIS power supply 2 holding relay (Internal short circuit)

Replace VIS power supply holding relay (L102) with another relay.







200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)

Wiring harness between HST (female) (17) – L111 (female) (2)

Resistance

Max. 1 z

Wiring harness between L102 (female) (3) – L111 (female) (1)

Resistance

Max. 1 z

Wiring harness between fuse FS1 (No. 3) – L102 (female) (5)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective HST controller

40-340

6

HST

Voltage

Between (17) – ground

Max. 1 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KA] HST safety relay: Disconnection

SEN03942-01



40-340

7

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KB] HST safety relay: Ground fault

SEN03942-01

Failure code [D1B0KB] HST safety relay: Ground fault Action code

Failure code

E01

D1B0KB

Contents of trouble

Related information

HST safety relay: Ground fault (HST controller system)

• Ground fault was detected in HST safety relay circuit when starting switch is turned ON.


Trouble


• Traction force decreases. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA). Causes


1








a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between L111 (male) (1) – (2)

Resistance

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND cirBetween wiring harness (HST (female) (17) Resiscuit) Min. 1 Mz – L111 (female) (2) and ground tance 3 Defective HST controller

40-340

8

If causes 1 and 2 are not detected, HST controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KB] HST safety relay: Ground fault

SEN03942-01



40-340

9

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KY] HST safety relay: Hot short

SEN03942-01

Failure code [D1B0KY] HST safety relay: Hot short Action code

Failure code

E03

D1B0KY

Contents of trouble

Related information

HST safety relay: Hot short (HST controller system)

• Hot short was detected in HST safety relay circuit.


Trouble


• Traction force decreases. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA). Causes


1






Resistance


3 Defective HST controller

10




40-340


200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness HST (female) (17) – L111 (female) (2) and ground

Voltage

Max. 1 V

If causes 1 and 2 are not detected, HST controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D1B0KY] HST safety relay: Hot short

SEN03942-01



40-340

11

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection

SEN03942-01

Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection Action code

Failure code

E01

D5ZHL6

Contents of trouble

Trouble

IGN C system: Ground fault/Disconnection (Machine monitor system)

• Machine monitor detected disconnection or ground fault in C terminal system. (When engine speed is above 500 rpm and there is alternator R terminal voltage and starting switch is ON, there is not C terminal signal input.) a If engine speed above 250 rpm is sensed in 3 seconds after starting switch is turned ON, however, error is not detected.

Action of • None in particular. machine monitor • When starting switch is turned OFF after trouble is repaired, system is reset. Problem that appears on machine Related information

• Engine cannot be started (It may be able to be started, depending on faulty part). • Input state (ON/OFF) from starting switch C terminal to machine monitor be checked with monitoring function. (MONITOR PANEL – 40900 – D-IN-2) • Method of reproducing failure code: Turn starting switch to START position. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch to ON/ OFF/START position and carry out troubleshooting.

1

Defective starting switch (Internal defect)


Starting switch position

Voltage

START

20 – 30 V

OFF/ON

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness L02 (female) (3) – Ground fault in wiring harL79 (female) (3) and ground 3 ness (Contact with GND cirBetween wiring harness L79 (female) (6) – cuit) L106 (female) (3) and ground Between wiring harness L106 (female) (5) – L25 (female) (2) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to ON/ OFF/START position and carry out troubleshooting. 4 Defective machine monitor


40-340

12

Starting switch position

Voltage

START

20 – 30 V

OFF/ON

Max. 1 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection

SEN03942-01



40-340

13

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection

SEN03942-01

Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection Action code

Failure code

E01

DAF3KK

Contents of trouble

Trouble

UNSW power supply: Ground fault/Disconnection (Machine monitor system)

• When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power supply (power supply for memory) has ground fault.

Action of • None in particular. machine monitor Problem that appears on machine Related information

• Service meter time gains or loses. • Odometer does not advance. • Fault history data is not saved. • Method of reproducing failure code: Turn starting switch ON.

Causes



Ground fault in wiring har1 ness (Contact with GND cirBetween wiring harness battery relay R01 – cuit) L24 (female) (4), (5) and ground


40-340

14

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between L24 (female) (4), (5) – (9), (10), (17), (18), (19), (20)

Voltage

20 – 30 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection

SEN03942-01



40-340

15

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection

SEN03942-01

Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection Action code

Failure code

E03

DAFRKR

Contents of trouble

Trouble

Machine monitor CAN-NET Signal: Disconnection (HST controller system)

• HST controller cannot get information from machine monitor

• Turns the centralized warning lamp and alarm buzzer ON. Action of • Uses CAN information that was sent from machine monitor before the occurrence of the error. machine monitor • If problem is removed, system is returned to normal operating state. Problem that appears on machine Related information

• The monitor does not display normally


Causes


1



16

Resistance

Between (A) and (B)

110 – 140 z


Resistance

Between (A) and (B)

110 – 140 z



40-340

CAN1 (male)

Wiring harness between HST (female) (28), (38) – L80 (female) (7), (8)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between HST (female) (28), (38) – EC2 (female) (46), (47)

Resistance

Max. 1 z

Wiring harness between HST (female) (28), (38) – C140 (female) (28), (38)

Resistance

Max. 1 z

Wiring harness between HST (female) (28), (38) – CAN1 (female) (A), (B)

Resistance

Max. 1 z


Resistance

Max. 1 z



Causes

SEN03942-01



Wiring harness between HST (female) (28), (38) – L80 (female) (7), (8) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between HST (female) (28), (38) – CAN1 (female) (A), (B) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Grounding fault in wiring harWiring harness between HST (female) (28), 3 ness (Contact with ground (38) – EC2 (female) (46), (47) and ground circuit) Wiring harness between HST (female) (28), (38) – C140 (female) (28), (38) and ground

4

Defective power supply circuit of machine monitor



a Power supply circuit or grounding circuit may be defective. Confirm that there is no disconnection of the circuit or defective mating of the connector. a If above troubleshootings 1 – 4 have not identified the cause of the trouble, failure on the machine monitor, HST controller, engine controller or KOMTRAX terminal should be suspected. (Since trouble is in system, troubleshooting cannot be carried out.)

40-340

17

SEN03942-01



40-340

18




SEN03942-01

40-340

19

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ0KK] HST controller power supply: Low voltage

SEN03942-01

Failure code [DAJ0KK] HST controller power supply: Low voltage Action code

Failure code

E03

DAJ0KK

Contents of trouble

Trouble

HST controller power supply: Low voltage (HST controller system)

• Low voltage was detected in HST controller power supply. (While engine was running and alternator voltage was above 20 V, controller voltage was below 18 V.)

• Turns all outputs OFF. Action of • Trouble which may be detected wrongly is not detected. machine monitor • Turns the centralized warning lamp and alarm buzzer ON. Problem that appears on machine Related information

• Machine cannot travel (in either direction). • Another trouble may be detected. • If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset. • Method of reproducing failure code: Turn starting switch ON Causes 1 Defective (Broken) fuse

Standard value in normal state/Remarks on troubleshooting Check fuse FS1 (No. 3) directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (1) – 2 or defective contact in con- fuse FS1 (No. 3) nector) Wiring harness between HST (female) (11) – fuse FS1 (No. 3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective HST controller

40-340

20

HST

Voltage

Between (1), (11) – ground

20 – 30 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ0KK] HST controller power supply: Low voltage

SEN03942-01



40-340

21

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality

SEN03942-01

Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality Action code

Failure code

E01

DAJ0KT

Contents of trouble

Trouble

HST controller memory (EEPROM): Abnormality (HST controller system)

• Information in HST controller ROM (non-volatile memory) is abnormal.

Action of • Sets internal adjustment values to defaults. machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. Problem that appears on machine Related information

• Performance may lower. For example, shift-down feel from 3rd or 4th gear speed may become bad.

• Method of reproducing failure code: Turn starting switch ON.

Causes


40-340

22


Standard value in normal state/Remarks on troubleshooting • Carry out troubleshooting according to the following procedure. 1. Change set information of HST controller. (Example: Change HST selection to B.) 2. Turn starting switch OFF. 3. Wait for at least 30 seconds, then turn starting switch ON again. 4. At this time, check that set information is reflected. (Example: See if HST selection is kept at B and value is returned to default A.) Set information is not reflected (Value is returned to default): HST controller is defective. Set information is reflected (Value is not returned to default): HST controller is normal.


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality


SEN03942-01

40-340

23

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault

SEN03942-01

Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault Action code

Failure code

E01

DAJ1L4

Contents of trouble

Trouble

HST controller main power line: Disconnection/Ground fault (HST controller system)

• Low voltage was detected in HST controller main power line (battery relay drive voltage system).

Action of • Starts starting key OFF processing earlier. machine monitor Problem that appears on machine

• Machine is not affected in particular.

Related information Causes



40-340

24


Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 1 or defective contact in con- Wiring harness between HST (female) (13) – ResisMax. 1 z nector) D09 (female) (1), D10 (female) (1) tance

HST (female)

Voltage


20 – 30 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault

SEN03942-01



40-340

25

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ1L6] HST controller main power line: Hot short

SEN03942-01

Failure code [DAJ1L6] HST controller main power line: Hot short Action code

Failure code

E01

DAJ1L6

Contents of trouble Action of machine monitor Problem that appears on machine Related information

Trouble

HST controller main power line: Hot short (HST controller system)

• Hot short was detected in HST controller main power line (battery relay drive voltage system). • Continues key OFF processing on assumption that battery relay is turned OFF. (Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is turned OFF.) • Displays error next time when starting switch is turned ON. • Battery voltage may lower earlier.

• After error is detected, it is displayed next time when starting switch is turned ON.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.



Between wiring harness HST (female) (13) – D09 (female) (1), circuit branch end and ground

Voltage

Max. 1 V

Wiring harness between L02 (female) (2) – D10 (female) (2), circuit branch end and ground

Voltage

Max. 1 V

Wiring harness between E02 (female) (1) – D09 (female) (2), circuit branch end and ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON to OFF and carry out troubleshooting. 2 Defective HST controller

40-340

26

HST (female)

Voltage


Max. 1 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ1L6] HST controller main power line: Hot short

SEN03942-01



40-340

27

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage

SEN03942-01

Failure code [DAJ2KK] Controller solenoid power supply: Low voltage Action code

Failure code

E03

DAJ2KK

Contents of trouble

Trouble

Controller solenoid power supply: Low voltage (HST controller system)

• Low voltage was detected in controller solenoid power supply system. (While VIS power supply self-holding relay is ON and battery voltage is above 20 V, solenoid power supply voltage below 18 V was detected.)

Action of • Turns all outputs OFF. machine monitor Problem that appears on machine Related information

• Machine cannot travel. • Another failure may not be detected. • If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace VIS power supply holding relay (L102) with another relay.



Condition does not Relay (L102) is become normal. normal. Defective VIS power supply 1 holding relay (Internal defect) a Prepare with starting switch OFF, then check unit. When 24 V is applied between (1) – (2)


Between terminals of L102 (male) (3) – (5) When no voltage is applied between (1) – (2)

Resistance

Max. 1 z

Resistance

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (30) – ResisMax. 1 z nector) L102 (female) (3) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective HST controller

40-340

28

Wiring harness between L102 (female) (5) – fuse FS1 (No. 3)

Resistance

HST

Voltage


20 – 30 V

Max. 1 z


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage

SEN03942-01



40-340

29

SEN03942-01

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness

Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness Action code E01 Contents of trouble

Failure code DAJ2L3

Trouble

HST controller load power supply holding line: Hot short in wiring harness (HST controller system)

• Hot short was detected in HST controller load power supply holding line. (When output command was ON, output terminal voltage above 5.7 V was detected.)

Action of • Turns output OFF (Control protection function works). machine monitor Problem that appears on machine

• If starting switch is turned OFF without applying parking brake securely on slope, machine moves down suddenly. • If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.



Replace VIS power supply holding relay Defective VIS power supply (L102) with another 1 holding relay (Internal defect) relay.







Resistance

Between L102 (male) (1) – (2) Hot short (Contact with 5 V, 2 24 V circuit) in wiring harness

200 – 400 z


Voltage

Max. 1 V


40-340

30

HST

Voltage


Max. 1 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness

SEN03942-01



40-340

31

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault

SEN03942-01

Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault Action code

Failure code

E01 Contents of trouble

DAJ2L4

Trouble

HST controller load power supply holding line: Disconnection/ Ground fault (HST controller system)

• Disconnection or ground fault was detected in load power supply holding line during HST controller final check. (During final check, when output command was OFF, voltage below 5.7 V was detected.

Action of • Relay cannot be driven while there is disconnection. machine monitor Problem that appears on machine

• While there is disconnection, when starting switch is turned OFF, parking brake check cannot be controlled and machine moves down. • If starting switch is turned OFF while disconnection is made or fan is rotating in reverse, peak pressure may occur.


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and OFF, wait for 30 seconds, and turn it ON again and carry out troubleshooting.

1








Between L102 (male) (1) – (2) Possible causes and standard value in normal state

200 – 400 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (7) – 2 or defective contact in con- L102 (female) (2) nector) Wiring harness between L102 (female) (1) – fuse FS1 (No.3)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Contact with GND cirBetween wiring harness HST (female) (7) – Resiscuit) Min. 1 Mz L102 (female) (2) and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective HST controller

40-340

32

HST

Voltage


Max. 1 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault

SEN03942-01



40-340

33

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range

SEN03942-01

Failure code [DAJ5KX] Sensor 5V power supply: Out of output range Action code

Failure code

E03

DAJ5KX

Contents of trouble

Trouble

Sensor 5 V power supply: Out of output range (HST controller system)

• Sensor 5 V power supply of HST controller is below 4.7 V or above 5.3 V.

Action of • Turns the centralized warning lamp and alarm buzzer ON. machine monitor • Even if cause of failure disappears, system does not reset itself until engine is started again. Problem that appears on machine Related information

• If this trouble occurs during travel, travel speed may not increase or traction force may be insufficient. • Once machine stops, maximum travel speed is about 4 km/h. • If there is disconnection or ground fault, [DHH1KX], [DDD7KX] or [DF10KA] is displayed, too. • If there is hot short, [DHH1KY], [DDD7KY] or [DF10KB] is displayed, too. • If this failure occurs during travel, [DLT4KX] or [DLT3KX] may be displayed, too. Causes


Defective travel speed control dial, defective speed range selector switch, defec1 tive resistor, defective travel speed sensor, or defective HST pressure sensor


Disconnect devices at right in order. If failure code [DAJ5KX] lights up (reset is indicated) when a device is disconnected, that device has trouble in it.


L54

Speed range selector switch

L03

Resistor

L70

Travel speed sensor

T09

HST pressure sensor

T11


Ground fault in wiring har2 ness (Contact with GND cir- Between wiring harness HST (female) (22) – L54 (female) (A) or L70 (female) (2), (4) or cuit) T09 (female) (1) or T11 (female) (B) and ground


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between wiring harness HST (female) (22) – L54 (female) (A) or L70 (female) (2), (4) or T09 (female) (1) or T11 (female) (B) and ground

Voltage

Max. 1 V


40-340

34

HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range

SEN03942-01



40-340

35

340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals

SEN03942-01

Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals Action code

Failure code

E03

DAJ9KQ

Contents of trouble

Trouble

HST controller model selection: Disagreement of model selection signals (Machine monitor system)

• The HST controller model is mistaken for another one.

• Action of machine monitor • •

Operates on the assumption that the controller model which has been used before occurrence of the failure code is still used. Turns the centralized warning lamp and alarm buzzer ON. Does not display failure codes which may be false detected.


• After HST controller or machine monitor is replaced, if model is not selected, this failure code is displayed. • Continuing the travel in this condition may damage the HST.

Related information

• If the model selection is not done correctly after the HST controller or machine monitor is replaced, this code is displayed. • Method of reproducing failure code: Turn the starting switch ON. Causes


40-340

36


1

Improper machine monitor model selection

Set the model using the adjustment function of the service mode of the machine monitor (See Special functions of machine monitor (EMMS) in Testing and adjusting)

2

HST controller part number error

Confirm the part number of the HST controller. It must be replaced if it is not the specified controller.


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

SEN03942-01

Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection Action code

Failure code

E03

DAJRKR

Contents of trouble

Trouble

HST controller CAN-NET signal: Disconnection (Machine monitor system)

• Machine monitor cannot get information from HST controller

• Uses CAN information that was sent from HST controller before the occurrence of the error. Action of • Turns the centralized warning lamp and alarm buzzer ON. machine monitor • If problem is removed, system is returned to normal operating state. Problem that appears on machine Related information

• The monitor does not display normally • If HST controller power supply circuit is defective, machine cannot travel in either direction. • Method of reproducing failure code: Turn the starting switch ON.

Causes


1


CAN1 (male)

Resistance

Between (A) and (B)

110 – 140 z


Resistance

Between (A) and (B)

110 – 140 z


Possible causes and standard value in normal state Disconnection in wiring harness 2 (Disconnection or defective contact in connector)



Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between HST (female) (28), (38) – EC2 (female) (46), (47)

Resistance

Max. 1 z

Wiring harness between HST (female) (28), (38) – C140 (female) (28), (38)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

40-340

37


SEN03942-01

Causes



40-340

38


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Grounding fault in wiring harWiring harness between HST (female) (28), 3 ness (38) – EC2 (female) (46), (47) and ground (Contact with ground circuit) Wiring harness between HST (female) (28), (38) – C140 (female) (28), (38) and ground


a Carry out troubleshooting in "When HST controller power supply circuit is defective" described later.


a If above troubleshootings 1 – 4 have not identified the cause of the trouble, failure on the machine monitor, HST controller, engine controller or KOMTRAX terminal should be suspected. (Since trouble is in system, troubleshooting cannot be carried out.)



SEN03942-01



40-340

39


SEN03942-01

When HST controller power supply circuit is defective Causes a

Broken fuse box FS1 fuse No. 3

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault etc. (See cause c.)

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring b or defective contact in con- Wiring harness between fuse box FS1 fuse ResisMax. 1 z nector) No. 3 – HST (female) (1) (11). tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness fuse box FS1 fuse No. 3 – HST (female) (1) (11), branch end and ground

Resistance

Min. 1 Mz

Between wiring harness L102 (female) (3) – branch end and ground

Resistance

Min. 1 Mz

Between wiring harness L101 (female) (2) – D07 (female) (1), T07 (3) and ground

Resistance

Min. 1 Mz

Between wiring harness L103 (female) (5) – D08 (female) (1), T07 (1) and ground Ground fault in wiring harc ness (Contact with GND cir- Between wiring harness L104 (female) (5) – cuit) R59 (female) (1) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Between wiring harness L63 (female) (5), (1) – HST (female) (25) and ground

Resistance

Min. 1 Mz

Between wiring harness L15 (female) (3), D01 (female) (5) – HST (female) (5) and ground

Resistance

Min. 1 Mz

Between wiring harness L15 (female) (2) – HST (female) (34) and ground

Resistance

Min. 1 Mz

Between wiring harness L15 (female) (4) – L126 (female) (1), HST (female) (15) and ground

Resistance

Min. 1 Mz


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L101 (male)

Resistance

Between (5) – (6)

200 – 400 z

a Prepare with starting switch OFF. a Test relay unit. Defective directional presd sure selector relay (L101) (Internal short circuit)

Directional pressure selector relay (L101)

Between (3) – (5)

(1) – (2)

Resistance

When 24 V is applied (relay is "ON")

Max. 1 z

Other than above (relay is "OFF")

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Replace directional pressure selector relay (L101) with another relay. If condition becomes normal, directional pressure selector relay is defective.

40-340

40



Causes

SEN03942-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L126 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF. a Test relay unit. Defective backup alarm/lamp e relay (L126) (Internal short circuit)

Backup alarm/lamp relay (L126)

Between (3) – (5)

(1) – (2)

Resistance


Max. 1 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Possible causes and standard value in normal state

Replace backup alarm/lamp relay (L126) with another relay. If condition becomes normal, backup alarm/lamp relay is defective.

f

a Prepare with starting switch OFF, then carry out troubleshooting Defective directional preswithout turning starting switch ON. sure selector solenoid (InterResisnal short circuit) Between T07 (male) (3) – T07 (male) (4) 20 – 30 z tance

Defective motor 2 solenoid g (Internal short circuit)

Defective fan reverse soleh noid (Internal short circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between T07 (male) (1) – T07 (male) (2)

Resistance

20 – 30 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between R59 (male) (1) – R59 (male) (2)

Resistance

35 – 45 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. i

Defective HST controller


HST

Voltage


20 – 30 V

40-340

41

SEN03942-01


Related circuit diagram (When HST controller power supply circuit is defective)

40-340

42


340 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAJRMA] HST controller: Disagreement in option selection

SEN03942-01

Failure code [DAJRMA] HST controller: Disagreement in option selection Action code

Failure code

E03

DAJRMA

Contents of trouble

Trouble

HST controller: Disagreement in option selection (Machine monitor system)

• Disagreement between the option setting done by the machine monitor and the option recognition by done the HST controller.

Action of • The HST controller follows the option setting being recognized by itself. machine monitor • Turns the centralized warning lamp and alarm buzzer ON. Problem that appears on machine

• After HST controller or machine monitor is replaced, if option is not set, this failure code is displayed. • The option setting does not work normally.

Related information

• If the option setting is not done correctly after the HST controller or machine monitor is replaced, this code is displayed. • Method of reproducing failure code: Turn the starting switch ON. Causes



1 Defective option setting

Set the option setting using the option select function of the machine monitor (See Special functions of machine monitor (EMMS) in Testing and adjusting)


The machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


The HST controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


40-340

43

SEN03942-01



40-340

44

SEN03943-01




40 Troubleshooting

40

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line......................................... 2 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................... 8 Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short........................................ 12 Failure code [DDB6KB] Parking brake indicator signal: Ground fault........................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble................................................................................................................... 16 Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22 Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 24 Failure code [DDE5MA] Emergency steering operation switch: Disconnection............................................ 26 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short .............................................. 28 Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................ 30 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 32 Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 36 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ............................... 38


40-350

1

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line

SEN03943-01

Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line Action code

Failure code

E03

DB2RKR

Contents of trouble



Trouble

Engine controller CAN-NET: Disconnection in signal line (HST controller system)

• Communication via CAN signal line between the HST controller and engine controller is defective. • • • • •

Uses CAN information that was sent from engine controller before the occurrence of the error. Once engine stops, recognized engine speed is fixed to low idle. Once engine stops, recognized operating degree of accelerator is fixed to 0%. Turns the centralized warning lamp and alarm buzzer ON. If problem is removed, system is returned to normal operating state.

• The monitor does not display normally • If engine controller power supply circuit is defective, engine stops. • Method of reproducing failure code: Turn the starting switch ON.

Causes


1



2

Resistance

Between (A) – (B)

110 – 140 z


Resistance

Between (A) – (B)

110 – 140 z



40-350

CAN1 (male)

Wiring harness between EC2 (female) (46), (47) – HST (female) (28), (38)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between EC2 (female) (46), (47) – C140 (female) (28), (38)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z



Causes

SEN03943-01



Wiring harness between EC2 (female) (46), (47) – HST (female) (28), (38) and ground

Resistance

Min. 1 Mz

Wiring harness between EC2 (female) (46), (47) – L80 (female) (7), (8) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Grounding fault in wiring harWiring harness between EC2 (female) (46), 3 ness (47) – L29 (female) (3), (8) and ground (Contact with ground circuit) Wiring harness between EC2 (female) (46), (47) – C140 (female) (28), (38) and ground

4

Defective power supply circuit of engine controller



• Carry out troubleshooting for "When engine controller power supply is defective" described later. a If above troubleshootings 1 – 4 have not identified the cause of the trouble, failure on the machine monitor, HST controller, engine controller or KOMTRAX terminal should be suspected. (Since trouble is in system, troubleshooting cannot be carried out.)

40-350

3

SEN03943-01



40-350

4




SEN03943-01

40-350

5


SEN03943-01

When engine controller power supply circuit is defective Causes a

Defective fuse No. 4 in fuse box FS1 or No. 15 in FS2

Standard value in normal state/Remarks on troubleshooting If fuse box is damaged, circuit probably has ground fault etc. (See cause c.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse box FS1, No. 4 fuse – L107 (female) (3), L108 (female) (3)

Resistance

Max. 1 z


Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between L107 (female) (2), L108 (female) (2) – EC2 (female) (33)

Resistance

Max. 1 z

Wiring harness between L02 (female) (4) – EC2 (female) (39)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between EC3 (female) (1), b or defective contact in con- (2) – ground nector) Wiring harness between L02 (female) (2) – L107 (female) (1), L108 (female) (1)



Between wiring harness fuse box FS1, No. 4 fuse – L107 (female) (3), L108 (female) (3) and ground

Resistance

Min. 1 Mz

Ground fault in wiring harBetween wiring harness L107 (female) (5), c ness (Contact with GND cir- L108 (female) (5) – EC3 (female) (3), (4) and cuit) ground

Resistance

Min. 1 Mz

Between wiring harness L02 (female) (2) – L107 (female) (1), L108 (female) (1) and ground

Resistance

Min. 1 Mz

Between wiring harness L02 (female) (4) – EC2 (female) (39) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L107, L108 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF. a Check relay unit. Defective engine controller d cut relay (L107, L108) (Internal defect)

Engine controller cut relay (L107, L108)

Between (3) – (5)

(1) – (2)

Resistance


Max. 1 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Replace engine controller cut relay (L107, L108) with another relay. If condition becomes normal, engine controller cut relay is defective.

40-350

6



Causes

SEN03943-01



e Defective engine controller

EC2

Voltage


Max. 1 V


20 – 30 V

EC3

Voltage


20 – 30 V


Max. 1 V

Related circuit diagram (When engine controller power supply circuit is defective)


40-350

7

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality

SEN03943-01

Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality Action code

Failure code

E01

DD1NL4


Trouble

Fan automatic reverse switch signal: Abnormality (HST controller system)

• Because of hot short in fan automatic reverse switch system, fan automatic reverse switch input and fan manual reverse switch input were sensed simultaneously. • Turns automatic reverse switch function OFF. • After error is detected, fan does not reverse. • Automatic reverse switch LED lamp keeps lighting. • Input state from fan automatic reverse switch can be checked with monitoring function (Code: HST – 93400 – FAN REVERSE SW) (Code: MONITOR PANEL – 40901 – D-IN-9). • Method of reproducing failure code: Turn starting switch ON and fan manual reverse switch ON. Causes


Defective fan automatic 1 reverse switch (Internal short circuit)

L69 (male) Between (3), (4) – (5)


2

Hot short in wiring harness (Contact with 5 V, 24 V circuit)

Fan automatic reverse switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Carry out troubleshooting with automatic reverse switch OFF) Wiring harness between L25 (female) (14) – L69 (female) (3), (4) and ground

Voltage

Max. 1 V


L25 (male) Between (14) and ground

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8

Fan automatic reverse switch

Voltage

ON

20 – 30 V

OFF

Max. 1 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality

SEN03943-01



40-350

9

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DD1NLD] Fan reverse switch signal: Abnormality

SEN03943-01

Failure code [DD1NLD] Fan reverse switch signal: Abnormality Action code

Failure code

E01

DD1NLD


Trouble

Fan reverse switch signal: Abnormality (HST controller system)

• Since the fan manual reverse switch system is shorted with the power source, the fan manual reverse switch remains at ON position. (Continuation for 30 seconds determines fault) • None in particular.

• Fan remains in the reverse rotation. • The input state (ON/OFF) from the fan manual reverse switch can be checked with the monitoring function (Code: HST – 93400 – FAN REVERSE SW). (Code: MONITOR PANEL – 40900 – D-IN-1). • Method of reproducing failure code: Turn the starting switch ON. Causes


1

Defective fan reverse switch (Internal short circuit)

L69 (male) Between (5) – (1), (16)


Fan manual reverse switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 5 V, 24V circuit) Wiring harness between L25 (female) (10) – Voltage Max. 1 V L69 (female) (1), (6) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor

L25 (male) Between (10) and ground

40-350

10

Fan manual reverse switch

Voltage

ON

20 – 30 V

OFF

Max. 1 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DD1NLD] Fan reverse switch signal: Abnormality

SEN03943-01



40-350

11

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short

SEN03943-01

Failure code [DDB6KA] Parking brake reminder signal: Disconnection/ Hot short Action code

Failure code

E01

DDB6KA


Related information

Trouble

Parking brake reminder signal: Disconnection/Hot short (HST controller system)

• HST controller detected disagreement with parking brake reminder signal from machine monitor. (While parking brake reminder signal of machine monitor was input (closed), there was not parking brake reminder signal of HST controller (open). • While there was not input signal (open), signal was input to parking brake indicator signal (closed). • None in particular. • If starting switch is turned OFF without applying parking brake securely on slope, machine moves down suddenly. • Operation of parking brake can be checked with monitoring function. [Parking brake reminder signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35) [Parking brake indicator signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-26 and 40904 – D-IN-36) [Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition) (Monitoring code: HST – 99100 – PARKING A/B) Causes

1

Defective diode (Internal defect)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (See Testing and adjusting, “Test procedure for diode”.) Between D02 (male) (6) – (2)

Continuity is secured

Between D03 (male) (5) – (1)


Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (6) – ResisMax. 1 z nector) L53 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (Test with parking brake applied.)


Ground fault in wiring har3 ness (Contact with GND cir- Between wiring harness HST (female) (16) – cuit) D02 (female) (5) and ground Between wiring harness L27 (female) (2), (14) – D02 (female) (8) and ground

4

Hot short (Contact with 5 V, 24V circuit) in wiring harness



40-350

12

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with parking brake released.) Between wiring harness HST (female) (6) – D02 (female) (6) and ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. (Test with parking brake applied.) HST

Voltage


Max. 1 V

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. (Test with parking brake applied.) L27

Voltage

Between (2) (14) – ground

20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short

SEN03943-01



40-350

13

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KB] Parking brake indicator signal: Ground fault

SEN03943-01

Failure code [DDB6KB] Parking brake indicator signal: Ground fault Action code

Failure code

E01

DDB6KB


Related information

Trouble

Parking brake indicator signal: Ground fault (HST controller system)

• While parking brake indicator signal of machine monitor was not input (open), there was input signal (switch B was closed). • None in particular. • Since machine can travel forward and reverse while parking brake is applied, parking brake may be damaged (Alarm buzzer sounds in this case, however). • Operation of parking brake can be checked with monitoring function. [Parking brake reminder signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35) [Parking brake indicator signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-26 and 40904 – D-IN-36) [Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition) (Monitoring code: HST – 99100 – PARKING A/B) Causes Defective diode 1 (Internal defect)



Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between L27 (female) (1), (6) ResisMax. 1 z nector) – L47 (female) (2) tance Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har(Test with parking brake applied.) 3 ness (Contact with GND circuit) Between wiring harness HST (female) (16) – ResisMin. D02 (female) (5) and ground tance 1 Mz



40-350

14

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. (Test with parking brake applied.) HST

Voltage


20 – 30 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with parking brake released.) L27

Voltage


Max. 1 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KB] Parking brake indicator signal: Ground fault

SEN03943-01



40-350

15

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble

SEN03943-01

Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble Action code

Failure code

E03

DDB6KZ

Contents of trouble

Trouble

Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble (Machine monitor system)

• Parking brake indicator signal was closed and opening of parking brake reminder signal was detected.

Action of • Turns the centralized warning lamp and alarm buzzer ON. machine monitor • Turns parking brake indicator and parking brake remind caution lamp ON. Problem that appears on machine Related information

• While parking brake is in intermediate position, parking brake reminder caution lamp does not light. • While parking brake is in intermediate position, parking brake reminder buzzer does not sound. • While parking brake is in intermediate position, centralized warning lamp does not light. • Input state (ON/OFF) of parking brake indicator signal and reminder signal can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40903 – D-IN-26, 28) (Monitoring code: MONITOR PANEL – 40904 – D-IN-35, 36) Causes

1





Between D03 (male) (5) – (1)


a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness (Disconnection in wiring (Test with parking brake released.) 2 or defective contact in conWiring harness between L27 (female) (2), Resisnector) Max. 1 z (14) – L53 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har(Test with parking brake applied.) 3 ness (Contact with GND circuit) Between wiring harness L27 (female) (1), (6) ResisMin. – D02 (female) (7) and ground tance 1 Mz 4 Defective machine monitor

40-350

16

If causes 1 – 3 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble

SEN03943-01



40-350

17

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6L0] Parking brake reminder signal: Ground fault

SEN03943-01

Failure code [DDB6L0] Parking brake reminder signal: Ground fault Action code

Failure code

E01

DDB6L0

Contents of trouble

Trouble

Parking brake reminder signal: Ground fault (HST controller system)

• While parking brake reminder signal operation signal of machine monitor was not input (open), parking brake reminder signal operation signal of HST controller was input (closed).


• When engine is stopped while parking brake is not applied securely, move-down prevention is not controlled.


• If starting switch is turned OFF without applying parking brake securely on slope, machine moves down suddenly.

Related information

• Operation of parking brake can be checked with monitoring function. [Parking brake reminder signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35) [Parking brake indicator signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-26 and 40904 – D-IN-36) [Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition) (Monitoring code: HST – 99100 – PARKING A/B) Causes Defective diode 1 (Internal defect)



a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness (Disconnection in wiring (Test with parking brake released.) 2 or defective contact in conWiring harness between L27 (female) (2), Resisnector) Max. 1 z (14) – L53 (female) (2) tance Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har(Test with parking brake applied.) 3 ness (Contact with GND circuit) Between wiring harness HST (female) (6) – ResisMin. D02 (female) (6) and ground tance 1 Mz



40-350

18

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with parking brake applied.) HST

Voltage


20 – 30 V


Voltage


Max. 1 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6L0] Parking brake reminder signal: Ground fault

SEN03943-01



40-350

19

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short

SEN03943-01

Failure code [DDB6L4] Parking brake indicator signal: Disconnection/ Hot short Action code

Failure code

E03

DDB6L4



Related information

Trouble

Parking brake indicator signal: Disconnection/Hot short (HST controller system)

• HST controller detected disagreement with parking brake indicator signal from machine monitor. (While signal was input to machine monitor (closed), signal was not input to HST controller (open). • • • •

Turns the centralized warning lamp and alarm buzzer ON. Stops neutralizer (parking brake drag prevention function). If error is detected during forward or reverse travel, gear is set in neutral. Once FNR selector lever or switch is set to N, normal control is started again.

• If error is detected while FNR selector lever or switch is in F or R, machine cannot start until gear is returned to neutral. • Since machine can travel forward and reverse while parking brake is applied, parking brake may be damaged (Caution buzzer sounds in this case, however). • Operation of parking brake can be checked with monitoring function. [Parking brake reminder signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35) [Parking brake indicator signal] (Recognition by machine monitor) (Monitoring code: MONITOR PANEL – 40903 – D-IN-26 and 40904 – D-IN-36) [Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition) (Monitoring code: HST – 99100 – PARKING A/B) Causes

1




Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (16) – ResisMax. 1 z nector) L47 (female) (2) tance


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har(Test with parking brake applied.) 3 ness (Contact with GND circuit) Between wiring harness L27 (female) (1), (6) ResisMin. – D02 (female) (7) and ground tance 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 V, 4 24V circuit) in wiring harness Between wiring harness HST (female) (16) – Voltage Max. 1 V D02 (female) (5) and ground



40-350

20

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with parking brake released.) HST

Voltage


Max. 1 V


Voltage


20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short

SEN03943-01



40-350

21

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault

SEN03943-01

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault Action code

Failure code

E01

DDD7KX


Trouble

Travel speed control dial signal: Disconnection/Ground fault (HST controller system)

• Travel speed control dial signal voltage lowered below 0.3 V. • Continue controls on assumption that travel speed control dial is set to minimum speed side. • Even if trouble disappears, system does not reset itself until starting switch is turned OFF.


• Travel speed cannot be adjusted with travel speed control dial. • If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.

Related information

• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.

Causes


Defective travel speed con1 trol dial (Internal defect)

Between L54 (female) (1) – (3)

Voltage

4.7 – 5.3 V

Between L54 (female) (2) – (3) (Max. speed side of dial)

Voltage

0.3 – 0.9 V

Between L54 (female) (2) – (3) (Min. speed side of dial)

Voltage

4.1 – 4.7 V



Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (23) – 2 or defective contact in con- L54 (female) (2) nector) Wiring harness between HST (female) (22) – L54 (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Contact with GND cirBetween wiring harness HST (female) (23) – ResisMin. cuit) L54 (female) (2) and ground tance 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-350

22

HST (female)

Resistance


Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HST (female)

Voltage


4.7 – 5.3 V


0.3 – 4.7 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault

SEN03943-01



40-350

23

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDD7KY] Travel speed control dial signal: Hot short

SEN03943-01

Failure code [DDD7KY] Travel speed control dial signal: Hot short Action code

Failure code

E01

DDD7KY


Trouble

Travel speed control dial signal: Hot short (HST controller system)

• Travel speed control dial signal voltage exceeded 4.7 V. • None in particular.


• Travel speed cannot be adjusted with travel speed control dial. • If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.

Related information

• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.

Causes


1


Defective travel speed control dial (Internal defect)


Voltage

4.7 – 5.3 V

Between L54 (female) (2) – (3) (Max. speed side of dial)

Voltage

0.3 – 0.9 V

Between L54 (female) (2) – (3) (Min. speed side of dial)

Voltage

4.1 – 4.7 V

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (32) – ResisMax. 1 z nector) L54 (female) (3) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with5 V, 3 24V circuit) in wiring harness Between wiring harness HST (female) (23) – Voltage Max. 1 V L54 (female) (2) and ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-350

24

HST (female)

Resistance


Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HST (female)

Voltage


4.7 – 5.3 V


0.3 – 4.7 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDD7KY] Travel speed control dial signal: Hot short

SEN03943-01



40-350

25

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDE5MA] Emergency steering operation switch: Disconnection

SEN03943-01

Failure code [DDE5MA] Emergency steering operation switch: Disconnection Action code

Failure code

E01

DDE5MA

Contents of trouble

Trouble

Emergency steering operation switch: Disconnection (Machine monitor system)

• While engine was stopped, steering pump oil pressure was sensed because of disconnection in steering oil pressure reduction switch (emergency steering operation switch) system.

Action of • None in particular. machine monitor Problem that appears on machine

Related information

• When steering oil pressure reduces, steering oil pressure caution lamp does not light. • This code is applied to only emergency steering specification model and is not turned ON if not selected as option with machine monitor. • Input state (ON/OFF) from steering oil pressure reduction switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40904 – D-IN-39) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and start engine and carry out troubleshooting in each case. F11 (male)

Defective steering oil pres1 sure reduction switch (Internal defect)

Between (1) – (2)

Between (1), (2) – ground Possible causes and standard value in normal state


Resistance

Oil pressure reduction (Engine is stopped)

Max. 1 z

Oil pressure normal (Engine is running)

Min. 1 Mz

Normally

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between L27 (female) (16) – 2 or defective contact in con- F11 (female) (1) nector) Between F11 (female) (2) – ground

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and start engine and carry out troubleshooting in each case. L27 3 Defective machine monitor Between (16) – ground

40-350

26


Voltage

Oil pressure reduction (Engine is stopped)

Max. 1 V

Oil pressure normal (Engine is running)

20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDE5MA] Emergency steering operation switch: Disconnection

SEN03943-01



40-350

27

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short

SEN03943-01

Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short Action code

Failure code

E03

DDK3KA


Trouble

Directional selector switch: Disconnection/Hot short (HST controller system)

• Since the directional selector switch input signal system is disconnected or not shorted, the directional selector switch signal is not recognized. • Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the directional selector switch is set to N (Neutral). • Machine travel with the right directional selector switch becomes unavailable. • Travel with FNR (directional) lever is available. • Shift lever position pilot lamp goes off. • Only for directional selector switch (if equipped) • Method of reproducing failure code: Turn the starting switch ON, turn the directional selector switch ON/OFF switch ON, then operate the FNR (directional) switch. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. MF1 (male)

Defective directional selector switch 1 (Internal disconnection or short circuit)

Between (1) – (2) Between (1) – (3) Between (1) – (4) Between (1), (2), (3), (4) and ground

Directional selector switch

Resistance

F (Forward)

Max. 1 z

Other than above

Min. 1 Mz

N (Neutral)

Max. 1 z

Other than above

Min. 1 Mz

R (Reverse)

Max. 1 z

Other than above

Min. 1 Mz

Constant

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between HST (female) (4) – MF1 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between MF1 (female) (1) – ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with turning on the directional selector ON/OFF switch) HST 3 Defective HST controller

Between (4) and ground Between (14) and ground Between (24) and ground

40-350

28


Voltage

F (Forward)

Max. 1 V

Other than above

20 – 30 V

N (Neutral)

Max. 1 V

Other than above

20 – 30 V

R (Reverse)

Max. 1 V

Other than above

20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short

SEN03943-01



40-350

29

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK3KB] Directional selector switch: Ground fault

SEN03943-01

Failure code [DDK3KB] Directional selector switch: Ground fault Action code

Failure code

E03

DDK3KB

Trouble

Directional selector switch: Ground fault (HST controller system)

Contents of trouble

• Since the directional selector switch input signal system has a ground fault, the directional selector switch signal is not recognized.


• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the directional selector switch is set to N (Neutral).


• Machine travel with the directional selector switch becomes unavailable. • Travel with FNR (directional) lever is available. • Shift lever position pilot lamp goes off. • Only for right FNR (directional) switch (if equipped) • Method of reproducing failure code: Turn the starting switch ON, turn the directional selector switch ON/OFF switch ON, then operate the directional selector switch. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. MF1 (male)

Defective directional selector switch 1 (Internal disconnection or short circuit)

Between (1) – (2) Between (1) – (3) Between (1) – (4) Between (1), (2), (3), (4) and ground


Resistance

F (Forward)

Max. 1 z

Other than above

Min. 1 Mz

N (Neutral)

Max. 1 z

Other than above

Min. 1 Mz

R (Reverse)

Max. 1 z

Other than above

Min. 1 Mz

Constant

Min. 1 Mz


Wiring harness between HST (female) (4) – MF1 (female) (2), L68 (female) (2) and Grounding fault in wiring har- ground 2 ness (Contact with ground circuit) Wiring harness between HST (female) (14) – MF1 (female) (3), D01 (female) (2) and ground Wiring harness between HST (female) (24) – MF1 (female) (4) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Test with turning on the directional selector ON/OFF switch) HST 3 Defective HST controller


40-350

30


Voltage

F (Forward)

Max. 1 V

Other than above

20 – 30 V

N (Neutral)

Max. 1 V

Other than above

20 – 30 V

R (Reverse)

Max. 1 V

Other than above

20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK3KB] Directional selector switch: Ground fault

SEN03943-01



40-350

31

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault

SEN03943-01

Failure code [DDK6KA] FNR lever: Disconnection/Ground fault Action code

Failure code

E03

DDK6KA

Trouble

FNR lever: Disconnection/Ground fault (HST controller system)

Contents of trouble

• No signal of FNR (directional) lever is input because of disconnection or ground fault in FNR (directional) lever switch signal system.


• If directional selector switch is not installed, gear is set in neutral. • If directional selector switch actuation switch is turned OFF, gear is set in neutral (Only machine with directional selector switch actuation switch). • If directional selector switch actuation switch is turned ON, FNR (directional) lever switch controls on assumption that gear is in neutral (Only machine with directional selector switch actuation switch). • Turns the centralized warning lamp and alarm buzzer ON. • Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neutral).


• Machine cannot be driven with FNR (directional) lever. • Machine can be driven with directional selector switch (only machine with directional selector switch actuation switch). • Gear shift lever position lamp goes off.

Related information

• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2). • Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever Causes 1

Defective fuse No. 3 of fuse box (FS1)

Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective FNR (directional) 2 lever switch (Internal disconnection or short circuit) Possible causes and standard value in normal state

L15

FNR (directional) lever

Voltage


Constant

20 – 30 V

N (Neutral)

20 – 30 V


Other than above

Max. 1 V

F (Forward)

20 – 30 V

Other than above

Max. 1 V

R (Reverse)

20 – 30 V

Other than above

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace VIS power supply holding relay Defective VIS power supply (L102) with another 3 holding relay (Internal defect) relay

Condition becomes normal

Relay (L102) is defective

Condition does not become normal



40-350

32

Resistance

200 – 400 z



Causes

SEN03943-01



Wiring harness between fuse No. 3 of fuse box (FS1) – L102 (female) (5) and ground

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 3 of fuse box (FS1) – L102 (female) (5) and ground Possible causes and standard value in normal state

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between HST (female) (5) – L15 (female) (3), D01 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between HST (female) (34) – L15 (female) (2) and ground

Resistance

Min. 1 Mz

Wiring harness between L102 (female) (3) – L15 (female) (1), circuit branch end and Grounding fault in wiring har- ground 5 ness Wiring harness between HST (female) (15) – (Contact with ground circuit) L15 (female) (4), L126 (female) (13) and ground

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HST





Voltage

N (Neutral)

20 – 30 V

Other than above

Max. 1 V

F (Forward)

20 – 30 V

Other than above

Max. 1 V

R (Reverse)

20 – 30 V

Other than above

Max. 1 V

40-350

33

SEN03943-01



40-350

34




SEN03943-01

40-350

35

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK6KY] FNR lever: Hot short

SEN03943-01

Failure code [DDK6KY] FNR lever: Hot short Action code

Failure code

E03

DDK6KY

Contents of trouble

Trouble

FNR lever: Hot short (HST controller system)

• Multiple FNR (directional) lever signals are input because of hot short in FNR (directional) lever switch signal system.


• Sets gear in neutral. • Turns the centralized warning lamp and alarm buzzer ON. • If directional selector switch actuation switch is turned ON, machine is driven according to directional selector switch setting (only machine with directional selector switch actuation switch). • Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neutral).


• Operator cannot travel machine at position other than position having hot short with FNR (directional) lever switch. (Example: When directional lever F system has hot short, if lever is set in F, trouble is reset and machine can travel forward.) • Multiple gear shift lever position lamp lights. • Machine can be driven with directional selector switch (only machine with directional selector switch).

Related information

• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2). • Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever Causes


Defective FNR (directional) 1 lever switch (Internal short circuit)


L15


Voltage


Constant

20 – 30 V


F (Forward)

20 – 30 V

Other than above

Max. 1 V


N (Neutral)

20 – 30 V

Other than above

Max. 1 V


R (Reverse)

20 – 30 V

Other than above

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hot short in wiring harness 2 (Contact with 5 V, 24V circuit)


Voltage

Max. 1 V


Voltage

Max. 1 V


Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HST


36

Voltage


N (Neutral)

20 – 30 V

Other than above

Max. 1 V


F (Forward)

20 – 30 V

Other than above

Max. 1 V

R (Reverse)

20 – 30 V

Other than above

Max. 1 V


40-350



350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDK6KY] FNR lever: Hot short

SEN03943-01



40-350

37

350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)

SEN03943-01

Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) Action code

Failure code

E03

DDS5L6

Contents of trouble

Trouble

Steering: Low oil pressure (Operation of emergency steering) (Machine monitor system)

• While engine was running, steering oil pressure sensor signal was “closed”.

Action of • Turns the centralized warning lamp and alarm buzzer ON. machine monitor • Turns steering oil pressure warning lamp ON. Problem that appears on machine Related information

• Steering system does not work except when HST circuit oil pressure is high during travel etc.

• This code is applied to only machine with emergency steering (optional).

Causes 1 Low steering oil pressure

Standard value in normal state/Remarks on troubleshooting System is normal. a Carry out troubleshooting for hydraulic and mechanical systems. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F11 (male)

Defective steering oil pres2 sure sensor (switch) (Internal defect) Between (1) – (2) Possible causes and standard value in normal state


Resistance

When oil pressure is low (While engine is stopped)

Max. 1 z

When oil pressure is normal (While engine is running)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Contact with GND cirBetween wiring harness L27 (female) (16) – ResisMin. cuit) F11 (female) (1) and ground tance 1 Mz a Prepare with starting switch OFF, then start engine and carry out troubleshooting. L27 4 Defective machine monitor Between (16) – ground

40-350

38


Voltage

When oil pressure is abnormal (low) (below 0.5 MPa {5.1 kg/cm2})

Max. 1 V

When oil pressure is normal (above 0.9 MPa {9.2 kg/cm2})

20 – 30 V


350 Troubleshooting by failure code (Display of code), Part 5 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)

SEN03943-01



40-350

39

SEN03943-01



40-350

40

SEN03944-01




40 Troubleshooting

40

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.............................. 2 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 8 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................. 9 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ......................................... 10 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault............................................ 12 Failure code [DHH1KY] HST oil pressure sensor: Hot short ........................................................................ 14 Failure code [DHTCL6] HST filter clogging sensor: Functional defect.......................................................... 16 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short ............................................................. 18 Failure code [DLT3KX] Travel speed sensor B: Abnormality ........................................................................ 20 Failure code [DLT4KX] Travel speed sensor A: Abnormality ........................................................................ 24 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality ................................................................. 26 Failure code [DV00KY] Alarm buzzer: Hot short........................................................................................... 28 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ....................................................... 30 Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................................... 32 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short .................................................................. 34 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault...................................... 36


40-360

1

SEN03944-01

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault

Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault Action code

Failure code

E01

DF10KA


Trouble

Travel speed range selector switch: Disconnection/Ground fault (HST controller system)

• Travel speed range selector switch signal is not input because of disconnection or ground fault in travel speed range selector switch input signal system. • Fixes gear to speed range before error occurrence. • If trouble disappears, system resets itself. • Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of selected speed range. • Gear is not set in selected speed range. • Indicator displays range before error occurrence. (Once starting switch is turned OFF, 4th gear is displayed) • Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L03 (female) Between (1) – (2)

Switch position

Resistance

2nd

Max. 1 z

Other than above

Min. 1 Mz

Between (1) – (3) Defective travel speed range 1 selector switch (Internal defect)

Min. 1 Mz Min. 1 Mz

3rd

Max. 1 z

4th

Max. 1 z

4th

Max. 1 z

Other than above

Min. 1 Mz

Between (2) – (3)

– (Anytime)

Min. 1 Mz

Between (2) – (4)

– (Anytime)

Min. 1 Mz

Between (1) – (4)


1st 2nd

Between (3) – (4)

1st

Max. 1 z

2nd

Min. 1 Mz

3rd

Min. 1 Mz

4th

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective travel speed range 2 selector resistor (Internal defect)

40-360

2

L70 (male)

Resistance

Between (1) – (5)

100 z ± 1%

Between (2) – (6)

220 z ± 1%

Between (3) – (7)

330 z ± 1%

Between (4) – (8)

470 z ± 1%



Causes

SEN03944-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between HST (female) (32) – L70 (female) (7)

Resistance

Max. 1 z

Wiring harness between HST (female) (39) – L03 (female) (3), L70 (female) (5), (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between HST (female) (22) – L70 (female) (2) (4)

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between L03 (female) (1) – 3 or defective contact in con- L70 (female) (6) nector) Wiring harness between L03 (female) (2) – L70 (female) (1)


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness HST (female) (32) – L70 (female) (7) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Between wiring harness L03 (female) (2) – L70 (female) (1) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Between wiring harness HST (female) (39) – L03 (female) (3), L70 (female) (5), (3) and Ground fault in wiring har4 ness (Contact with GND cir- ground cuit) Between wiring harness L03 (female) (1) – L70 (female) (6) and ground

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. HST 5 Defective HST controller Between (39) – (32)


Switch position

Voltage

1st

1.9 – 2.3 V

2nd

2.4 – 2.7 V

3rd

2.9 – 3.2 V

4th

3.3 – 3.7 V

40-360

3

SEN03944-01



40-360

4




SEN03944-01

40-360

5

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DF10KB] Travel speed range selector switch: Hot short

SEN03944-01

Failure code [DF10KB] Travel speed range selector switch: Hot short Action code

Failure code

E01

DF10KB


Trouble

Travel speed range selector switch: Hot short (HST controller system)

• Multiple travel speed range selector switch signal is input because of hot short in travel speed range selector switch input signal system. • Fixes gear to speed range before error occurrence. • If trouble disappears, system resets itself. • Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of selected speed range. • Gear is not set in selected speed range. • Indicator displays range before error occurrence. (Once starting switch is turned OFF, 4th gear is displayed) • Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L03 (female) Between (1) – (2)

Switch position 2nd

Max. 1 z

Other than above

Min. 1 Mz

1st

Min. 1 Mz

2nd

Min. 1 Mz

Between (1) – (3)

3rd

Max. 1 z

4th

Max. 1 z

4th

Max. 1 z

Other than above

Min. 1 Mz

Defective travel speed range 1 selector switch (Internal defect) Between (1) – (4)


Resistance

Between (2) – (3)

– (Anytime)

Min. 1 Mz

Between (2) – (4)

– (Anytime)

Min. 1 Mz

1st

Max. 1 z

2nd

Min. 1 Mz

3rd

Min. 1 Mz

4th

Max. 1 z

Between (3) – (4)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective travel speed range 2 selector resistor (Internal defect)

L70 (male)

Resistance

Between (1) – (5)

100 z ± 1%

Between (2) – (6)

220 z ± 1%

Between (3) – (7)

330 z ± 1%

Between (4) – (8)

470 z ± 1%


Hot short (Contact with 5V, 3 24V circuit) in wiring harness Between wiring harness HST (female) (39) – L03 (female) (3), L70 (female) (5), (3) and ground Between wiring harness L03 (female) (1) – L70 (female) (6) and ground

40-360

6

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

Max. 1 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DF10KB] Travel speed range selector switch: Hot short

Causes

Hot short (Contact with 24V 3 circuit) in wiring harness Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting Between wiring harness L03 (female) (2) – L70 (female) (1) and ground

Voltage

Max. 1 V


Voltage

Max. 1 V

Wiring harness between HST (female) (22) – L70 (female) (2) (4) and ground

Voltage

Max. 1 V

HST 4 Defective HST controller

SEN03944-01

Between (39) – (32)

Switch position

Voltage

1st

1.9 – 2.3 V

2nd

2.4 – 2.7 V

3rd

2.9 – 3.2 V

4th

3.3 – 3.7 V



40-360

7

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault

SEN03944-01

Failure code [DGH1KX] HST oil temperature sensor: Ground fault Action code

Failure code

E01

DGH1KX

Contents of trouble

Trouble

HST oil temperature sensor: Ground fault (Machine monitor system)

• HST oil temperature higher than 150°C was detected. (Ground fault in HST oil temperature signal circuit was detected.)

Action of • HST oil overheat is not detected. machine monitor Problem that appears on machine Related information

• HST oil temperature gauge indicates maximum. • Input state from HST oil temperature sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 04408 – HST OIL TEMP (°C) (Monitoring code: MONITOR PANEL – 04409 – HST OIL TEMP (V) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. T10 (male)

Defective HST oil tempera1 ture sensor (Internal defect)


Between (1) – (2) Between (1) (2) and ground

HST oil temperature

Resistance

At 25°C

35 – 50 kz

At 100°C

3.1 – 4.5 kz

– (Anytime)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND cirBetween wiring harness L28 (female) (2) – Resiscuit) Min. 1 Mz T10 (female) (1) and ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor

L28 (female) Between (2) – ground

HST oil temperature

Voltage

At 25°C

4.4 – 4.6 V

At 100°C

2.1 – 2.3 V


40-360

8


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault

SEN03944-01

Failure code [DGR2KB] Brake oil temperature sensor: Ground fault Action code

Failure code

E01

DGR2KB

Contents of trouble

Trouble

Brake oil temperature sensor: Ground fault (Machine monitor system)

• Front brake oil temperature above 150°C was detected. (Ground fault was detected in front brake oil temperature signal circuit.)

Action of • Brake oil overheat is not detected. machine monitor Problem that appears on machine Related information

• Brake oil temperature gauge indicates upper limit. • Brake performance lowers (while system is normal). • Input state from front brake oil temperature sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C) (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V) • System resets itself after brake oil temperature reduces below 130°C. Causes Front brake overheat 1 (When system is normal)

Standard value in normal state/Remarks on troubleshooting Check for cause of overheat directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Defective front brake (axle) 2 oil temperature sensor (Internal defect)

F14 (male) Between (1) – (2) Between (1) (2) and ground


Resistance

At 25°C

35 – 50 kz

At 100°C

3.1 – 4.5 kz

– (Anytime)

Min. 1 Mz

Ground fault in wiring harBetween wiring harness F14 (female) (1) – 3 ness (Contact with GND cirL28 (female) (7) and ground cuit)

Resistance

Min. 1 Mz


L25, L28


Voltage

Between L28 (7) – L25 (9)

At 25°C

4.4 – 4.6 V

At 100°C

2.1 – 2.3 V



40-360

9

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short

SEN03944-01

Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short Action code

Failure code

E01

DGR2KZ

Contents of trouble

Trouble

Brake oil temperature sensor: Disconnection/Hot short (Machine monitor system)

• Disconnection or hot short was detected in front brake oil temperature signal circuit. Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison with HST oil temperature.

Action of • None in particular. machine monitor Problem that appears on machine Related information

• Brake oil temperature gauge indicates lower limit. • Brake may be broken and brake may not work because of brake oil temperature error. • Input state from front brake oil temperature sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C) (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V) • System resets itself after brake oil temperature increases above 25°C. Causes

Defective front brake (axle) 1 oil temperature sensor (Internal defect)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F14 (male) Between (1) – (2)


Resistance

At 25°C

35 – 50 kz

At 100°C

3.1 – 4.5 kz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between F14 (female) (1) – 2 or defective contact in con- L28 (female) (7) nector) Wiring harness between F14 (female) (2) – L25 (female) (9)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

Hot short (Contact with 5 V, Between wiring harness F14 (female) (1) – 24V circuit) in wiring harness L28 (female) (7) and ground

Voltage

Max. 1 V

Between wiring harness F14 (female) (2) – L25 (female) (9) and ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective machine monitor

40-360

10

L25, L28


Voltage

Between L28 (7) – L25 (9)

At 25°C

4.4 – 4.6 V

At 100°C

2.1 – 2.3 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short

SEN03944-01



40-360

11

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault

SEN03944-01

Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault Action code

Failure code

E03

DHH1KX


Trouble

HST oil pressure sensor: Disconnection/Ground fault (HST controller system)

• HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pressure sensor system (Input voltage is below 0.3 V) • If trouble occurs during travel, control value (output) before trouble occurrence is held. • Once machine stops, gear is assumed to be in 1st for control. • Turns the centralized warning lamp and alarm buzzer ON. • Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control dial, however.) • If [DAJ5KX] is displayed, carry out troubleshooting for it first. • Input state from HST oil pressure sensor can be checked with monitoring function. (Monitoring code: HST 32600 HST PRESS (MPa)) (Monitoring code: HST 32601 HST PRESS (V)) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting twitch ON and carry out troubleshooting.

1

Defective HST oil pressure sensor (Internal defect)

T11

Voltage

Between (C) – (A)

0.5 – 4.5 V

Between (B) – (A)

4–6V



Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector)

Wiring harness between HST (female) (33) – T11 (female) (C)

Resistance

Max. 1 z

Wiring harness between HST (female) (32) – T11 (female) (A)

Resistance

Max. 1 z

Wiring harness between HST (female) (22) – T11 (female) (B)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween wiring harness HST (female) (33) – 3 ness (Contact with GND cirT11 (female) (C) and ground cuit) Between wiring harness HST (female) (22) – T11 (female) (B) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective HST controller

40-360

12

HST

Voltage

Between (33) – (32)

0.5 – 4.5 V

Between (22) – (32)

4–6V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault

SEN03944-01



40-360

13

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHH1KY] HST oil pressure sensor: Hot short

SEN03944-01

Failure code [DHH1KY] HST oil pressure sensor: Hot short Action code

Failure code

E03

DHH1KY


Trouble

HST oil pressure sensor: Hot short (HST controller system)

• Abnormal HST oil pressure sensor signal was input because of hot short in HST oil pressure sensor system (Input voltage was above 4.7 V). • If trouble occurs during travel, control value (output) before trouble occurrence is held. • Once machine stops, gear is assumed to be in 1st for control. • Turns the centralized warning lamp and alarm buzzer ON. • Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control dial, however.) • If [DAJ5KX] is displayed, carry out troubleshooting for it first. • Input state from HST oil pressure sensor can be checked with monitoring function. (Monitoring code: HST 32600 HST PRESS (MPa)) (Monitoring code: HST 32601 HST PRESS (V)) Causes


1


Defective HST oil pressure sensor (Internal defect)

T11

Voltage

Between (C) – (A)

0.5 – 4.5 V

Between (B) – (A)

4–6V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 V, 2 24V circuit) in wiring harness Between wiring harness HST (female) (33) – Voltage Max. 1 V T11 (female) (C) and ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3 Defective HST controller

40-360

14

HST

Voltage

Between (33) – (32)

0.5 – 4.5 V

Between (22) – (32)

4–6V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHH1KY] HST oil pressure sensor: Hot short

SEN03944-01



40-360

15

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHTCL6] HST filter clogging sensor: Functional defect

SEN03944-01

Failure code [DHTCL6] HST filter clogging sensor: Functional defect Action code

Failure code

E01

DHTCL6

Contents of trouble

Trouble

HST filter clogging sensor: Functional defect (Machine monitor system)

• When engine stopped, HST filter clogging sensor was turned ON (Ground fault was detected).

Action of • Turns HST filter clogging caution lamp OFF. machine monitor Problem that appears on machine Related information

• Foreign matter may enter HST hydraulic circuit. • Input state (ON/OFF) of HST filter clogging sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40903 – D-IN-24) Causes Defective HST filter clogging 1 sensor (Internal defect)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between T13 – T14

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND cirBetween wiring harness L26 (female) (5) – Resiscuit) Min. 1 Mz T13 and ground tance 3 Defective machine monitor

If causes 1 – 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


40-360

16


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DHTCL6] HST filter clogging sensor: Functional defect


SEN03944-01

40-360

17

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short

SEN03944-01

Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short Action code

Failure code

E01

DJF1KA

Contents of trouble

Trouble

Fuel level sensor: Disconnection/Hot short (Machine monitor system)

• Voltage above 4 V was detected in fuel level sensor signal circuit.

Action of • None in particular. machine monitor Problem that appears on machine

• Fuel level gauge does not indicated normally (but keeps indicating “empty”).

Related information

• Input signal from fuel level sensor can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 04200 – FUEL SENSOR (V)) (Monitoring code: MONITOR PANEL – 04202 – FUEL SENSOR (%)) • Method of reproducing failure code: Turn starting switch ON. Causes


1

Defective fuel level sensor (Internal defect)

R21 (male)

Fuel level

Resistance

When full

7 – 11 z

Between (1) – (2)

When 1/2

25 – 35 z

When empty

60 – 95 z



Disconnection in wiring harness (Disconnection in wiring Wiring harness between L28 (female) (1) – 2 or defective contact in con- R21 (female) (1) nector) Wiring harness between L26 (female) (6) – R21 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3

Between wiring harness L28 (female) (1) – Hot short (Contact with 5 V, R21 (female) (1) and ground 24V circuit) in wiring harness (Value is upper limit when empty.)

Voltage

Max. 2 V

Wiring harness between L26 (female) (6) – R21 (female) (2)

Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L26, L28 4 Defective machine monitor Between L28 (1) – L26 (6)

40-360

18

Fuel level

Voltage

When full

0.1 – 0.4 V

When 1/2

0.7 – 1.0 V

When empty

1.4 – 2.0 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short

SEN03944-01



40-360

19

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DLT3KX] Travel speed sensor B: Abnormality

SEN03944-01

Failure code [DLT3KX] Travel speed sensor B: Abnormality Action code

Failure code

E03

DLT3KX


Trouble

Travel speed sensor B: Abnormality (HST controller system)

• While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor B was lost. • Recognizes travel speed by input signal of travel speed sensor A. • Turns the centralized warning lamp and alarm buzzer ON. • None in particular. • If failure code [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously, see causes 6 and after. Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine (but do not travel) and carry out troubleshooting.

1

Defective travel speed sensor (Internal defect)

T09

Voltage

Between (1) – (2)

4.7 – 5.3 V


Max. 1 V

a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting. T09

Voltage

Between (4) – (2)

Below 1 V – Above 4 V (Changes at regular intervals)

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (36) – ResisMax. 1 z nector) T09 (female) (4) tance Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness HST (female) (36) – T09 (female) (4) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, travel at conGround fault in wiring harstant speed, and carry out troubleshooting. 3 ness (Contact with GND circuit) Below 1 V – Above Between wiring harness HST (36) – T09 (4) 4V Voltage and ground (Changes at regular intervals) a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting. 4

40-360

20

Hot short (Contact with 5 V, 24V circuit) in wiring harness Between wiring harness HST (36) – T09 (4) and ground

Voltage

Below 1 V – Above 4V (Changes at regular intervals)



Causes

SEN03944-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting without traveling.




HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


Max. 1 V

a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting. HST

Voltage

Between (36) – (32)


40-360

21


SEN03944-01 a

When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously Contents of trouble

• While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A and B were lost.


• Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble. • Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled. • Turns the centralized warning lamp and alarm buzzer ON.


• Travel speed does not increase or traction force is insufficient. • Machine monitor indicates 0 km/h as travel speed. • If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not turned ON. • In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to 4 – 7 km/h. Causes


Defective travel speed sen6 sor (Internal defect)

T09

Voltage

Between (1) – (2)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (3) – (2)


Between (4) – (2)



Wiring harness between HST (female) (22) – T09 (female) (1)

Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (32) – 7 or defective contact in con- T09 (female) (2) nector) Wiring harness between HST (female) (26) – T09 (female) (3) Wiring harness between HST (female) (36) – T09 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness HST (female) (22) – Ground fault in wiring harT09 (female) (1) and ground 8 ness (Contact with GND cirBetween wiring harness HST (female) (26) – cuit) T09 (female) (3) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Between wiring harness HST (female) (36) – T09 (female) (4) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 V, 9 24V circuit) in wiring harness Between wiring harness HST (32) – T09 (2) Voltage Max. 1 V and ground

40-360

22



Causes

SEN03944-01


Possible causes and standard value in normal 10 Defective HST controller state

HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (26) – (32)


Between (36) – (32)




40-360

23

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DLT4KX] Travel speed sensor A: Abnormality

SEN03944-01

Failure code [DLT4KX] Travel speed sensor A: Abnormality Action code

Failure code

E03

DLT4KX


Trouble

Travel speed sensor A: Abnormality (HST controller system)

• While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor A was lost. • Recognizes travel speed by input signal of travel speed sensor B. • Turns the centralized warning lamp and alarm buzzer ON. • None in particular. • If failure code [DLT4KX] and [DLT3KX] (Travel speed sensor B: Abnormality) are turned ON simultaneously, see [DLT3KX], causes 6 and after. Causes


1

Defective travel speed sensor (Internal defect)

T09

Voltage

Between (1) – (2)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (3) – (2)


Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between HST (female) (26) – ResisMax. 1 z nector) T09 (female) (3) tance Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness HST (female) (26) – T09 (female) (3) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, travel at conGround fault in wiring harstant speed, and carry out troubleshooting. 3 ness (Contact with GND circuit) Below 1 V – Above Between wiring harness HST (26) – T09 (3) 4V Voltage and ground (Changes at regular intervals) a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting. 4

40-360

24

Hot short (Contact with 5 V, 24V circuit) in wiring harness Between wiring harness HST (26) – T09 (3) and ground

Voltage



360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DLT4KX] Travel speed sensor A: Abnormality

Causes

SEN03944-01




HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (26) – (32)




40-360

25

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality

SEN03944-01

Failure code [DLT4LC] Travel speed sensor A & B: Abnormality Action code

Failure code

E03

DLT4LC


Trouble

Travel speed sensor A & B: Abnormality (HST controller system)

• Difference between values sensed by travel speed sensors A and B during travel is large. • Turns the centralized warning lamp and alarm buzzer ON. • None in particular other than above (Uses higher value normally).


• Even trouble disappears, system does not reset itself until engine is started again.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine (but do not travel) and carry out troubleshooting without traveling.

Defective travel speed sen1 sor (Internal defect)

T09

Voltage

Between (1) – (2)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (3) – (2)


Between (4) – (2)




Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (26) – 2 or defective contact in con- T09 (female) (3) nector) Wiring harness between HST (female) (36) – T09 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween wiring harness HST (female) (26) – 3 ness (Contact with GND cirT09 (female) (3) and ground cuit) Between wiring harness HST (female) (36) – T09 (female) (4)

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting.

Between wiring harness HST (female) (26) – T09 (female) (3) and ground 4

26

Voltage



Between wiring harness HST (female) (36) – T09 (female) (4)

40-360

Voltage



360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality

Causes

SEN03944-01




HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (26) – (32)


Between (36) – (32)




40-360

27

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DV00KY] Alarm buzzer: Hot short

SEN03944-01

Failure code [DV00KY] Alarm buzzer: Hot short Action code

Failure code

E01

DV00KY

Contents of trouble

Trouble

Alarm buzzer: Hot short (Machine monitor system)

• The alarm buzzer output circuit is shorted with the power source.

• Stops alarm buzzer output. Action of • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF. machine monitor • If trouble occurs while backup alarm/lamp is in operation, backup alarm/lamp output is turned OFF. • If trouble occurs while ECSS is in operation, ECSS output is turned OFF. Problem that appears on machine

Related information

• Alarm buzzer does not sound. • Backup alarm/lamp may not operate. • ECSS may not operate. • The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function. (Monitoring code: MONITOR PANEL – 40925 – D-OUT-0) • Output state (ON/OFF) to backup alarm/lamp relay can be checked with monitoring function. (Code: MONITOR PANEL – 40952 – D-OUT-2) • Output state (ON/OFF) to ECSS relay can be checked with monitoring function. (Code: MONITOR PANEL – 40952 – D-OUT-3) • Method of reproducing failure code: Turn the starting switch ON. Causes Hot short in wiring harness 1 (Contact with 5 V, 24V circuit)


2

Defective alarm buzzer (Internal short circuit)


40-360

28

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between L24 (female) (14) – L46 (female) (2) and chassis ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Remove the buzzer, then connect +24 V to L46 (male) (1) and GND to L46 (male) (2). Alarm buzzer sounds

Alarm buzzer is normal

Alarm buzzer does not sound

Defective alarm buzzer

• When above 1 and 2 are normal, failure on the machine monitor can be suspected. (Since trouble is in system, troubleshooting cannot be carried out.)


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DV00KY] Alarm buzzer: Hot short

SEN03944-01



40-360

29

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault

SEN03944-01

Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault Action code

Failure code

E01

DW26KA

Trouble

Motor 2 solenoid: Disconnection/Ground fault (HST controller system)

Contents of trouble

• Motor 2 cannot be controlled because of disconnection or ground fault in motor 2 solenoid relay output system.


• Keeps output to motor 2 solenoid relay turned OFF (If there is ground fault, output cannot be turned OFF actually). • Even if trouble disappears, system does not reset itself until starting switch is turned OFF.


• When there is disconnection: Travel speed is not limited and maximum speed is equivalent to 4th gear speed in 3rd speed range. • When there is ground fault: Travel speed is set equivalent to 3rd gear speed in 4th speed range. • Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-16) • Method of reproducing failure code: Travel at speed above about 11 km/h in 4th speed range. Causes


1

Defective motor 2 solenoid relay (Internal defect)

Replace motor 2 solenoid relay (L103) with another relay.







200 – 400 z


Defective VIS power supply 2 holding relay (Internal short circuit) Possible causes and standard value in normal state








200 – 400 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (27) – 3 or defective contact in con- L103 (female) (2) nector) Wiring harness between L103 (female) (1) – L102 (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 4 ness (Contact with GND cirBetween wiring harness HST (female) (27) – Resiscuit) Min. 1 Mz L103 (female) (2) and ground tance a Prepare with starting switch OFF, then start engine, travel, and carry out troubleshooting. HST

Condition

Voltage

Stopped

Max. 1 V


Speed range: 4th Travel speed: Above 11 km/h

20 – 30 V


40-360

30


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault

SEN03944-01



40-360

31

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW26KY] Motor 2 solenoid: Hot short

SEN03944-01

Failure code [DW26KY] Motor 2 solenoid: Hot short Action code

Failure code

E01

DW26KY


Trouble

Motor 2 solenoid: Hot short (HST controller system)

• Motor 2 solenoid cannot be operated because of hot short in motor 2 solenoid relay output system. • Keeps output to motor 2 solenoid relay turned OFF. • Even if trouble disappears, system does not reset itself until starting switch is turned OFF. • When the gear is shifted to 3rd, travel speed is not limited and maximum travel speed is equivalent to 4th-gear speed. • Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-16) Causes


1

Defective motor 2 solenoid relay (Internal defect)

Condition becomes Replace motor 2 normal solenoid relay (L103) Condition does not with another relay. become normal

Relay (L103) is defective Relay (L103) is normal



Resistance


2

Hot short (Contact with 24V circuit) in wiring harness

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between HST (female) (27) – L103 (female) (2)

Voltage (When stopped)

Max. 1 V


40-360

32

HST

Voltage


Max. 1 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW26KY] Motor 2 solenoid: Hot short

SEN03944-01



40-360

33

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short

SEN03944-01

Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short Action code

Failure code

E01

DW7BKY


Trouble

Fan reverse solenoid circuit: Hot short (HST controller system)

• Abnormal voltage was generated because of hot short in fan reverse solenoid relay output system when fan reverse solenoid relay output was turned ON. • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function. • Even if trouble disappears, system does not reset itself until starting switch is turned OFF. • Fan does not reverse (Manual reverse function and automatic reverse function do not work). • Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-17) • Method of reproducing failure code: Start engine, wait for at least 30 seconds, and then press manual reverse switch. Causes


1

Defective fan reverse solenoid relay (Internal defect)

Condition becomes Replace fan reverse normal solenoid relay (L104) Condition does not with another relay. become normal



Resistance


200 – 400 z

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 2

Hot short (Contact with 5 V, Voltage (In fan for24V circuit) in wiring harness Wiring harness between HST ward mode) (female) (37) – L104 (female) (2) Voltage (In fan reverse mode)

20 – 30 V Max. 1 V

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3 Defective HST controller

40-360

34

HST

Fan condition

Voltage


In fan forward mode

20 – 30 V

In fan reverse mode

Max. 1 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short

SEN03944-01



40-360

35

360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault

SEN03944-01

Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault Action code

Failure code

E01

DW7BKZ


Trouble

Fan reverse solenoid circuit: Disconnection/Ground fault (HST controller system)

• Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan reverse solenoid relay output system. • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function. • Even if trouble disappears, system does not reset itself until starting switch is turned OFF. • Manual reverse function and automatic reverse function do not work. • Fan always turns forward (When there is disconnection). • Fan always turns in reverse (When there is ground fault). • Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-17) • Method of reproducing failure code: Turn starting switch ON. Causes


1

Defective fan reverse solenoid relay (Internal defect)

Condition becomes Replace fan reverse normal solenoid relay (L104) Condition does not with another relay. become normal




200 – 400 z



Defective VIS power supply 2 holding relay (Internal short circuit)








200 – 400 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (37) – 3 or defective contact in con- L104 (female) (2) nector) Wiring harness between L104 (female) (1) – L102 (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 4 ness (Contact with GND cirBetween wiring harness HST (female) (37) – Resiscuit) Min. 1 Mz L104 (female) (2) and ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective HST controller

40-360

36

HST

Fan condition

Voltage


In fan forward mode

20 – 30 V

In fan reverse mode

Max. 1 V


360 Troubleshooting by failure code (Display of code), Part 6 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault

SEN03944-01



40-360

37

SEN03944-01



40-360

38

SEN03945-00




40 Troubleshooting

40

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX16KA] Fan EPC solenoid: Disconnection............................................................................. 2 Failure code [DX16KB] Fan EPC solenoid: Ground fault................................................................................ 3 Failure code [DX16KY] Fan EPC solenoid: Hot short..................................................................................... 4 Failure code [DX19KA] Motor 1 solenoid: Disconnection ............................................................................... 6 Failure code [DX19KB] Motor 1 solenoid: Ground fault .................................................................................. 8 Failure code [DX19KY] Motor 1 solenoid: Hot short ..................................................................................... 10 Failure code [DX20KA] Clutch EPC solenoid: Disconnection....................................................................... 12 Failure code [DX20KB] Clutch EPC solenoid: Ground fault.......................................................................... 14 Failure code [DX20KY] Clutch EPC solenoid: Hot short............................................................................... 16 Failure code [DXH7KB] Reverse solenoid: Ground fault .............................................................................. 18 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short ............................................................ 20 Failure code [DXH8KB] Forward solenoid: Ground fault .............................................................................. 22 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short ............................................................ 24 Failure code [J141N1] Steering pump: Overrun alarm.................................................................................. 26 Failure code [M100N1] HST pump: Overrun alarm ...................................................................................... 26 Failure code [M400N1] Motor 1: Overrun alarm ........................................................................................... 27


40-370

1

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX16KA] Fan EPC solenoid: Disconnection

SEN03945-00

Failure code [DX16KA] Fan EPC solenoid: Disconnection Action code

Failure code

E01

DX16KA

Trouble

1

Fan EPC solenoid: Disconnection (HST controller system)

Contents of trouble

• Since the fan EPC solenoid system is disconnected, no current flows when the fan EPC solenoid output is ON.


• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• The fan speed is set to the maximum. • If [DX16KY] is displayed, carry out troubleshooting for it first. • The output state (current) to the fan EPC solenoid can be checked with the monitoring function (Code: HST – 41400 – FAN EPC DIR). • Method of reproducing failure code: Turn the starting switch ON. Causes


Defective fan EPC solenoid (Internal disconnection)



Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R29 (male)

Resistance

Between (1) – (2)

5 – 10 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between HST (female) (40) – R29 (female) (2)

Resistance

Max. 1 z

Wiring harness between HST (female) (29) – R29 (female) (1)

Resistance

Max. 1 z

• If causes 1 – 2 are not detected, HST controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)


40-370

2


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX16KB] Fan EPC solenoid: Ground fault

SEN03945-00

Failure code [DX16KB] Fan EPC solenoid: Ground fault Action code

Failure code

E01

DX16KB

Trouble

1

Fan EPC solenoid: Ground fault (HST controller system)

Contents of trouble

• Since the fan EPC solenoid system is shorted, abnormal current flows when the fan EPC solenoid output is ON.


• Turns the output to the fan EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.


• The fan speed is set to the maximum. • The output state (current) to the fan EPC solenoid can be checked with the monitoring function (Code: HST – 41400 – FAN EPC DIR). • Method of reproducing failure code: Turn the starting switch ON. Causes



Defective fan EPC solenoid (Internal short circuit)

R29 (male)

Resistance

Between (1) – (2)

5 – 10 z

Between (1), (2) and ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring harwithout turning starting switch ON. 2 ness Resis(Contact with ground circuit) Wiring harness between HST (female) (29) – Min. 1 Mz R29 (female) (1) and ground tance 3 Defective HST controller




40-370

3

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX16KY] Fan EPC solenoid: Hot short

SEN03945-00

Failure code [DX16KY] Fan EPC solenoid: Hot short Action code

Failure code

E01

DX16KY


Trouble

1

Fan EPC solenoid: Hot short (HST controller system)

• Since the fan EPC solenoid system is shorted with the power source, abnormal voltage is applied when the fan EPC solenoid output is OFF. • Turns the output to the fan EPC solenoid OFF. • If problem is removed, system is returned to normal operating state. • The fan speed is minimized. • The output state (current) to the fan EPC solenoid can be checked with the monitoring function (Code: HST – 41400 – FAN EPC DIR). • Method of reproducing failure code: Turn the starting switch ON. Causes



Defective fan EPC solenoid (Internal short circuit)

Hot short in wiring harness 2 (Contact with 5 V, 24V circuit) 3 Defective HST controller

R29 (male)

Resistance

Between (1) – (2)

5 – 10 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between HST (female) (29) – R29 (female) (1) and ground

Voltage

Max. 1 V



40-370

4


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX16KY] Fan EPC solenoid: Hot short


SEN03945-00

40-370

5

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KA] Motor 1 solenoid: Disconnection

SEN03945-00

Failure code [DX19KA] Motor 1 solenoid: Disconnection Action code

Failure code

E03

DX19KA

Contents of trouble



Related information

Trouble

1

Motor 1 solenoid: Disconnection (HST controller system)

• Disconnection was detected in motor 1 solenoid circuit. (Difference between output command value and actual current is large.) • • • • •

Turns motor 1 solenoid output OFF. Turns HST safety relay output OFF. Turns clutch EPC solenoid output OFF. Even if trouble disappears, system does not reset itself until starting switch is turned OFF. Turns the centralized warning lamp and alarm buzzer ON.

• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) • If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first. Causes


1

Defective motor 1 solenoid (Internal defect)

T06 (male)

Resistance

Between (1) – (2)

15 – 30 z


Min. 1 Mz



Resistance

Max. 1 z

Wiring harness between T06 (female) (2) – L111 (female) (3)

Resistance

Max. 1 z

Wiring harness between L111 (female) (5) – HST (female) (40)

Resistance

Max. 1 z


3

Defective HST safety relay (L111) (Internal defect)

Replace HST safety relay (L111) with another relay





a Prepare with starting switch OFF and check safety relay unit. Apply 24 V between Between L111 (male) (1) – (2). (3) – (5) Apply no voltage between (1) – (2).


40-370

6

Resistance

Max. 1 z

Resistance

Min. 1 Mz



370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KA] Motor 1 solenoid: Disconnection

SEN03945-00



40-370

7

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KB] Motor 1 solenoid: Ground fault

SEN03945-00

Failure code [DX19KB] Motor 1 solenoid: Ground fault Action code

Failure code

E03

DX19KB

Contents of trouble



Related information

Trouble

1

Motor 1 solenoid: Ground fault (HST controller system)

• Ground fault was detected in motor 1 solenoid circuit. • • • • •


• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) Causes



8

T06 (male)

Resistance

Between (1) – (2)

15 – 30 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND cirBetween wiring harness HST (female) (19) – Resiscuit) Min. 1 Mz T06 (female) (1) and ground tance 3

40-370





370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KB] Motor 1 solenoid: Ground fault

SEN03945-00



40-370

9

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KY] Motor 1 solenoid: Hot short

SEN03945-00

Failure code [DX19KY] Motor 1 solenoid: Hot short Action code

Failure code

E03

DX19KY

Contents of trouble



Related information

Trouble

1

Motor 1 solenoid: Hot short (HST controller system)

• Hot short was detected in motor 1 solenoid circuit. • • • • •


• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) • [DX19KA], [DX20KA] or [DX20KY] may be also displayed, depending on condition when error was detected. Causes


1


T06 (male)

Resistance

Between (1) – (2)

15 – 30 z


Min. 1 Mz



Between wiring harness T06 (female) (1) – HST (female) (19) 2

40-370

10

Max. 1 V

Wiring harness between T06 (female) (2) – Hot short (Contact with 5 V, Voltage Max. 1 V L111 (female) (3) and ground. 24V circuit) in wiring harness a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Check with traction control OFF and machine stopped.) Between wiring harness HST (female) (19) – T06 (female) (1)

3

Voltage


Voltage

10 – 15 V



370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX19KY] Motor 1 solenoid: Hot short

SEN03945-00



40-370

11

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KA] Clutch EPC solenoid: Disconnection

SEN03945-00

Failure code [DX20KA] Clutch EPC solenoid: Disconnection Action code

Failure code

E03

DX20KA

Contents of trouble



Related information

Trouble

1

Clutch EPC solenoid: Disconnection (HST controller system)

• Disconnection was detected in clutch EPC solenoid circuit. (When output command was above 250 mA, difference between command value and sensed current exceeded 200 mA.) • • • • •


• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) • If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first. Causes


1

Defective clutch EPC solenoid (Internal defect)

T05 (male)

Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz



Resistance

Max. 1 z

Wiring harness between T05 (female) (2) – L111 (female) (3)

Resistance

Max. 1 z

Wiring harness between L111 (female) (5) – HST (female) (40)

Resistance

Max. 1 z


3


Replace HST safety relay (L111) with another relay





a Prepare with starting switch OFF and check safety relay unit. Apply 24 V between Between L111 (male) (1) – (2). (3) – (5) Apply no voltage between (1) – (2).


40-370

12

Resistance

Max. 1 z

Resistance

Min. 1 Mz



370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KA] Clutch EPC solenoid: Disconnection

SEN03945-00



40-370

13

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KB] Clutch EPC solenoid: Ground fault

SEN03945-00

Failure code [DX20KB] Clutch EPC solenoid: Ground fault Action code

Failure code

E03

DX20KB

Contents of trouble



Related information

Trouble

1

Clutch EPC solenoid: Ground fault (HST controller system)

• Ground fault was detected in clutch EPC solenoid circuit. • • • • •


• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly. • Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) Causes




14

Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND cirBetween wiring harness HST (female) (9) – Resiscuit) Min. 1 Mz T05 (female) (1) and ground tance 3 Defective HST controller

40-370

T05 (male)



370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KB] Clutch EPC solenoid: Ground fault

SEN03945-00



40-370

15

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KY] Clutch EPC solenoid: Hot short

SEN03945-00

Failure code [DX20KY] Clutch EPC solenoid: Hot short Action code

Failure code

E03

DX20KY

Contents of trouble


Trouble

1

Clutch EPC solenoid: Hot short (HST controller system)

• Hot short was detected in clutch EPC solenoid circuit. • • • • •



• Traction force is decreased. • Travel speed is not limited with speed range selector switch and travel speed control dial. • If engine is stopped without applying parking brake securely on slope, machine moves down suddenly.

Related information

• Following output command values can be checked with monitoring function. Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA) HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF) Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA) • [DX19KA], [DX19KY] or [DX20KA] may be also displayed, depending on condition when error was detected. Causes


1


T05 (male)

Resistance

Between (1) – (2)

5 – 15 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state



16

Max. 1 V

Between wiring harness L111 (female) (3) – Voltage Max. 1 V Hot short (Contact with 5 V, T05 (female) (2) 2 24V circuit) in wiring harness a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Troubleshoot with traction switch OFF and machine is stopped (do not travel)) Between wiring harness HST (female) (9) – T05 (female) (1) and ground

40-370

Voltage

Voltage

10 – 15 V



370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DX20KY] Clutch EPC solenoid: Hot short

SEN03945-00



40-370

17

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH7KB] Reverse solenoid: Ground fault

SEN03945-00

Failure code [DXH7KB] Reverse solenoid: Ground fault Action code

Failure code

E03

DXH7KB


Trouble

1

Reverse solenoid: Ground fault (HST controller system)

• Reverse solenoid is not turned ON. • Turns output to reverse solenoid OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Machine does not travel in reverse. • Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-19) Causes


1

2

Defective reverse solenoid (Internal defect)


T01 (male)

Resistance

Between (3) – (4)

15 – 30 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (See Testing and adjusting, “Test procedure for diode”.) Between T01B (male) (1) – (2)

No continuity

a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Possible causes and standard value in normal state

Condition becomes Replace FR pressure normal select relay (L101) Defective FR pressure select with another relay Condition does not 3 relay (Internal defect) become normal



Resistance

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 4 ness (Contact with GND cirBetween wiring harness HST (female) (20) – Resiscuit) Min. 1 Mz T01 (female) (3) and ground tance


40-370

18

a Prepare with starting switch OFF, then start engine, release parking brake, set directional lever in R position, and carry out troubleshooting. HST

Voltage


20 – 30 V


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH7KB] Reverse solenoid: Ground fault

SEN03945-00



40-370

19

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short

SEN03945-00

Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short Action code

Failure code

E03

DXH7KZ


Trouble

1

Reverse solenoid: Disconnection/Hot short (HST controller system)

• Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is disconnection). • Reverse solenoid cannot be turned OFF (Where there is hot short). • Turns output to reverse solenoid OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Machine does not travel in reverse (when there is disconnection). • Machine may start in reverse suddenly (when there is hot short). • Gear is not set in neutral (when there is hot short). • Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-19) Causes


1


Defective diode 2 (Internal defect)

T01 (male)

Resistance

Between (3) – (4)

15 – 30 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (See Testing and adjusting, “Test procedure for diode”.) Between T01B (male) (2) – (1)

No continuity

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Condition becomes Replace FR pressure normal select relay (L101) Condition does not Defective FR pressure select with another relay 3 become normal relay (Internal defect)




Resistance


200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (20) – Resis4 Max. 1 z or defective contact in con- T01 (female) (3) tance nector) Wiring harness between T01 (female) (4) – ResisMax. 1 z ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 V, 5 24V circuit) in wiring harness Between wiring harness HST (female) (20) – Voltage Max. 1 V T01 (female) (3) and ground a Prepare with starting switch OFF, then start engine and release parking brake, and carry out troubleshooting. 6 Defective HST controller

HST Between (20) – ground

40-370

20


Voltage

R (Reverse)

20 – 30 V

Other than above

Max. 1 V


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short

SEN03945-00



40-370

21

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH8KB] Forward solenoid: Ground fault

SEN03945-00

Failure code [DXH8KB] Forward solenoid: Ground fault Action code

Failure code

E03

DXH8KB


Trouble

1

Forward solenoid: Ground fault (HST controller system)

• Forward solenoid is not turned ON. • Turns output to forward solenoid OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Machine does not travel forward. • Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-18) Causes


1


2

Defective forward solenoid (Internal defect)


22

Resistance

Between (1) – (2)

15 – 30 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (See Testing and adjusting, “Test procedure for diode”.) Between T01A (male) (1) – (2)

No continuity


Ground fault in wiring har3 ness (Contact with GND cirBetween wiring harness HST (female) (10) – cuit) T01 (female) (1) and ground


40-370

T01 (male)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, release parking brake, set directional lever in F position, and carry out troubleshooting. HST

Voltage


20 – 30 V


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH8KB] Forward solenoid: Ground fault

SEN03945-00



40-370

23

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short

SEN03945-00

Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short Action code

Failure code

E03

DXH8KZ


Trouble

1

Forward solenoid: Disconnection/Hot short (HST controller system)

• Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is disconnection). • Forward solenoid cannot be turned OFF (Where there is hot short). • Turns output to forward solenoid OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Machine does not travel forward (when there is disconnection). • Machine may start forward suddenly (when there is hot short). • Gear is not set in neutral (when there is hot short). • Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-18) Causes


1


Defective diode 2 (Internal defect)

T01 (male)

Resistance

Between (1) – (2)

15 – 30 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. (See Testing and adjusting, “Test procedure for diode”.) Between T01A (male) (1) – (2)


No continuity


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (10) – 3 or defective contact in con- T01 (female) (1) nector) Wiring harness between T01 (female) (2) – ground

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 V, 4 24V circuit) in wiring harness Between wiring harness HST (female) (10) – Voltage Max. 1 V T01 (female) (1) and ground a Prepare with starting switch OFF, then start engine and release parking brake, and carry out troubleshooting. 5 Defective HST controller

HST Between (10) – ground

40-370

24


Voltage

F (Forward)

20 – 30 V

Other than above

Max. 1 V


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short

SEN03945-00



40-370

25

370 Troubleshooting by failure code (Display of code), Part 7 Failure code [J141N1] Steering pump: Overrun alarm

SEN03945-00

Failure code [J141N1] Steering pump: Overrun alarm Action code

Failure code

E02

J141N1

Trouble

Steering pump: Overrun alarm (HST controller system)

Contents of trouble

• Steering pump speed exceeded alarm operation set value.



Problem that appears on machine Related information Possible causes and standard value in normal state

• Steering pump may be broken (If it is broken, machine may not steer). • Advance alarm is turned ON before this code is displayed. • If steering pump speed decreases below alarm reset value, system resets itself. Causes


1 Steering pump overrun

a Give operator instructions to use engine in range where alarm is not turned ON.

Failure code [M100N1] HST pump: Overrun alarm Action code

Failure code

E02

M100N1


40-370

26

1

Trouble

1

HST pump: Overrun alarm (HST controller system)

• HST pump speed exceeded alarm operation set value. • Turns the centralized warning lamp and alarm buzzer ON.

• HST pump may be broken (If it is broken, machine cannot travel). • Advance alarm is turned ON before this code is displayed. • If HST pump speed decreases below alarm reset value, system resets itself. Causes 1 HST pump overrun

Standard value in normal state/Remarks on troubleshooting a Give operator instructions to use engine in range where alarm is not turned ON.


370 Troubleshooting by failure code (Display of code), Part 7 Failure code [M400N1] Motor 1: Overrun alarm

SEN03945-00

Failure code [M400N1] Motor 1: Overrun alarm Action code

Failure code

E02

M400N1

Trouble

Motor 1: Overrun alarm (HST controller system)

Contents of trouble

• HST motor 1 speed exceeded alarm operation set value.



Problem that appears on machine Related information Possible causes and standard value in normal state

1

• HST motor 1 may be broken (If it is broken, machine cannot travel). • Advance alarm is turned ON before this code is displayed. • If HST motor 1 speed decreases below alarm reset value, system resets itself. Causes 1 HST motor 1 overrun


Standard value in normal state/Remarks on troubleshooting a Give operator instructions to use engine in range where alarm is not turned ON.

40-370

27

SEN03945-00



40-370

28

SEN03946-01




40 Troubleshooting

40

400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start ............................................................................................................................... 4 E-2 Preheater does not operate normally ..................................................................................................... 12 E-3 Travel speed is low or high..................................................................................................................... 16 E-4 ECSS does not operate.......................................................................................................................... 22 E-5 ECSS keeps operating ........................................................................................................................... 25 E-6 Defective boom kick-out function and cancellation ................................................................................ 28 E-7 Defective bucket positioner function and cancellation............................................................................ 32 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 36 E-9 Travel direction selection system does not function ............................................................................... 40 E-10 Fan does not reverse ........................................................................................................................... 44 E-11 Fan keeps rotating in reverse ............................................................................................................... 48 E-12 Wiper does not operate ........................................................................................................................ 50 E-13 Windshield washer does not operate ................................................................................................... 54 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off........................................................ 58 E-15 Working lamp does not light up or go off .............................................................................................. 66 E-16 Turn signal lamp and hazard lamp do not light up or go off ................................................................. 72 E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 78 E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 80 E-19 Backup alarm does not sound or it keeps sounding............................................................................. 83 E-20 Horn does not sound or it keeps sounding........................................................................................... 86 E-21 Alarm buzzer does not sound or it keeps sounding ............................................................................. 88 WA320, 320PZ-6 (KA SPEC.)

40-400

1

SEN03946-01

400 Troubleshooting of electrical system (E-mode)

E-22 Air conditioner does not operate or stop............................................................................................... 90 E-23 The KOMTRAX system does not work properly................................................................................... 94

40-400

2


400 Troubleshooting of electrical system (E-mode)


SEN03946-01

40-400

3

400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start

SEN03946-01

E-1 Engine does not start

1

Contents of trouble

• The engine does not start.

Related information

• Before starting troubleshooting, check the following. a. Directional lever is in N (Neutral). b. Directional switch is in N (Neutral). c. Starting of engine is prohibited by function of KOMTRAX. d. Battery cable is not disconnected from battery. • The engine does not start, because the starting motor does not run due to troubles in the starting motor system and starting switch terminal C signal system. • Check that fuse is normal. (If it is broken, check the related wiring harness for grounding fault.) • The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked with the monitoring function (Code: MONITOR PANEL 40900, D-IN-2). • If failure code is indicated, carry out troubleshooting for it first. Causes 1 Defective battery

2

Defective battery relay (Internal defect)

3 Defective fuse

Standard value in normal state/Remarks on troubleshooting Specific gravity

Min. 1.26

Voltage

Min. 25 V

The battery relay can be judged normal if operating sounds are audible when the starting switch is operated. • Starting switch operation in the order of OFF o ON o OFF If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 18.) a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch START and carry out troubleshooting Starting motor

4


Defective starting motor (Internal defect)

Voltage

Between terminals B (E30) and ground

Power supply input

20 – 30 V

Between terminals C (E21) and ground

Starting input

20 – 30 V

If the starting motor does not run even if power supply input, battery input and starting input is normal, the starting motor is defective.

5

Defective alternator (Internal defect)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between alternator terminal R E02 (female) (1) – ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting with starting OFF and START each. L02 (male) Defective starting switch 6 (Internal defect)

Defective multifunction lever switch 7 (Internal disconnection or short circuit)

Position of switch

Resistance

OFF

Min. 1 Mz

START

Max. 1 z

Between (1) and (2)

OFF

Min. 1 Mz

Between (1) and (4)

ON

Max. 1 z

Between (1) and (3)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. MF1 (male) Between (1) and (3)

40-400

4


Voltage

N (Neutral).

20 – 30 V

Other than above

Max. 1 V



Causes

SEN03946-01


Defective directional switch (Internal defect)

L62 (male) Between (1) – (3)

Switch position

Resistance

N (Neutral)

Max. 1 z

Other than above

Min. 1 Mz


8 Defective directional selector switch actuation switch (Internal defect)

L63 (male)

Between (3) – (4)

Switch position

Resistance

ON (Directional switch is selected)

Max. 1 z

OFF (Lever is selected)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D21 (male)


Diode range

Continuity

Measure at (2) in Defective diodes (D21, Between (2) and (1) Continue diode range. D22) (Internal defect) 9 a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting withare detective out turning starting switch ON. D22 (male)

Diode range

Continuity

Between (2) and (1)

Measure at (2) in diode range.

Continue

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 10

Defective diodes (D01) (Internal defect)

D01 (male)

Diode range

Continuity

Between (5) and (1)


Continue

Between (6) and (2)


Continue



D03 (male)

Diode range

Continuity

Between (7) and (3)


Continue

Between (8) and (4)


Continue


Defective diode (D10) (Internal defect)


D10 (male)

Diode range

Continuity

Between (2) – (1)

Measure on (2) side in diode range


40-400

5


SEN03946-01

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (with wiring harness connected), then carry out troubleshooting without turning starting switch ON. Starting motor safety relay

Defective starting motor 13 safety relay (Internal defect)

Voltage

Between B-terminal E20 – E-terminal

Power supply input

20 – 30 V

Between R-terminal E01 (male) (2) – E-terminal

Charge input

Max. 1 V

Between S-terminal E01 (male) (1) – E-terminal

Starting input

20 – 30 V

Between C-terminal E19 – E-terminal

Output

20 – 30 V

If power supply input and starting input are normal but output voltage is low, starting motor safety relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L106 (male)

Resistance

Between (1) and (2)

200 – 400 z

a Prepare with starting switch OFF. a Check neutral safety relay unit.


Defective neutral safety 14 relay (L106) (Internal defect)

Neutral safety relay (L106)

Between (3) – (5)

(1) – (2)

Resistance

When 24 V is applied (When relay is “ON”)

Max. 1 z

Other than above (When relay is “OFF”)

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. When neutral safety relay (L106) is replaced with a relay of the same type, if the condition becomes normal, the neutral safety relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L107 (male), L108 (male)

Resistance

Between (1) and (2)

200 – 400 z

a Prepare with starting switch OFF. a Check engine control cut-out relay unit. Defective engine control 15 cut-out relays (L107, L108) (Internal defect)

Engine control cut-out relay (L107), (L108)

Between (3) – (5)

(1) – (2)

Resistance


Max. 1 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. When engine control cut-out relay (L107, L108) is replaced with a relay of the same type, if the condition becomes normal, the engine control cut-out relay is defective.

40-400

6



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L79 (male)

Resistance

Between (1) and (2) 200 – 400 z Defective KOMTRAX Between (3) and (6) Min. 1 Mz 16 engine cut-out relay (L79) (Internal defect) a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. When KOMTRAX engine cut-out relay (L79) is replaced with a relay of the same type, if the condition becomes normal, the KOMTRAX engine cut-out relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L102 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF. a Check VIS power supply holding relay Defective VIS power sup17 ply holding relay (L102) (Internal defect)

VIS power supply holding relay (L102)

Between (3) – (5)

(1) – (2)

Resistance


Max. 1 z


Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting.


When VIS power supply holding relay (L102) is replaced with another relay, if condition becomes normal, VIS power supply holding relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness 18 (Disconnection in wiring harness or defective contact)


Wiring harness between battery relay R04 – starting motor terminal B (E30)

Resistance

Max. 1 z

Between starting motor B-terminal E30 – starting motor safety relay B-terminal E20

Resistance

Max. 1 z

Between starting motor C-terminal E21 – starting motor safety relay C-terminal E19

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L106 (female) (5) – E01 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L106 (female) (2) – MF1 (female) (3), L63 (female) (3)

Resistance

Max. 1 z

Wiring harness between MF1 (female) (1), L63 (female) (4) – ground

Resistance

Max. 1 z

Wiring harness between L02 (female) (2) – L107 (female) (1), L108 (female) (1)

Resistance

Max. 1 z

Wiring harness between L02 (female) (4) – EC2 (female) (2)

Resistance

Max. 1 z

40-400

7


SEN03946-01

Causes

Disconnection in wiring harness 18 (Disconnection in wiring harness or defective contact)

Standard value in normal state/Remarks on troubleshooting Wiring harness between L107 (female) (2), L108 (female) (2) – EC2 (female) (33)

Resistance

Max. 1 z

Wiring harness between fuse No. 4 of fuse box (FS1) – L107 (female) (3), L108 (female) (3)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Possible causes and Ground fault in wiring harstandard value ness 19 in normal state (Contact with ground circuit)

Wiring harness between battery relay R04 – starting motor terminal B (E30) and ground

Resistance

Min. 1 Mz

Between wiring harness starting motor B-terminal E30 – starting motor safety relay B-terminal E20 and ground

Resistance

Min. 1 Mz

Between wiring harness starting motor C-terminal E21 – starting motor safety relay C-terminal E19 and ground

Resistance

Min. 1 Mz

Wiring harness between L02 (female) (3) – L79 (female) (3), – circuit branch end and ground

Resistance

Min. 1 Mz

Wiring harness between L79 (female) (6) – L106 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between L106 (female) (5) – E01 (female) (1) and ground

Resistance

Min. 1 Mz

Between wiring harness L02 (female) (2) – L107 (female) (1), L108 (female) (1) and ground

Resistance

Min. 1 Mz

Between wiring harness L02 (female) (4) – EC2 (female) (2) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Between wiring harness fuse box (FS1) No. 3 fuse – L102 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between L107 (female) (2), L108 (female) (2) – EC2 (female) (33) and ground

Resistance

Min. 1 Mz

Wiring harness between fuse No. 4 of fuse box (FS1) – L107 (female) (3), L108 (female) (3) and ground

Resistance

Min. 1 Mz

Wiring harness between L107 (female) (5), L108 (female) (5) – EC3 (female) (3), (4) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness Wiring harness between L107 (female) (2), L108 20 (Contact with 5V, 24V cir- (female) (2) – EC2 (female) (33), alternator terminal R E02 (female) (1) – E01 (female) (2), – cuit) circuit branch end and ground (Note: if hot short occurs across them, the charging lamp will be lighted as the starting switch is ON.

40-400

8

Voltage

Max. 1 V



Causes

SEN03946-01


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and Between EC2 (33) – ground Voltage Max. 1 V standard value 21 Defective engine controller Between EC2 (39) – ground Voltage 20 – 30 V in normal state Between EC3 (3), (4) – ground Voltage 20 – 30 V Between EC3 (1), (2) – ground


Voltage

Max. 1 V

40-400

9

SEN03946-01



40-400

10




SEN03946-01

40-400

11

400 Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate normally

SEN03946-01

E-2 Preheater does not operate normally

1

a) Preheater does not operate Contents of trouble

• When temperature is low (engine boost air temperature is below –4°C), preheater does not operate.

Related information

• If failure codes are displayed, carry out troubleshooting for them first. • Engine boost air temperature can be checked with monitoring function. (Monitoring code: ENG-18500-CHG TEMP (°C)) (Monitoring code: ENG-18501-CHG TEMP (V)) Causes

Standard value in normal state/Remarks on troubleshooting a Turn starting switch OFF and remove heater relay. a Check heater relay unit. Heater relay

1

Defective heater relay (Internal defect)

Between E05 – E07A

E06 – R90

Resistance


Max. 1 z


Min. 1 Mz 19 – 25 z

Between E06 – R90 Defective intake air heater 2 (Internal defect)


Between E07B – ground

0.17 – 0.27 z

a Prepare with starting switch OFF. a Replace diode (E06A). Possible causes and standard value in normal state

Condition becomes normal. Defective diode (E06A) 3 (Internal defect)

Diode (E06A) is defective.

Condition does not become norDiode (E06A) is normal. mal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. a Measure in diode range. Between (2) – (1) a Apply (+) side of tester to (2).

Continuity is secured.


Disconnection in wiring harness (Disconnection in wiring 4 Wiring harness between E07A – E07B or defective contact in connector) Wiring harness between R11 – E05

Resistance

Max. 1 z

Resistance

Max. 1 z


Ground fault in wiring harness Between wiring harness E07A – E07B and (Contact with GND circuit) ground Between wiring harness R11 – E05 and ground

40-400

12

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



SEN03946-01



40-400

13


SEN03946-01 b) Preheater operates constantly Contents of trouble

• Preheater operates constantly.

Related information

• If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it first. • Engine boost air temperature can be checked with monitoring function. (Monitoring code: ENG-18500-CHG TEMP (°C)) (Monitoring code: ENG-18501-CHG TEMP (V)) Causes

Standard value in normal state/Remarks on troubleshooting a Turn starting switch OFF and remove heater relay. a Check heater relay unit. Heater relay

1

Defective heater relay (Internal defect)

Between E05 – E07A

E06 – R90

Resistance


Max. 1 z


Min. 1 Mz 19 – 25 z

Between E06 – R90 Possible causes and standard value in normal state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 2 (Contact with GND circuit) Between wiring harness EC2 (40) – E06 (5) ResisMin. 1 Mz and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5V, 3 24V circuit) in wiring harness


Between wiring harness E07A – E07B and ground

When preheater is ON

Voltage

20 – 30 V

When preheater is OFF

Voltage

Max. 1 V

If cause 1 – 3 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Related circuit diagram a See the circuit diagram in “E-2 a) Preheater does not operate”.

40-400

14




SEN03946-01

40-400

15

400 Troubleshooting of electrical system (E-mode) E-3 Travel speed is low or high

SEN03946-01

E-3 Travel speed is low or high

1

a) Max. speed is 7 km/h or below and speedometer indicates 0 km/h Contents of trouble

• Travel speed does not increase above 4 – 7 km/h. • Speedometer of machine monitor keeps indicating 0 km/h during travel.

Related information

• If failure code [DLT3KX] or [DLT4KX] is also displayed, carry out troubleshooting for it first.

Causes


1

T09

Voltage

Between (1) – (2)

4.7 – 5.3 V


Max. 1 V

Defective travel speed sensor a Prepare with starting switch OFF, then start engine, travel at con(Internal defect) stant speed, and carry out troubleshooting. T09

Voltage

Between (3) – (2)


Between (4) – (2)




Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (32) – 2 or defective contact in connec- T09 (female) (2) tor) Wiring harness between HST (female) (26) – T09 (female) (3) Wiring harness between HST (female) (36) – T09 (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness HST (female) (22) – Ground fault in wiring harness T09 (female) (1) and ground 3 (Contact with GND circuit) Between wiring harness HST (female) (26) – T09 (female) (3) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Hot short (Contact with 5V, 4 24V circuit) in wiring harness

40-400

16

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness HST (32) – T09 (2) and ground

Voltage

Max. 1 V



Causes

SEN03946-01




HST

Voltage

Between (22) – (32)

4.7 – 5.3 V


Max. 1 V


Voltage

Between (26) – (32)


Between (36) – (32)




40-400

17


SEN03946-01

b) When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed level Contents of trouble

• When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed level.

Related information

• If failure code [DW26KA] or [DW26KY] is also displayed, carry out troubleshooting for it first.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace HST motor 2 solenoid relay (L103) with another relay.

1

Defective HST motor 2 solenoid relay (Internal defect)

Between (3) – (5)

2

Defective HST motor 2 solenoid (Internal defect)




a Prepare with starting switch OFF. a Check relay unit. HST motor 2 solenoid relay (L103)



(1) – (2)

Resistance

When 24 V is applied (Relay is ON)

Max. 1 z

Other than above (Relay is OFF)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between T07 (male) (1) – T07 (male) (2)

Resistance

15 – 30 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)

Wiring harness between L103 (female) (5) – T07 (female) (1)

Resistance

Max. 1 z

Wiring harness between T07 (female) (2) – ground

Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Between wiring harness L103 (female) (5) – ResisMin. 1 Mz T07 (female) (1) and ground tance

40-400

18



SEN03946-01



40-400

19


SEN03946-01

c) When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level Contents of trouble

• When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level.

Related information

• If failure code [DW26KA] is also displayed, carry out troubleshooting for it first.

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace HST motor 2 solenoid relay (L103) with another relay


1

Defective HST motor 2 solenoid relay (Internal defect)

Between (3) – (5)

40-400

20




a Prepare with starting switch OFF. a Check relay unit. HST motor 2 solenoid relay (L103)

Hot short (Contact with 24V 2 circuit) in wiring harness


(1) – (2)

Resistance

When 24 V is applied (Relay is ON)

Max. 1 z

Other than above (Relay is OFF)

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness L103 (female) (5) – T07 (female) (1) and ground

Resistance

Max. 1 V



SEN03946-01



40-400

21

400 Troubleshooting of electrical system (E-mode) E-4 ECSS does not operate

SEN03946-01

E-4 ECSS does not operate

1

Contents of trouble

• When ECSS switch is turned ON, ECSS does not operate.

Related information

• If failure code [D192KY] is also displayed, carry out troubleshooting for it first. • Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-3) • Input state (ON/OFF) from ECSS switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40901 – D-IN-8) Causes 1

Defective fuse No. 9 in fuse box FS-2

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault, etc. (See cause 6.) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. L09 (male)

Switch position ON

Max. 1 z

OFF

Min. 1 Mz

– (Always)

Min. 1 Mz

Between (5) – (6) 2

Defective ECSS switch (Internal defect)

Between (5), (6) – another terminal

Resistance



200 – 400 z



3

Defective ECSS solenoid relay (L110) (Internal defect)

Replace ECSS solenoid relay (L110) with another relay.







Defective ECSS solenoid 4 (Internal defect)

200 – 400 z


Between F07 (male) (1) – (2)

15 – 30 z



40-400

22

Wiring harness between fuse box FS-2, No. 9 – L09 (female) (6)

Resistance

Max. 1 z

Wiring harness between L09 (female) (5) – L25 (female) (5), L110 (female) (1), (3)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L110 (female) (5) – F07 (female) (1)

Resistance

Max. 1 z

Wiring harness between F07 (female) (2) – ground

Resistance

Max. 1 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness fuse box FS-2, No. 9 – L09 (female) (6), branch end and ground


Ground fault in wiring harness 6 Between wiring harness L09 (female) (5) – (Contact with GND circuit) L25 (female) (5), L110 (female) (1), (3), branch end and ground

Between wiring harness L110 (female) (5) – F07 (female) (1), branch end and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn ECSS switch ON, start engine, and carry out troubleshooting. 7

Defective machine monitor or HST controller

L24 Between (5) – (6)


Travel speed

Voltage

0 – 4 km/h

20 – 30 V

Min. 5 km/h

Max. 1 V

40-400

23

SEN03946-01



40-400

24


400 Troubleshooting of electrical system (E-mode) E-5 ECSS keeps operating

SEN03946-01

E-5 ECSS keeps operating

1

Contents of trouble

• When ECSS switch is turned OFF, ECSS keeps operating. • When ECSS switch is turned ON, ECSS operates even at low travel speed (4 km/h or below).

Related information

• Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40952 – D-OUT-3) • Input state (ON/OFF) from ECSS switch can be checked with monitoring function. (Monitoring code: MONITOR PANEL – 40901 – D-IN-8) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. L09 (male)

Switch position ON

Max. 1 z

OFF

Min. 1 Mz

– (Always)

Min. 1 Mz

Between (5) – (6) 1

Defective ECSS switch (Internal defect)

Between (5), (6) – another terminal

Resistance


Resistance

200 – 400 z


2

Defective ECSS solenoid relay (L110) (Internal defect)

Replace ECSS solenoid relay (L110) with another relay.







Defective ECSS solenoid 3 (Internal defect)

Resistance

200 – 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between F07 (male) (5) – (6)

Resistance

15 – 30 z



Wiring harness between fuse box FS-2, No. 9 – L09 (female) (6)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L110 (female) (5) – F07 (female) (1)

Resistance

Max. 1 z

Wiring harness between F07 (female) (2) – ground

Resistance

Max. 1 z


Ground fault in wiring harness Between wiring harness L24 (female) (11) – (Contact with GND circuit) L110 (female) (2) and ground

Resistance

Min. 1 Mz

Reference: If above is defective, ECSS operates when ECSS switch is turned ON even at low travel speed (4 km/h or below).


40-400

25


SEN03946-01

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON, turn ECSS switch OFF, and carry out troubleshooting.

6

Hot short (Contact with 24V circuit) in wiring harness


Between wiring harness L09 (female) (5) – L25 (female) (5), L110 (female) (1), (3), branch end and ground

Voltage

Max. 1 V

Between wiring harness L110 (female) (5) – F07 (female) (1), branch end and ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then turn ECSS switch ON, start engine, and carry out troubleshooting. L24 7


Between (5) – (6)

Travel speed

Voltage

0 – 4 km/h

20 – 30 V

Min. 5 km/h

Max. 1 V

a Prepare with starting switch OFF, then turn starting switch ON, turn ECSS switch OFF, and carry out troubleshooting. Between L24 (11) – ground

40-400

26

Voltage

Max. 1 V



SEN03946-01



40-400

27

400 Troubleshooting of electrical system (E-mode) E-6 Defective boom kick-out function and cancellation

SEN03946-01

E-6 Defective boom kick-out function and cancellation Contents of trouble

1

• Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch system, boom kick-out PPC detent system and lift arm detent relay system.

Related information

—

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. a Replace boom kick-out relay (L113) with normal relay. a Operate boom kick-out with engine started. Boom kick-out function is normal.

Defective relay L113.

Boom kick-out does not function.

Relay L113 is normal.

a Turn starting switch OFF, then carry out troubleshooting without turning starting switch ON.

1

Defective boom kick-out relay (L113) (Internal defect) Between L113 (male) (1) and (2)

Resistance

200 – 400 z

Applies 24V impressed voltage between L113 (male) (1) – (2)

Resistance

Max. 1 z

Does not apply voltage between L113 (male) (1) – (2)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF. a Solid part check. Between L113 (male) (3) and (5)

a Prepare with starting switch OFF. a Replace detent active relay (L115) with normal relay. a Operate boom kick-out with engine started.


Boom kick-out function is normal.





Defective detent active relay (Internal defect)

Resistance

Between L115 (male) (1) and (2)

200 – 400 z

a Prepare with starting switch OFF. a Solid part check. a Applies impressed voltage between L115 (male) (1) – (2) Between L115 (male) (3) and (5)


Resistance

Max. 1 z


Resistance

Min. 1 Mz

Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective boom kick-out PPC Between L36 (male) (1) and (2) detent (Internal defect) Between L36 (male) (1), (2) – ground

Resistance

30 – 50 z

Resistance

Min. 1 Mz

a Prepare with starting switch OFF. a Interchange lift arm positioner proximity switch (F04) with bucket positioner proximity switch (F03). a Operate boom kick-out with engine started. Defective lift arm positioner 4 proximity switch (Internal defect)

40-400

28


Defective boom kickout proximity switch F04


Boom kick-out proximity switch F04 is normal.



Causes

SEN03946-01


Wiring harness discontinuity 5 (Disconnection or defective contact)

Wiring harness between F04 (female) (A) and fuse (FS1) (13)

Resistance

Max. 1 z

Wiring harness between F04 (female) (B) and L113 (female) (2)

Resistance

Max. 1 z

Wiring harness between F04 (female) (C) and ground

Resistance

Max. 1 z

Wiring harness between L113 (female) (1), (3) and L115 (female) (5)

Resistance

Max. 1 z

Wiring harness between L115 (female) (3) and fuse FS1 (13)

Resistance

Max. 1 z

Wiring harness between L113 (female) (5) and L36 (female) (1)

Resistance

Max. 1 z

Wiring harness between L36 (female) (2) and ground

Resistance

Max. 1 z

Wiring harness between E02 (female) (1) – L115 (female) (1)

Resistance

Max. 1 z

Wiring harness between L115 (female) (2) – ground

Resistance

Max. 1 z

a With all the above items, the boom kick-out does not function a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between F04 (female) (B) and L113 (female) (2) and ground

Resistance

Min. 1 Mz

Wiring harness between L113 (female) (5) and L36 (female) (1) and ground

Resistance

Min. 1 Mz

a In this case, the boom kick-out detent does not function (lever returns to neutral) 6

Wiring harness ground fault (Contact with GND circuit)

Wiring harness between F04 (female) (A) and fuse (FS1) (13) and ground

Resistance

Min. 1 Mz

Wiring harness between L113 (female) (1) (3) and L115 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between L115 (female) (3) and fuse FS1 (13) and ground

Resistance

Min. 1 Mz

Wiring harness between E02 (female) (1) – L115 (female) (1) and ground

Resistance

Min. 1 Mz

a In this case, the fuse is blown and no detents function (lever returns to neutral) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short-circuiting between 7 harnesses (Contact with 5 V, 24V circuit)


Voltage

Max. 1 V

a In this case, the boom kick-out does not function (lever does not return to neutral) Wiring harness between L113 (female) (1), (3) – L115 (female) (5) and ground

Voltage

Max. 1 V

a In this case, lift arm detent operates even if engine is stopped.


40-400

29


SEN03946-01


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON, raise lift arm to the highest position (kick-out operated), and carry out troubleshooting.

Hot short-circuiting between Wiring harness between F04 (female) (B) – 7 harnesses (Contact with 5 V, 24V circuit) L113 (female) (2) and ground

Voltage

Max. 1 V

a In this case, boom kick-out detent does not function (lever returns to neutral).

40-400

30



SEN03946-01



40-400

31

400 Troubleshooting of electrical system (E-mode) E-7 Defective bucket positioner function and cancellation

SEN03946-01

E-7 Defective bucket positioner function and cancellation

1

Contents of trouble

• Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system, bucket PPC detent system and bucket detent relay system.

Related information

—

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. a Replace bucket leveler relay (L114) with normal relay. a Operate bucket positioner with engine started. Bucket positioner function is normal.


Bucket positioner does not function.



Defective bucket leveler relay Between L114 (male) (1) and (2) (L114)

Resistance

200 – 400 z



Resistance

Max. 1 z


Resistance

Min. 1 Mz

a Turn starting switch OFF. a Replace detent active relay (L115) with normal relay. a Operate boom kick-out with engine started.


2

Defective detent active relay (L113)






Between L115 (male) (1) and (2)

200 – 400 z


3 Defective bucket PPC detent


Resistance

Max. 1 z


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between L37 (male) (1) and (2)

40-400

32

Resistance

30 – 50 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. a Interchange bucket positioner proximity switch (F03) with lift arm positioner proximity switch (F04). a Operate bucket positioner with engine started.

4

Defective bucket positioner proximity switch

Bucket positioner function is normal.

Defective bucket positioner proximity switch F03

Bucket positioner does not function.

Bucket positioner proximity switch F03 is normal.




Wiring harness between F03 (female) (A) and fuse FS1 (13)

Resistance

Max. 1 z

Wiring harness between F03 (female) (B) and L114 (female) (2)

Resistance

Max. 1 z

Wiring harness between F03 (female) (C) and ground

Resistance

Max. 1 z

Wiring harness between L114 (female) (1) (3), and L115 (female) (5)

Resistance

Max. 1 z

Wiring harness between L115 (female) (3) and fuse FS1 (13)

Resistance

Max. 1 z

Wiring harness between L114 (female) (5) and L37 (female) (1)

Resistance

Max. 1 z

Wiring harness between L37 (female) (2) and ground

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a With all the above items, the bucket positioner does not function


40-400

33


SEN03946-01

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F03 (female) (B) – L114 (female) (2) and ground

Resistance

Min. 1 Mz

a In this case, the bucket positioner detent does not function (lever does not return to neutral) Wiring harness between L114 (female) (5) – L37 (female) (1) and ground

6 Wiring harness ground fault


Resistance

Min. 1 Mz

a In this case, the bucket positioner does not function (lever returns to neutral) Wiring harness between F03 (female) (A) – fuse FS1 (13) and ground

Resistance

Min. 1 Mz

Wiring harness between L114 (female) (1) (3) – L115 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between L115 (female) (3) – fuse FS1 (13) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a In this case, the fuse is blown and no detents function (lever returns to neutral) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Wiring harness between L114 (female) (5) – L37 (female) (1) and ground

Voltage

Max. 1 V

a In this case, the bucket positioner does not function (lever does not return to neutral) Hot short-circuiting between 7 harnesses (Contact with 5 V, 24 V circuit)

Wiring harness between L114 (female) (1), (3) – L115 (female) (5) and ground

Voltage

Max. 1 V


Voltage

Max. 1 V

a In this case, bucket detent operates even if engine is stopped. a Prepare with starting switch OFF, then turn starting switch ON, tilt bucket, and carry out troubleshooting. Wiring harness between F03 (female) (B) – L114 (female) (2) and ground

Voltage

Max. 1 V

a In this case, bucket positioner detent does not function (lever returns to neutral).

40-400

34



SEN03946-01



40-400

35

400 Troubleshooting of electrical system (E-mode) E-8 Defective lift arm FLOATING holding function and cancellation

SEN03946-01

E-8 Defective lift arm FLOATING holding function and cancellation

1

Contents of trouble

• Lift arm FLOATING holding does not function or cannot be cancelled due to defective boom kick-out proximity switch system, lift arm FLOATING PPC detent system and kick-out proximity switch system.

Related information

—

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. a Replace boom kick-out relay (L113) with normal relay. a Operate lift arm FLOATING with engine started. Lift arm FLOATING function is normal.


Lift arm FLOATING does not function.


a Turn starting switch OFF, then carry out troubleshooting without turning starting switch ON.

1

Defective boom kick-out relay (L113) (Internal defect) Between L113 (male) (1) – (2)

Resistance

200 – 400 z


Resistance

Max. 1 z


Resistance

Min. 1 Mz

a Prepare with starting switch OFF. a Solid part check. Between L113 (male) (3) and (5)

a Prepare with starting switch OFF. a Replace detent active relay (L115) with normal relay. a Operate lift arm FLOATING with engine started.


Lift arm FLOATING function is normal.





Defective detent active relay (Internal defect)

Resistance


200 – 400 z



Resistance

Max. 1 z


Resistance

Min. 1 Mz

Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Defective lift arm FLOATING PPC detent (Internal defect)


Resistance

30 – 50 z

Between L35 (1), (2) – ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF. a Interchange lift arm positioner proximity switch (F04) with bucket positioner proximity switch (F03). a Operate lift arm FLOATING with engine started. Defective lift arm positioner 4 proximity switch (Internal defect)

40-400

36

Lift arm FLOATING function is normal.

Defective boom kickout proximity switch F04


Boom kick-out proximity switch F04 is normal.



Causes

SEN03946-01



Wiring harness between F04 (female) (A) – fuse (FS1) (13)

Resistance

Max. 1 z

Wiring harness between F04 (female) (B) – L113 (female) (2)

Resistance

Max. 1 z

Wiring harness between F04 (female) (C) – ground

Resistance

Max. 1 z

Wiring harness between L113 (female) (1), (3) – L115 (female) (5)

Resistance

Max. 1 z

Wiring harness between L115 (female) (3) – fuse FS1 (13)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a With all the above items, the boom kick-out does not function a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between F04 (female) (B) – L113 (female) (2) and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a In this case, the boom kick-out detent does not function (lever returns to neutral) 6

Wiring harness ground fault (Contact with GND circuit)

Wiring harness between F04 (female) (A) – fuse (FS1) (13) and ground

Resistance

Min. 1 Mz

Wiring harness between L113 (female) (1) (3) – L115 (female) (5) and ground

Resistance

Min. 1 Mz

Wiring harness between L115 (female) (3) – fuse FS1 (13) and ground

Resistance

Min. 1 Mz

Wiring between harness E02 (female) (1) – L115 (female) (1) and ground

Resistance

Min. 1 Mz

a In this case, the fuse is blown and no detents function (lever returns to neutral) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short-circuiting between 7 harnesses (Contact with 5 V, 24V circuit)


Voltage

Max. 1 V

a In this case, the boom kick-out does not function (lever does not return to neutral) Wiring between harness L113 (female) (1), (3) – L115 (female) (5) and ground

Voltage

Max. 1 V

a In this case, lift arm detent operates even if engine is stopped.


40-400

37


SEN03946-01


40-400

38

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON, operate lift arm FLOATING, and carry out troubleshooting.

Hot short-circuiting between Wiring harness between F04 (female) (B) – Voltage Max. 1 V 7 harnesses L113 (female) (2) and ground (Contact with 5 V, 24V circuit) a In this case, lift arm FLOATING detent does not function (lever returns to neutral).



SEN03946-01



40-400

39

400 Troubleshooting of electrical system (E-mode) E-9 Travel direction selection system does not function

SEN03946-01

E-9 Travel direction selection system does not function

1

a) When parking brake is released, parking brake indicator of machine monitor keeps lighting. Contents of trouble

• Machine does not travel forward and reverse because of trouble in parking brake system, forward solenoid valve system or directional lever system.

Related information

• Before starting troubleshooting, check following items (1) and (2). (1) Parking brake is released. (2) Parking brake is released and parking brake indicator lamp is OFF. • If any failure code is displayed, carry out troubleshooting for it first. • Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring function of machine monitor. (Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2) • Output state of directional solenoid FR output can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19) Causes


Defective parking brake bot1 tom switch (Malfunction or wrong positioning)



Parking brake lever position

Resistance

Bottom

Max. 1 z

Other than above

Min. 1 Mz


Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (16), 2 or defective contact in connec- L27 (female) (1), (6) – (2) – L47 (female) (2) tor) L47 (female) (1) – ground

Resistance

Max. 1 z

Resistance

Max. 1 z


40-400

40


D02 (male)

Diode range

Continuity

Between (5) – (1)


Continue

Between (7) – (3)


Continue



SEN03946-01



40-400

41


SEN03946-01

b) When parking brake is released, parking brake indicator of machine monitor goes off but machine does not travel forward Contents of trouble

• Machine does not travel forward because of trouble in parking brake system, forward solenoid valve system or directional lever system.

Related information

• Before starting troubleshooting, check following items (1) and (2). (1) Parking brake is released. (2) Parking brake is released and parking brake indicator lamp is OFF. • If any failure code is displayed, carry out troubleshooting for it first. • Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring function of machine monitor. (Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2) • Output state of directional solenoid FR output can be checked with monitoring function. (Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19) Causes


1


Between T01 (male) (1) – (2)

Resistance

30 – 60 z

Between T01 (male) (1), (2) – ground

Resistance

Min. 1 Mz



Between T01 (male) (3) – (4)

Resistance

30 – 60 z

Between T01 (male) (3), (4) – ground

Resistance

Min. 1 Mz



3

Defective FNR (directional) lever switch (Internal defect)

Between (1) – (2) Between (1) – (3) Between (1) – (4)

FNR (Directional) lever

Resistance

F (Forward)

Max. 1 z

Other than above

Min. 1 Mz

N (Neutral)

Max. 1 z

Other than above

Min. 1 Mz

R (Reverse)

Max. 1 z

Other than above

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, release parking brake, and carry out troubleshooting. HST Between (10) – ground 4 Defective HST controller

F (Forward)

20 – 30 V

Other than above

Max. 1 V

R (Reverse)

20 – 30 V

Other than above

Max. 1 V


F (Forward)

20 – 30 V

Other than above

Max. 1 V

N (Neutral)

20 – 30 V

Other than above

Max. 1 V

R (Reverse)

20 – 30 V

Other than above

Max. 1 V


42

Voltage



40-400

FNR (Directional) lever



SEN03946-01



40-400

43

400 Troubleshooting of electrical system (E-mode) E-10 Fan does not reverse

SEN03946-01

E-10 Fan does not reverse

1

Contents of trouble

• When fan manual reverse switch is turned ON, fan does not reverse. • When fan auto-reverse switch is turned ON, fan does not reverse

Related information

• If failure code [DD1NL4], [DW7BKY] or [DW7BKZ] is also displayed, carry out troubleshooting for it first. • Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with monitoring function. (Monitoring code: HST – 93400 – FAN REVERSE SW) (Manual reverse switch: Monitoring code: MONITOR PANEL – 40900 – D-IN-1) (Auto- reverse switch: Monitoring code: MONITOR PANEL – 40901 – D-IN-9) • Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode. (Monitoring code: HST – 40980 – D-OUT-17) Causes 1

Defective fuse No. 13 in fuse box (FS1)

Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has ground fault etc. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. L69 (male)

Switch position

Resistance

Manual reverse ON

Max. 1 z

Other than above

Min. 1 Mz

Auto-reverse ON

Max. 1 z

Other than above

Min. 1 Mz

Between (5) – terminal other than (4) and (6)

Any position

Min. 1 Mz

Between (4), (6) – terminal other than (5)

Any position

Min. 1 Mz

Between (1), (3) – (2)

Any position

5 – 20 kz


Any position

Min. 1 Mz

Between (5) – (6)

Defective cooling fan auto2 reverse switch (Internal defect)


Between (5) – (4)

a Prepare with starting switch OFF. a Replace relay (L104). Condition becomes normal.





Defective fan reverse solenoid Between L104 (male) (1) – (2) relay (L104) (Internal defect) a Prepare with starting switch OFF. a Check relay unit. Fan reverse solenoid relay (L104)

Between (3) -– (5)

Defective fan reverse solenoid 4 (Internal defect)

40-400

44

Resistance

200 – 400 z

(1) – (2)

Resistance

When 24 V is applied (When relay is ON)

Max. 1 z

Other than above (When relay is OFF)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between R59 (male) (1) – (2)

Resistance

30 – 50 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between No. 13 in fuse box (FS1) – L69 (female) (5)

Resistance

Max. 1 z


Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between L104 (female) (5) – R59 (female) (1)

Resistance

Max. 1 z

Wiring harness between R59 (female) (2) – ground

Resistance

Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between L69 (female) (6) – 5 or defective contact in connec- L25 (female) (10) tor) Wiring harness between L102 (female) (3) – L104 (female) (3)


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness No. 13 in fuse box Ground fault in wiring harness (FS1) – L69 (female) (5) and ground 6 (Contact with GND circuit) Between wiring harness L69 (female) (3), (4) – L25 (female) (14) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Between wiring harness L69 (female) (1), (6) – L25 (female) (10) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then start engine, operate cooling fan reverse switch, and carry out troubleshooting. 7



HST

Indicator

Voltage


OFF

20 – 30 V

ON

Max. 1 V

40-400

45

SEN03946-01



40-400

46




SEN03946-01

40-400

47

400 Troubleshooting of electrical system (E-mode) E-11 Fan keeps rotating in reverse

SEN03946-01

E-11 Fan keeps rotating in reverse

1

Contents of trouble

• When fan manual reverse switch is turned OFF, fan keeps rotating in reverse. • When fan auto-reverse switch is turned OFF, fan starts rotating in reverse automatically.

Related information

• If failure code [DD1NLD] or [DW7BKZ] is also displayed, carry out troubleshooting for it first. • Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with monitoring function. (Monitoring code: HST – 93400 – FAN REVERSE SW) (Manual reverse switch: Monitoring code: MONITOR PANEL – 40900 – D-IN-1) (Auto-reverse switch: Monitoring code: MONITOR PANEL – 40901 – D-IN-9) • Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode. (Monitoring code: HST – 40980 – D-OUT-17) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. L69 (male) Between (5) – (6)

Defective cooling fan auto1 reverse switch (Internal defect)

Between (5) – (4)

Switch position

Resistance

Manual reverse ON

Max. 1 z

Other than above

Min. 1 Mz

Auto-reverse ON

Max. 1 z

Other than above

Min. 1 Mz

Between (5) – terminal other than (4) and (6)

Any position

Min. 1 Mz


Any position

Min. 1 Mz

Between (1), (3) – (2)

Any position

5 – 20 z


Any position

Min. 1 Mz

a Prepare with starting switch OFF. a Replace relay (L104). Possible causes and standard value in normal state






Defective fan reverse solenoid Between L104 (male) (1) – (2) relay (L104) (Internal defect) a Prepare with starting switch OFF. a Check relay unit. Fan reverse solenoid relay (L104)

Between (3) – (5)

Resistance

200 – 400 z

(1) – (2)

Resistance

When 24 V is applied (When relay is ON)

Max. 1 z

Other than above (When relay is OFF)

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Hot short (Contact with 5V, 3 24V circuit) in wiring harness

40-400

48


Voltage

Max. 1 V


Voltage

Max. 1 V

Between wiring harness L104 (female) (5) – R59 (female) (1) and ground

Voltage

Max. 1 V


400 Troubleshooting of electrical system (E-mode) E-11 Fan keeps rotating in reverse


SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine, operate cooling fan reverse switch, and carry out troubleshooting.

4


HST

Indicator

Voltage


OFF

20 – 30 V

ON

Max. 1 V



40-400

49

400 Troubleshooting of electrical system (E-mode) E-12 Wiper does not operate

SEN03946-01

E-12 Wiper does not operate

1

Contents of trouble

(1) Front wiper does not operate.

Related information

• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.

Causes 1


Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

2

Defective front wiper motor (Internal defect)

L57

Front wiper switch

Voltage


Constant

20 – 30 V


Lo

20 – 30 V


Hi

20 – 30 V

• If wiper switch is turned OFF while wiper is operating, voltage is applied between L57 (5) and ground until wiper motor stops. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


3

Defective wiper timer (relay) (Internal defect)

L48

Front wiper switch

Voltage


Constant

20 – 30 V


INT

20 – 30 V


Washer side

20 – 30 V

INT (If wiper switch is Repeat 20 to 30 V o Between (5) – ground set in INT, voltage is 0V output intermittently.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

4

Defective front wiper switch (Internal defect)

L05

Voltage


20 – 30 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L05

Front wiper switch

Resistance

Between (7) – (5)

Lo

Max. 1 z

Between (7) – (4)

Hi

Max. 1 z

Between (7) – (2)

INT

Max. 1 z

Between (3) – (5)

INT

Max. 1 z

Other than above

40-400

50

Min. 1 Mz



Causes

SEN03946-01





Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L05 (female) (7) – fuse No. 14 of fuse box (FS1), – circuit branch end

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Grounding fault in wiring har6 ness (Contact with ground circuit)



Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between L05 (female) (7) – fuse No. 14 of fuse box (FS1), – circuit branch end and ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

40-400

51


SEN03946-01

Contents of trouble

(2) Rear wiper does not operate.

Related information

• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.

Causes


Defective rear wiper motor 1 (Internal defect)

L52

Rear wiper switch

Voltage


Constant

20 – 30 V


ON

20 – 30 V

• If wiper switch is turned OFF while wiper is operating, voltage is applied between L52 (3) and ground until wiper motor stops. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

2

Defective rear wiper switch (Internal defect)


L05

Voltage


20 – 30 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L05

Rear wiper switch

Resistance

Between (7) – (9)

ON

Max. 1 z

Between (8) – (9)

OFF

Max. 1 z

Other than above

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector)

Wiring harness between L05 (female) (7) – fuse No. 14 of fuse box (FN1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (7) – fuse No. 14 of fuse box (FS1), – circuit Ground fault in wiring harness branch end and ground 4 (Contact with ground circuit) Wiring harness between L05 (female) (8) – L52 (female) (3) and ground Wiring harness between L05 (female) (9) – L52 (female) (2) and ground

40-400

52

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz



SEN03946-01



40-400

53

400 Troubleshooting of electrical system (E-mode) E-13 Windshield washer does not operate

SEN03946-01

E-13 Windshield washer does not operate

1

Contents of trouble

Windshield washer does not operate.

Related information

• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the windshield washer does not operate. • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not operate normally, carry out troubleshooting for “E-12 Wiper does not operate” first.) Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then hold starting switch OFF or turn it ON and carry out troubleshooting.

1

Defective front washer motor (Internal defect)

B07

Front wiper switch

Voltage/Resistance


Window washer operation position

20 – 30 V


Max. 1 z

If voltage and resistance are normal but front washer does not operate, front washer motor is defective.

2

Defective rear washer motor (Internal defect)

B06

Rear wiper switch

Voltage/Resistance


Window washer operation position

20 – 30 V


Max. 1 z

If voltage and resistance are normal but rear washer does not operate, rear washer motor is defective. B07

Front wiper switch

Voltage/Resistance

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state

Defective front wiper switch 3 (Internal defect)

L05

Voltage


20 – 30 V


Washer switch for front wiper

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

Constant

Min. 1 Mz

Between (7) – (6) Between (7), (6) – ground


Defective rear wiper switch 4 (Internal defect)

L05

Voltage


20 – 30 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L05 (male) Between (7) – (10) Between (7), (10) – ground

40-400

54

Washer switch for rear wiper

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

Constant

Min. 1 Mz



Causes

SEN03946-01


5

Defective wiper timer (relay) (for only front wiper)

L48

Washer switch for front wiper

Voltage


Constant

20 – 30 V


ON

20 – 30 V

Between (5) – ground 0.2 – 0.8 sec after ON

20 – 30 V




Wiring harness between L05 (female) (6) – B07 (female) (1), – L48 (female) (2)

Resistance

Max. 1 z

Wiring harness between L05(female) (7) – fuse No. 14 of fuse box (FS1)

Resistance

Max. 1 z

Wiring harness between L05 (female) (10) – B06 (female) (1)

Resistance

Max. 1 z

Wiring harness between B07 (female) (2), B06 (female) (2) – ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (6) – B07 (female) (1), – L48 (female) (2), – circuit branch end and ground

7

Ground fault in wiring harness (Contact with ground circuit) Wiring harness between L05 (female) (7) – fuse No. 14 of fuse box (FS1), – circuit branch end and ground

Wiring harness between L05 (female) (10) – B06 (female) (1), – circuit branch end and ground


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

40-400

55

SEN03946-01



40-400

56




SEN03946-01

40-400

57

400 Troubleshooting of electrical system (E-mode) E-14 Headlamp, clearance lamp and tail lamp do not light up or go off

SEN03946-01

E-14 Headlamp, clearance lamp and tail lamp do not light up or go off

1

Contents of trouble

(1) Headlamp, clearance lamp and tail lamp do not light up or go off.

Related information

• Since the lamp system GND circuit is disconnected or shorted with the ground, none of the lamps lights up. Reference: • Headlamp at SMALL position: Clearance lamp, tail lamp, machine monitor night lamp light up (when normal). • Headlamp at HEAD position: Above lamps and headlamp light up (when normal). • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP). • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0). • The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34). Causes



Defective lamp switch 1 (Internal defect)

58

Lamp switch

Resistance

OFF

Min. 1 Mz

Between (2) – (3)

1st line

Min. 1 Mz

2nd line

Max. 1 z

OFF

Min. 1 Mz

1st line

Max. 1 z

2nd line

Max. 1 z

Between (1) – (3)

Disconnection in wiring harness 2 (Disconnection or defective connector contact)

40-400

L04 (male)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L04 (female) (3) – ground

Resistance

Max. 1 z



SEN03946-01

Contents of trouble

(2) Either of headlamp (low and high beams) does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective. • Carry out the following troubleshooting when the clearance lamp and tail lamp light up and go off normally. • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0). • The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34). Causes


Defective fuses No. 8 and No. If the fuse is burn, the circuit probably has a grounding fault, etc. 1 9 of fuse box (FS1) (See cause 7.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L120 (male) 2

Resistance

Defective headlamp relay, left Between (1) – (2) 200 – 400 z (L120) (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When headlamp relay (L120) is replaced with a relay of the same type, if the condition becomes normal, the headlamp relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


3

Defective headlamp relay, right (L119)

L119 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When headlamp relay (L119) is replaced with a relay of the same type, if the condition becomes normal, the headlamp relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4

Defective lamp switch (Internal defect)


Headlamp switch

Resistance

OFF

Min. 1 Mz

1st position

Min. 1 Mz

2nd position

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L04 (male) Defective dimmer switch 5 (Internal defect)

Between (5) – (3) Between (4) – (3)


Dimmer switch

Resistance

Low

Min. 1 Mz

High

Max. 1 z

Low

Max. 1 z

High

Min. 1 Mz

40-400

59


SEN03946-01

Causes




Resistance

Max. 1 z

Wiring harness between fuse No. 8 of fuse box (FS1) – L120 (female) (1), (3)

Resistance

Max. 1 z

Wiring harness between L120 (female) (5) – L25 (female) (1), – left FLH (female) (B)

Resistance

Max. 1 z

a Carry out above 3 items when left side does not light. Wiring harness between L04 (female) (2) – L119 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L119 (female) (5) – right FLH (female) (B)

Resistance

Max. 1 z

a Carry out above 3 items when right side does not light. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L04 (female) (2) – L120 (female) (2), – circuit branch end and ground Possible causes and standard value in normal state

Resistance

Min. 1 Mz

a Carry out above when left side does not go off. Wiring harness between fuse No. 8 of fuse box (FS1) – L120 (female) (1), (3) and ground

Resistance

Min. 1 Mz

Wiring harness between L120 (female) (5) – ResisMin. 1 Mz Ground fault in wiring harness L25 (female) (1), – left FLH (female) (B) and tance 7 (Contact with ground circuit) ground a Carry out above 2 items when left side does not light. Wiring harness between L04 (female) (2) – L119 (female) (2) and ground

Resistance

Min. 1 Mz

a Carry out above when right side does not go off. Wiring harness between fuse No. 9 of fuse box (FS1) – L119 (female) (1), (3) and ground

Resistance

Min. 1 Mz

Wiring harness between L119 (female) (5) – right FLH (female) (B) and ground

Resistance

Min. 1 Mz

a Carry out above 2 items when right side does not light. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Headlamp switch is OFF Wiring harness between L120 (female) (5) – L25 (female) (1), – left FLH (female) (B) and Voltage Hot short in wiring harness 8 (Contact with 5 V, 24V circuit) ground a Carry out above when left side does not go off. Wiring harness between L119 (female) (5) – right FLH (female) (B) and ground

Voltage

Max. 1 V

Max. 1 V

a Carry out above when left side does not light.

40-400

60



SEN03946-01

Contents of trouble

(3) Headlamp (low beam) does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the ground. • Carry out the following troubleshooting when the high beam lights up (goes off) normally. • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0). • The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34). Causes 1 Broken bulb

Standard value in normal state/Remarks on troubleshooting If a specific headlamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L04 (male)

Defective dimmer switch 2 (Internal defect) Possible causes and standard value in normal state



Dimmer switch

Resistance

Low

Min. 1 Mz

High

Max. 1 z

Low

Max. 1 z

High

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FLH (female) (A) – L04 (female) (4)

Resistance

Max. 1 z

Reference: Connector “FLH” is installed to both right and left sides. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

Ground fault in wiring harness Wiring harness between FLH (female) (A) – (Contact with ground circuit) L04 (female) (4) and ground

Resistance

Min. 1 Mz

Reference: Connector “FLH” is installed to both right and left sides.


40-400

61


SEN03946-01

Contents of trouble

(4) Headlamp (high beam) does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the ground. • Carry out the following troubleshooting when the low beam lights up (goes off) normally. • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0). • The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34). Causes 1 Broken bulb

Standard value in normal state/Remarks on troubleshooting If a specific headlamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L04 (male)

Defective dimmer switch 2 (Internal defect) Possible causes and standard value in normal state



Dimmer switch

Resistance

Low

Min. 1 Mz

High

Max. 1 z

Low

Max. 1 z

High

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FLH (female) (C) – L04 (female) (5)

Resistance

Max. 1 z

Reference: Connector “FLH” is installed to both right and left sides. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4

Ground fault in wiring harness Wiring harness between FLH (female) (C) – (Contact with ground circuit) L04 (female) (5), – circuit branch end and ground

Resistance

Min. 1 Mz

Reference: Connector “FLH” is installed to both right and left sides.

40-400

62



SEN03946-01

Contents of trouble

(5) Clearance lamp does not light up or go off. (6) Tail lamp does not light up or go off.

Related information

• Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system. • When the headlamp and turn signal lamp light up. • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP). Causes 1 Broken bulb 2

Defective fuses No. 10 and No. 11 of fuse box (FS2)

Standard value in normal state/Remarks on troubleshooting If a specific lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

L117 (male)

Resistance

Between (1) – (2)

200 – 400 z

Defective small lamp relay, left a Prepare with starting switch OFF, then turn starting switch ON (L117) (Internal defect) and carry out troubleshooting. When small lamp relay (L117) is replaced with a relay of the same type, if the condition becomes normal, the small lamp relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4

Defective small lamp relay, right (L118) (Internal defect)


L118 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When small lamp relay (L118) is replaced with a relay of the same type, if the condition becomes normal, the small lamp relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5

Defective lamp switch (Internal defect)


Lamp switch

Resistance

OFF

Min. 1 Mz

1st position

Max. 1 z

2nd position

Max. 1 z



Wiring harness between L04 (female) (1) – L117 (female) (2), – L118 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z

a Carry out above 2 items when left side does not light. Wiring harness between fuse No. 11 of fuse box (FS2) – L118 (female) (1), (3)

Resistance

Max. 1 z

a Carry out above when right side does not light.


Wiring harness between L117 (female) (5) – FLC1 (female) (A), – R22 (female) (6)

Resistance

Max. 1 z

Wiring harness between L118 (female) (5) – FLC (female) (A), – R23 (female) (6)

Resistance

Max. 1 z

40-400

63


SEN03946-01

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L04 (female) (1) – L117 (female) (2), – L118 (female) (2) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Carry out above when lamp does not go off. Wiring harness between fuse No. 10 of fuse box (FS2) – L117 (female) (1), (3) and ground 7


Ground fault in wiring harness a Carry out above when left side does not go off. (Contact with ground circuit) Wiring harness between fuse No. 11 of fuse Resisbox (FS2) – L118 (female) (1), (3) and tance ground

Min. 1 Mz

a Carry out above when right side does not light. Wiring harness between L117 (female) (5) – FLC1 (female) (A), – R22 (female) (6) and ground

Resistance

Min. 1 Mz

Wiring harness between L118 (female) (5) – FLC (female) (A), – R23 (female) (6) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Headlamp switch is OFF Wiring harness between L04 (female) (1) – L117 (female) (2), – L118 (female) (2), – circuit branch end and ground

Hot short in wiring harness 8 (Contact with 5 V, 24V circuit) Wiring harness between L117 (female) (5) – FLC1 (female) (A), – R22 (female) (6), – circuit branch end and ground Wiring harness between L118 (female) (5) – FLC (female) (A), – R23 (female) (6), – circuit branch end and ground

40-400

64

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

Max. 1 V



SEN03946-01



40-400

65

400 Troubleshooting of electrical system (E-mode) E-15 Working lamp does not light up or go off

SEN03946-01

E-15 Working lamp does not light up or go off

1

Contents of trouble

(1) Front working lamp does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the front working lamp system is defective • When the rear working lamp is normal • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance lamp first. Causes 1 Broken bulb 2


Standard value in normal state/Remarks on troubleshooting If a specific working lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Defective front working lamp relay (L122) (Internal defect)

L122 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When front working lamp relay (L122) is replaced with a relay of the same type, if the condition becomes normal, the front working lamp relay is defective.


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L07 (male) 4

Defective front working lamp switch (Internal defect)


Front working lamp switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

Constant

Min. 1 Mz



40-400

66


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L122 (female) (5) – C04 (female) (1), – C05 (female) (1)

Resistance

Max. 1 z

Wiring harness between C04 (female) (2), C05 (female) (2) – ground

Resistance

Max. 1 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L07 (female) (5) – L122 (female) (1) and ground


Resistance

Min. 1 Mz

Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse (Contact with ground circuit) box (FS2) – L07 (female) (6), L122 (female) (3) and ground

Resistance

Min. 1 Mz

Wiring harness between L122 (female) (5) – C04 (female) (1), – C05 (female) (1), – circuit branch end and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Front working lamp switch turned off 7

Hot short in wiring harness Wiring harness between L07 (female) (5) – (Contact with 5 V, 24V circuit) L122 (female) (1) and ground Wiring harness between L122 (female) (5) – C04 (female) (1), – C05 (female) (1), – circuit branch end and ground


Voltage

Max. 1 V

Voltage

Max. 1 V

40-400

67


SEN03946-01

Contents of trouble

(2) Rear working lamp does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the rear working lamp system is defective. • When the front working lamp is normal • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance lamp first. Causes 1 Broken bulb 2


Standard value in normal state/Remarks on troubleshooting If a specific working lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Defective rear working lamp relay (L123) (Internal defect)

L123 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When rear working lamp relay (L123) is replaced with a relay of the same type, if the condition becomes normal, the rear working lamp relay is defective.


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective rear working lamp 4 switch (Internal defect)

L08 (male) Between (5) – (6) Between (5), (6) – ground

Rear working lamp switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

Constant

Min. 1 Mz



40-400

68


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L123 (female) (5) – B01 (female) (1), – B02 (female) (1)

Resistance

Max. 1 z

Wiring harness between B01 (female) (2), B02 (female) (2) – ground

Resistance

Max. 1 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L08 (female) (5) – L123 (female) (1) and ground


Resistance

Max. 1 z

Ground fault in wiring harness Wiring harness between fuse No. 13 of fuse (Contact with ground circuit) box (FS2) – L08 (female) (6), L123 (female) (3) and ground

Resistance

Max. 1 z

Wiring harness between L123 (female) (5) – B01 (female) (1), – B02 (female) (1), – circuit branch end and ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Front working lamp switch turned off 7

Hot short in wiring harness Wiring harness between L08 (female) (5) – (Contact with 5 V, 24V circuit) L123 (female) (1) and ground Wiring harness between L123 (female) (5) – B01 (female) (1), – B02 (female) (1), – circuit branch end and ground


Voltage

Max. 1 V

Voltage

Max. 1 V

40-400

69

SEN03946-01



40-400

70




SEN03946-01

40-400

71

400 Troubleshooting of electrical system (E-mode) E-16 Turn signal lamp and hazard lamp do not light up or go off

SEN03946-01

E-16 Turn signal lamp and hazard lamp do not light up or go off

1

Contents of trouble

(1) Either of turn signal lamp and hazard lamp does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective. • The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-IN-12). • The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, DIN-13). Causes Defective No.2 and No.10 1 fuses of fuse box (FS1)

Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 8.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L125 (male)

2

Resistance

Defective hazard relay (L125) Between (1) and (2) 200 – 400 z (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When hazard relay (L125) is replaced with a relay of the same type, if the condition becomes normal, the hazard relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Defective hazard/turn signal 3 relay (L124)

L124 (male)

Resistance

Between (5) and (6)

200 – 400 z

(1), (2), (3), (4) – (6)

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When hazard/turn signal relay (L124) is replaced with a relay of the same type, if the condition becomes normal, the hazard/turn signal relay is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L49

Defective flasher unit 4 (Internal defect)

Voltage

Between (3) and (1)

20 – 30 V

Between (4) and (1)

20 – 30 V and 0 V are indicated repeatedly.


40-400

72

L49 (male)

Resistance


Min. 1 Mz



Causes

SEN03946-01




Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L125 (female) (3) – L49 (female) (3) and ground


Wiring harness between L49 (female) (4) – L04 (female) (6), L124 (female) (1), (3) and Ground fault in wiring harness 6 ground (Contact with ground circuit) Wiring harness between L04 (female) (7) – R23 (female) (1) – FLC [left] (female) (C) and ground Wiring harness between L04 (female) (8) – R22 (female) (1) – FLC [right] (female) C and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


7

Hot short in wiring harness (Contact with 5 V, 24V circuit)



Voltage

Max. 1 V

Wiring harness between L49 (female) (4) – L04 (female) (6), L124 (female) (1), (3) and ground

Voltage

Max. 1 V

Wiring harness between L04 (female) (7) – R23 (female) (1) – FLC [left] (female) (C) and ground

Voltage

Max. 1 V

Wiring harness between L04 (female) (8) – R22 (female) (1) – FLC [right] (female) C and ground

Voltage

Max. 1 V

40-400

73


SEN03946-01

Contents of trouble

(2) Turn signal lamp does not light up or go off.

Related information

• The switch, lamp, or wiring harness of the turn signal lamp system is defective. • When the hazard lamp lights up. • The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-IN-12). • The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch (left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-IN-13). Causes 1 Broken bulb

Standard value in normal state/Remarks on troubleshooting If a specific turn signal lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. L04 (male)

2

Defective turn signal lamp switch (Internal defect)


Turn signal lamp switch

Resistance

Left

Min. 1 Mz

Right

Max. 1 z

Left

Max. 1 z

Right

Min. 1 Mz

a Prepare with starting switch OFF, then check relay unit. 3 Defective hazard relay (L125)

Resistance


Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 4 (Disconnection or defective contact in connector)

Wiring harness between fuse box FS1 No. 10 – L125 (female) (6)

Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L04 (female) (7) – R23 (female) (1), – FLC (female) (C)

Resistance

Max. 1 z

Wiring harness between L04 (female) (8) – R22 (female) (1), – FLC1 (female) (C)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between FLC (female) (B) – ground

Resistance

Max. 1 z

Wiring harness between FLC1 (female) (B) – ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 5 (Contact with ground circuit) Wiring harness between fuse box FS1 No. ResisMin. 1 Mz 10 – L125 (female) (6) and ground tance

40-400

74



SEN03946-01

Contents of trouble

(3) Hazard lamp does not light up or go off.

Related information

• The switch or lamp of the hazard lamp is defective. • Carry out the following troubleshooting when the turn signal lamp flashes normally. Causes 1


Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L125 (male)

Resistance

Defective hazard relay (L125) Between (1) – (2) 200 – 400 z 2 (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When hazard relay (L125) is replaced with a relay of the same type, if the condition becomes normal, the hazard relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Defective hazard/turn signal relay (L124) (Internal defect)

L124 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When hazard/turn signal relay (L124) is replaced with a relay of the same type, if the condition becomes normal, the hazard/turn signal relay is defective.



Defective hazard lamp switch (Internal defect)


Hazard lamp switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz




Wiring harness between fuse No. 2 of fuse box (FS1) – L125 (female) (5)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Between L124 (female) (6) – ground

Resistance

Max. 1 z

Between L125 (female) (2) – ground

Resistance

Max. 1 z

Between L49 (female) (4) – L124 (female) (1), (3)

Resistance

Max. 1 z

Between L124 (female) (2) – FLC [right] (C), R23 (1)

Resistance

Max. 1 z

Between L124 (female) (4) – FLC [left] (C), R22 (1)

Resistance

Max. 1 z

40-400

75


SEN03946-01

Causes


Wiring harness between fuse No. 2 of fuse Ground fault in wiring harness box (FS1) – L125 (female) (5) and ground 6 (Contact with ground circuit) Wiring harness between fuse No. 2 of fuse box (FS1) – L06 (female) (6) and ground Wiring harness between L125 (female) (1) – L06 (female) (1), (5) and ground Possible causes and standard value in normal state

76

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • When hot short resulted on the wiring harnesses of the following two circuits

7

40-400

Resistance

Hot short in wiring harness (Contact with 5 V, 24V circuit)

Wiring harness between L04 (female) (7) – R23 (female) (1), – FLC (female) (C), – circuit branch end and ground

Voltage

Max. 1 V

Wiring harness between L04 (female) (8) – R22 (female) (1), – FLCL (female) (C), – circuit branch end and ground

Voltage

Max. 1 V

Wiring harness between L124 (female) (5), L125 (female) (1) – L06 (female) (1), (5) and ground

Voltage

Max. 1 V



SEN03946-01



40-400

77

400 Troubleshooting of electrical system (E-mode) E-17 Brake lamp does not light or it keeps lighting up

SEN03946-01

E-17 Brake lamp does not light or it keeps lighting up Contents of trouble

Brake lamp does not light or it keeps lighting up.

Related information

• The lamp or wiring harness of the brake lamp system is abnormal.

Causes 1 Broken bulb 2

Defective fuse No.11 of fuse box (FS1)

1

Standard value in normal state/Remarks on troubleshooting If a specific brake lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Defective brake lamp relay (L121) (Internal defect)

L121 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When brake lamp relay (L121) is replaced with a relay of the same type, if the condition becomes normal, the brake lamp relay is defective. a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. L34 (male)

Defective brake lamp switch 4 (Internal defect)



Brake pedal

Resistance

Press

Max. 1 z

Released

Min. 1 Mz

Constant

Min. 1 Mz



Wiring harness between fuse No. 11 of fuse box (FS1) – L121 (female) (3), – L34 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L121 (female) (5) – R22 (female) (5), R23 (female) (5)

Resistance

Max. 1 z

Wiring harness between R22 (female) (4), R23 (female) (4) – ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 11 of fuse box (FS1) – L121 (female) (3), – L34 Ground fault in wiring harness (female) (1), – circuit branch end and ground 6 (Contact with ground circuit) Wiring harness between L34 (female) (2) – L121 (female) (1) and ground Wiring harness between L121 (female) (5) – R22 (female) (5), – R23 (female) (5) and ground

40-400

78

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


400 Troubleshooting of electrical system (E-mode) E-17 Brake lamp does not light or it keeps lighting up


SEN03946-01


7

Wiring harness between L34 (female) (2) – Hot short in wiring harness L121 (female) (1) and ground (Contact with 5 V, 24V circuit) Wiring harness between L121 (female) (5) – R22 (female) (5), – R23 (female) (5) and ground

Voltage

Max. 1 V

Voltage

Max. 1 V



40-400

79

400 Troubleshooting of electrical system (E-mode) E-18 Backup lamp does not light or it keeps lighting up

SEN03946-01

E-18 Backup lamp does not light or it keeps lighting up

1

Contents of trouble

Backup lamp does not light or it keeps lighting up.

Related information

• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble. (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. Carry out troubleshooting for it first.) • If another failure code is displayed, carry out troubleshooting for it first. Causes 1 Broken bulb 2


Standard value in normal state/Remarks on troubleshooting If a specific backup lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 7.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

L109 (male)

Resistance

Between (1) – (2)

200 – 400 z

Defective backup lamp 1 relay a Prepare with starting switch OFF, then turn starting switch ON (L109) (Internal defect) and carry out troubleshooting. When backup lamp 1 relay (L109) is replaced with a relay of the same type, if the condition becomes normal, the backup lamp 1 relay is defective.



Resistance

Defective backup lamp 2 relay Between (1) – (2) 200 – 400 z 4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON or short circuit) and carry out troubleshooting. When backup lamp 2 relay (L126) is replaced with a relay of the same type, if the condition becomes normal, the backup lamp 2 relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5

Defective FR pressure select relay (L101) (Internal defect)

L101 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When FR pressure select relay (L101) is replaced with a relay of the same type, if the condition becomes normal, the FR pressure select relay is defective.

40-400

80



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 14 of fuse box (FS2) – L109 (female) (3), (1)

Resistance

Max. 1 z

Wiring harness between L109 (female) (5) – R22 (female) (2), – R23 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z

Reference: Following 4 items are circuits for turning lamp ON with directional lever in R position.




Resistance

Max. 1 z

Wiring harness between L126 (female) (5) – R22 (female) (2), – R23 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Reference: Following 4 items are circuits for turning lamp ON when HST controller outputs signal to reverse solenoid. Wiring harness between fuse box FS2 No. 14 – L101 (female) (3)

Resistance

Max. 1 z

Wiring harness between L101 (female) (4) – R22 (female) (2) or R23 (female) (2)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between fuse box FS1 No. 5 – L24 (female) (4), (5)

Resistance

Max. 1 z

Reference: If above wiring harness is disconnected, when directional switch is set in R and lamp lights and then directional lever or directional switch is set in position other than R, lamp may not go off. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 14 of fuse box (FS2) – L109 (female) (3), (1) – circuit Ground fault in wiring harness branch end and ground 7 (Contact with ground circuit) Wiring harness between L109 (female) (5) – R22 (female) (2), – R23 (female) (2), – circuit branch end and ground Wiring harness between L24 (female) (12) – L109 (female) (2) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


8

Hot short in wiring harness (Contact with 5 V, 24V circuit) Wiring harness between L109 (female) (5) – R22 (female) (2), – R23 (female) (2), – circuit branch end and ground


Voltage

Max. 1 V

40-400

81

SEN03946-01



40-400

82


400 Troubleshooting of electrical system (E-mode) E-19 Backup alarm does not sound or it keeps sounding

SEN03946-01

E-19 Backup alarm does not sound or it keeps sounding

1

Contents of trouble

Backup alarm does not sound or it keeps sounding.

Related information

• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble. (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In such case, give precedence to the troubleshooting of the failure indicated with the code.) • If another failure code is displayed, carry out troubleshooting for it first. Causes


1

Defective backup alarm (Internal defect)

B03 Between (1) – (2)

2


Gear shift lever

Voltage

R

20 – 30 V

Other than R

Max. 1 V

If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 7.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L109 (male)

3

Resistance

Between (1) – (2) 200 – 400 z Defective backup lamp 1 relay a Prepare with starting switch OFF, then turn starting switch ON (L109) (Internal defect) and carry out troubleshooting. When backup lamp 1 relay (L109) is replaced with a relay of the same type, if the condition becomes normal, the backup lamp 1 relay is defective.



Resistance

Defective backup lamp 2 relay Between (1) – (2) 200 – 400 z 4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON or short circuit) and carry out troubleshooting. When backup lamp 2 relay (L126) is replaced with a relay of the same type, if the condition becomes normal, the backup lamp 2 relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5

Defective FR pressure select relay (L101) (Internal defect)

L101 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When FR pressure select relay (L101) is replaced with a relay of the same type, if the condition becomes normal, the FR pressure select relay is defective.


40-400

83


SEN03946-01

Causes

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 14 of fuse box (FS2) – L109 (female) (3), (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Reference: Following 4 items are circuits for turning backup alarm ON with directional lever in R position.




Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Reference: Following 4 items are circuits for turning backup alarm ON when HST controller outputs signal to reverse solenoid. Wiring harness between fuse box FS2 No. 14 – L101 (female) (3)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between B03 (female) (2) – ground

Resistance

Max. 1 z

Wiring harness between fuse box FS1 No. 5 – L24 (female) (4), (5)

Resistance

Max. 1 z

Reference: If above wiring harness is disconnected, when directional switch is set in R and backup alarm turned ON and then directional lever or directional switch is set in position other than R, backup alarm may not go OFF. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 14 of fuse box (FS2) – L109 (female) (3), (1) – circuit Ground fault in wiring harness branch end and ground 7 (Contact with ground circuit) Wiring harness between L109 (female) (5) – R22 (female) (2), – R23 (female) (2), – circuit branch end and ground Wiring harness between L24 (female) (12) – L109 (female) (2) and ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz


8

40-400

84

Hot short in wiring harness (Contact with 5 V, 24V circuit) Wiring harness between L109 (female) (5) – R22 (female) (2), – R23 (female) (2), – circuit branch end and ground

Voltage

Max. 1 V



SEN03946-01



40-400

85

400 Troubleshooting of electrical system (E-mode) E-20 Horn does not sound or it keeps sounding

SEN03946-01

E-20 Horn does not sound or it keeps sounding Contents of trouble

1

Horn does not sound or it keeps sounding.

Related information

—

Causes 1


Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 6.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective horn relay (L116) 2 (Internal defect)

L116 (male)

Resistance

Between (1) – (2)

200 – 400 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When horn relay (L116) is replaced with a relay of the same type, if the condition becomes normal, the horn relay is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Defective L13 horn switch (Internal defect)

L13 (male) Between (1) – ground

Horn switch

Resistance

ON

Max. 1 z

OFF

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Disconnect connector and measure on female side)


F01, F02 4

Defective horn (Internal defect)

Between F01 (1) – (2) Between F02 (1) – (2)

Horn switch

Voltage

ON

Max. 1 V

OFF

20 – 30 V

ON

Max. 1 V

OFF

20 – 30 V

a If horn does not sound normally under above condition, it is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


40-400

86


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between L116 (female) (5) – F01 (female) (1), – F02 (female) (1)

Resistance

Max. 1 z

Wiring harness between F01 (female) (2) – F02 (female) (2) – ground

Resistance

Max. 1 z

Wiring harness between steering wheel horn switch – ground

Resistance

Max. 1 z


400 Troubleshooting of electrical system (E-mode) E-20 Horn does not sound or it keeps sounding

Causes

SEN03946-01



Wiring harness between fuse No. 9 of fuse box (FS2) – L116 (female) (1), (3), – circuit Ground fault in wiring harness branch end and ground 6 (Contact with ground circuit) Wiring harness between L116 (female) (5) – F01 (female) (1), – F02 (female) (1), – circuit branch end and ground Wiring harness between L116 (female) (2) – L13 (female) (1) and ground

7


Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting while not pressing horn switch. Wiring harness between L116 (female) (5) – F01 (female) (1) or F02 (female) (1) and ground

Voltage

Max. 1 V



40-400

87

400 Troubleshooting of electrical system (E-mode) E-21 Alarm buzzer does not sound or it keeps sounding

SEN03946-01

E-21 Alarm buzzer does not sound or it keeps sounding

1

Contents of trouble

• Alarm buzzer does not sound or it keeps sounding.

Related information

• Disconnection or ground fault in alarm buzzer output circuit • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the monitoring function (Code: MONITOR PANEL 40952, D-OUT-0). • If failure code is indicated, carry out troubleshooting for it first. Causes 1

2


Defective fuse No.5 of fuse box FS1

Defective alarm buzzer (Internal defect)


Standard value in normal state/Remarks on troubleshooting If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 4.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Remove the buzzer then connect +24 V to L46 (male) (1) and GND to L46 (male) (2). Alarm buzzer sounds

Alarm buzzer is normal

Alarm buzzer does not sound

Defective alarm buzzer

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 5 of fuse box FS1 – L46 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Wiring harness between fuse No. 5 of fuse Ground fault in wiring harness box FS1 – L46 (female) (1), – circuit branch (Contact with ground circuit) end and ground Wiring harness between L46 (female) (2) – L24 (female) (14) and ground


40-400

88

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

• When above 1 – 4 are normal, failure on the machine monitor can be suspected.


400 Troubleshooting of electrical system (E-mode) E-21 Alarm buzzer does not sound or it keeps sounding

SEN03946-01



40-400

89

400 Troubleshooting of electrical system (E-mode) E-22 Air conditioner does not operate or stop

SEN03946-01

E-22 Air conditioner does not operate or stop

1

Contents of trouble

Air conditioner does not operate or stop.

Related information

• The following is troubleshooting applicable only to the power supply and GND circuit between the air conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual for the air conditioner. Causes


Defective No.1 and No.2 fuses of fuse box (FS2) or defective If the fuse is burn, the circuit probably has a grounding fault, etc. 1 5A and 15A fuses of the main (See cause 2.) circuit in the air conditioner unit. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 1 of fuse box (FS2) is blown Wiring harness between fuse No. 1 of fuse box A – 5A fuse of air conditioner main circuit, – 15A fuse in the air conditioner and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 1 of fuse box (FS2) is broken

Grounding fault in power 2 supply wiring harness (Contact with ground circuit) Possible causes and standard value in normal state

Wiring harness between fuse No. 1 of fuse box A – compressor clutch relay and ground

Resistance

Min. 1 Mz

Wiring harness between compressor clutch relay – E10 (female) (2) and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When 5A fuse of the air conditioner unit main circuit is broken Wiring harness between 5A fuse of air conditioner unit main circuit – C48 (female) (7), – pressure switch, – blower OFF relay primary side and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When 15A fuse of the air conditioner unit is broken Wiring harness between 15A fuse of air conditioner unit – blower OFF relay and ground

Resistance

Min. 1 Mz

Wiring harness between blower OFF relay – blower motor and ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C48

Starting switch

Voltage

ON 20 – 30 V Defective A/C control panel Between (7) and (1) power supply and disconnecOFF Max. 1 V 3 tion of GND wring harness a Prepare with starting switch OFF, then carry out troubleshooting (disconnection or defective without turning starting switch ON. contact in connector) Wiring harness between fuse No. 1 of fuse ResisMax. 1 z box (FS2) – C48 (female) (7) tance Wiring harness between C48 (female) (1) – ground

40-400

90

Resistance

Max. 1 z



Causes

SEN03946-01

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Blower OFF relay, pressure switch Blower OFF relay (15A fuse line) and ground Blower OFF relay (5A fuse line of main circuit) and ground


Disconnection in wiring harness of relay power supply 4 (Disconnection or defective contact in connector)


Pressure switch (5A fuse line of main circuit) and ground

Starting switch

Voltage

ON

20 – 30 V

OFF

Max. 1 V

ON

20 – 30 V

OFF

Max. 1 V

ON

20 – 30 V

OFF

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 1 of fuse box (FS2) – blower OFF relay (on the 15A fuse line)

Resistance

Max. 1 z

Wiring harness between fuse No. 1 of fuse box (FS2) – blower OFF relay (on the 5A fuse line of main circuit)

Resistance

Max. 1 z

Wiring harness between fuse No. 1 of fuse box (FS2) – pressure switch (on the 5A fuse line of main circuit)

Resistance

Max. 1 z

Wiring harness between pressure switch – compressor clutch relay

Resistance

Max. 1 z

40-400

91

SEN03946-01



40-400

92




SEN03946-01

40-400

93

400 Troubleshooting of electrical system (E-mode) E-23 The KOMTRAX system does not work properly

SEN03946-01

E-23 The KOMTRAX system does not work properly Trouble Related information

1

• The KOMTRAX system does not work properly. • If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine system, carry out the following troubleshooting. • A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon. Cause

Standard value in normal state/Remarks on troubleshooting L80

1 Defective power supply

Signal

Voltage

Between (39), (40) – Constant power sup(37) and (38) ply

20 – 30 V

a Turn the starting switch ON, then start engine and carry out troubleshooting. LED (1)

Normal state

LED-C1

ON

Defective starting switch a Prepare with starting switch OFF, then start engine and carry out 2 ACC signal and alternator R troubleshooting. signal L80 Signal Voltage Between (36) and (37), (38)

Starting switch ACC

20 – 30 V

Between (28) – (37), (38)

Alternator R

20 – 30 V

a Turn the starting switch ON, then carry out troubleshooting.


Defective starting switch C 3 signal

LED (3)

Normal state

LED-C3

During cranking: Blinking Other than above: OFF

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L80

Signal

Voltage


S-NET

6–9V

Starting switch C

During cranking: 20 – 30 V Other than above: Max. 1 V

Between (27) and (37), (38)

a Turn the starting switch ON, and carry out troubleshooting.

4

Defective CAN connection state

LED (4)

Normal state

LED-C4

ON

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L80 (female)

Signal

Resistance

Between (7) and (8)

CAN

40 – 80 z

a Turn the starting switch ON, and carry out troubleshooting. 5 Number of unsent mails

LED (7)

Normal state

7 segments

0–9

a Turn the starting switch ON, and carry out troubleshooting.

6

40-400

94

Defective GPS positioning status

LED (8)

Normal state

Dot

ON

One or more minute may be taken until GPS positioning is completed after the starting switch was turned ON even in an outdoor service area.


400 Troubleshooting of electrical system (E-mode) E-23 The KOMTRAX system does not work properly

LED display

SEN03946-01 L80 connector

LED lamps for CPU 1. LED-C1 (State of R or ACC signal) 2. LED-C2 (Starting output state) 3. LED-C3 (State of C signal) 4. LED-C4 (CAN state) 5. LED-C5 (Download write state) 6. LED-C6 (Download write state) 7 segment and dot displays for CPU 7. 7 segments (Number of unsent mails) 8. Dot (GPS positioning state)


40-400

95

SEN03946-01



40-400

96

SEN03947-01




40 Troubleshooting

40

500 Troubleshooting of hydraulic and mechanical system (H-mode) Method of using troubleshooting chart............................................................................................................ 3 Failure code and cause table .......................................................................................................................... 6 H-1 The machine does not start...................................................................................................................... 8 H-2 The travel speed is slow........................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively............................................................11 H-5 Shift range is not shifted......................................................................................................................... 12 H-6 The steering wheel does not turn........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks .............................................................................................................. 15 H-9 Machine deviates naturally to one side when traveling.......................................................................... 15 H-10 The brake does not work or does not work well................................................................................... 16 H-11 The brake is not released or is dragged ............................................................................................... 17 H-12 The lift arm does not rise or lower ........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height ....................................................... 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) .................................. 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21 H-19 The bucket does not tilt back ............................................................................................................... 22 WA320, 320PZ-6 (KA SPEC.)

40-500

1

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode)

H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27

40-500

2


500 Troubleshooting of hydraulic and mechanical system (H-mode) Method of using troubleshooting chart

SEN03947-01

Method of using troubleshooting chart

1

This troubleshooting chart determines the location from the problem occurring on the machine and categorizes the problem under one of the main components, such as the steering system or work equipment hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly. Step 1. Ask operator questions q The questions to ask the operator are given under the problem. If the answer to the question matches the content given, the cause given after the arrow is the probable cause.Keeping the content of the questions in mind, read the matrix and proceed with Step 2 and Step 3 to pinpoint the correct cause.

Step 3. Method of reading matrix 1. Operate the machine when carrying out troubleshooting of the items in the Diagnosis column. If any problems occur as the result of the troubleshooting, put a check against the item. a When carrying out the troubleshooting, check the easier items first. It is not necessary to follow the number order. [Example]

Example: Steering does not turn Ask the operator and check the following points. q Did the problem suddenly start? o Related equipment broken q Was the steering wheel heavy before? o Wear of related parts, defective seal Step 2. Checks before troubleshooting q Before measuring the oil pressure or starting the troubleshooting, confirm the checks before starting items, check for leakage of oil, or for loose bolts. This will prevent wasting time when troubleshooting. The items given under “Checks before troubleshooting” are checks that are particularly important to make about the condition of the machine before starting the actual troubleshooting. Example: Checks before starting troubleshooting q Is oil level and type of oil in hydraulic tank correct? q Is there any oil leakage from steering valve or demand valve? q Is steering linkage adjusted properly?


No.

2.

Remedys Diagnosis

1

Steering does not turn in both directions (left and right)

2

Steering turns only in one direction (left or right)

3

Steering is heavy when turned in both directions (left and right)

4

Steering wheel is heavy in one direction (left or right)

5

Work equipment moves

Find the matching cause in the Cause column. In the same way as in Step 2), if a problem is found, the Q marks on the same line for the troubleshooting item are the causes. (In Diagnosis item 2 in the same diagram below the cause is (c) or (e).) When there is one Q mark: Carry out troubleshooting for the other items marked with Q in the same Cause column to check if the problem occurs, then make repairs. When there are two Q marks: Go to Step 3) to narrow down the cause.

40-500

3

SEN03947-01 3.


Operate the machine and carry out troubleshooting of the items not checked in Step 1. Operate the machine in the same way as in Step 1, and if any problem occurs, put a check against the item. (In Troubleshooting item 5 in the diagram below, the problem was reenacted.)

4.

Find the matching cause in the Cause column. In the same way as in Step 2), if a problem is found, the Q marks on the same line for the troubleshooting item are the causes. (In Diagnosis item 5 in the diagram below the cause is (b) or (e).)

5.

Narrow down the causes. Of the causes found in Step 2) and Step 4), there are common items (Q marks on the line for each Diagnosis item and in the same Cause column as each other) that have causes common with the problem items found in the troubleshooting in Step 1) and Step 3). a The items that are not common (items that do not have Q marks in the same cause common as each other) are probably not the cause, so they can be eliminated. (The causes for Diagnosis item 2 in the diagram below are (c) or (e), and the causes in Diagnosis item 5 are (b) or (e), so Cause (e) is the common cause.)

40-500

4

6.

Repeat the operation in Steps 3, 4, and 5 until the cause is narrowed down to 1 item (1 common item). a If cause items are 2 or more, continue until number of items becomes minimum.

7.

Remedy After narrowing down the common causes, take the action given in the remedy line. Marks and remedies in remedy line ×: Replace E: Repair A: Adjust C: Clean




SEN03947-01

40-500

5

500 Troubleshooting of hydraulic and mechanical system (H-mode) Failure code and cause table

SEN03947-01

Failure code and cause table

1

Q

Q

Q

The travel speed is slow at forward (Reverse is normal)

Q

Q

The travel speed is slow at reverse (Forward is normal)

Q

Q Q

Q

The traction force is weak at reverse (Forward is normal)

Q Q

Steering wheel

Brake

Shift range is not shifted

The brake does not work or does not work well

Q

Q

Q

Engine stalls when traveling or engine speed drops excessively

The steering wheel does not turn

Q

Q Q

The traction force is weak in both forward and reverse

Q

Q

Q

The traction force is weak at forward (Reverse is normal)

Q

Inching valve linkage

Q

Inching valve

Q

Angle stopper control solenoid valve

Motor body

Q

HST motor 1

Motor body

Directional solenoid valve

Q

Q

The machine does not start at reverse (Forward is normal) HST related

Q Q

Does not travel forward (reverse is normal) Speed is slow in both forward and reverse

DA valve

Q

Low pressure relief valve (Charge relief valve)

Q

High pressure cut-off valve

Pump body (Charge pump end)

Q

High pressure relief valve

Pump body (Piston pump end)

Does not travel forward or in reverse

Damper

Failure Code

HST motor 2

HST pump

Mode selector solenoid valve (SOL a) Angle stopper solenoid valve (SOL b)

Part causing problem

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

The steering wheel is heavy There is play in steering wheel or excessive shock Machine deviates naturally to one side when traveling The brake is not released or is dragged The lift arm does not rise or lower

Q

Q Q

The lift arm moves slowly or the lift arm rising force is insufficient When the lift arm is rising, the lift arm comes to move slowly at specific height The lift arm cylinder cannot be hold down the bucket (The bucket rises in the air) Work equipment system

Hydraulic drift of the lift arm occurs often The lift arm wobbles during operation When the control lever is switched from “HOLD” to “RAISE”, the lift arm falls temporarily The bucket does not tilt back The bucket moves slowly or the tilting-back force is insufficient

Q

Q Q

The bucket comes to operate slowly in the midst of tilting-back The bucket cylinder cannot be hold down to bucket Hydraulic drift of the bucket occurs often The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) When the control lever is switched from “HOLD” to “TILT”, the bucket falls temporarily

Hydraulic fan

ECSS (if equipped)

The control levers of the lift arm and bucket do not move smoothly and heavy ECSS does not operate but pitches and bounces ECSS does not move at all Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) Fan always revolves in reverse

40-500

6


Q

Q Q

Q

Q

Q

Q


Q Q

Q Q

Q Q

Q Q

Q

Q Q

Q

Q Q Q Q

Q Q Q Q

Q

Q Q Q

Q Q Q Q Q H-6

Q Q Q Q Q H-7

Q Q Q Q Q H-8

Q Q Q Q Q Q H-10

H-9

Q Q Q Q H-11

Q

Q

Q H-16

Q Q H-17

Q H-18

Q Q Q Q Q Q H-19

Q Q Q Q Q Q Q

Q H-20

Q

H-21

H-22

H-23

Q

H-24

Q

H-25

Q Q

H-26

Q

Q Q

H-27

Q Q Q

Q

H-28

40-500

7

HST related

H-2

Brake Steering wheel

Q Q Troubleshooting No.

Charge valve

Fan motor

Fan pump

Accumulator

ECSS solenoid valve

Cushion valve

2-way restrictor valve

Bypass valve

Bucket PPC valve

Lift arm PPC valve

Bucket cylinder

Lift arm cylinder

Suction valve

Suction and safety valve

Bucket spool

Lift arm spool

Axle

Main relief valve

Wheel brake linkage

Brake piston

Brake disc and plate

Slack adjuster

Brake valve

Accumulator charge valve

Tire inflation pressure

Steering cylinder

Safety valve

Relief valve

Priority valve

Orbit-roll

Steering valve

Work equipment system

Q Brake pump

Work equipment and steering pump

Transfer

Clutch

Clutch solenoid

500 Troubleshooting of hydraulic and mechanical system (H-mode) Failure code and cause table

SEN03947-01

Work equipment control valve

Q Q Q H-1

Q Q

H-3

H-4

H-5

H-12

H-13

H-14

H-15

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-1 The machine does not start

H-1 The machine does not start

1

HST motor 1 j

k

l m n o

Motor body

Inching valve


Clutch

Clutch solenoid

Others

HST motor 2 i

Motor body


g h

DA valve





Damper

q

f Low pressure relief valve (Charge relief valve)

Damper

Inspection before diagnosis Are the oil level in the hydraulic tank and the oil type appropriate? q Is inching valve linkage properly adjusted? q Is the any external oil leak found around the hydraulic piping, pump and motor?

Cause

HST pump

Ask the operator about the following: q Has the machine come not start suddenly? o Breakage of HST pump and motor related equipment q Was there any problem of not traveling before? o Internal wear of HST pump and motor related a b c d e equipment, defective seal

Transfer

SEN03947-01

Diagnosis

E E E E E E E E E E E E E E E X X X X X X X X X X X X X X X A

1

Does not travel forward or in reverse

Q Q Q

2

Does not travel forward (reverse is normal)

Q

Q

3

Does not start at reverse (Forward is normal)

Q

Q

4

Does not travel forward or in reverse, motor makes sound of rotation

No.

Remedy

40-500

8

Q Q Q Q Q Q Q Q Q Q Q

Q Q Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-2 The travel speed is slow

SEN03947-01

H-2 The travel speed is slow

n

o

Clutch

m

Clutch solenoid

l

E X

E X

E X

E X

E X

E X

E X

E X A

E X

E X

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

1

Travel speed is slow in both forward and reverse

2

The travel speed is slow at forward (Reverse is normal)

Q

Q

3

The travel speed is slow at reverse (Forward is normal)

Q

Q

4

Maximum travel speed in both forward and reverse is approx. 4 km/h

5

Maximum travel speed in both forward and reverse is approx. 18 km/h

6

Abnormal sound comes from motor in both forward and reverse when travel speed is 10 km/h or more


k


Q

j

Inching valve

Q

i

Angle stopper control solenoid valve

E X

h

Motor body

E X

g

Angle stopper solenoid valve (SOL b)

Q

E X

f

Mode selector solenoid valve (SOL a)

Q

e

Others

Motor body

E X

d

HST motor 1


E X

c

DA valve

Diagnosis

b

Low pressure relief valve (Charge relief valve)

Remedy

a

HST motor 2


No.

HST pump


Inspection before diagnosis q Are the oil level in the hydraulic tank and the oil type appropriate? q Is the inching valve linkage adjusting appropriate? q Is the any external oil leak found around the hydraulic piping, pump and motor?

Cause


Ask the operator about the following: q Did the travel speed suddenly become slower? o Breakage of HST pump and motor related equipment q Was there any problem of travel speed becoming slower before? o Internal wear of HST pump and motor related equipment, defective seal

1

Q Q

40-500

9

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-3 The traction force is weak

H-3 The traction force is weak

e

f

g

h

i

j

Inching valve


Clutch solenoid

Clutch

Transfer

E X

E E E E E E E X X X X X X X A

Q

Q

Q

2

The traction force is weak at forward (Reverse is normal)

Q

3

The traction force is weak at reverse (Forward is normal)

Q

4

The traction force is weak in both forward and reverse, but maximum travel speed is reached the line.

10

d

E E X X

The traction force is weak in both forward and reverse

40-500

c

Inclination control solenoid valve

b

Motor body

a

Others

Motor body

1

Remedy Diagnosis

Cause HST HST HST pump motor 2 motor 1


No.

When the travel speed is slow, carry out troubleshooting for H-2 first.


a

1

Q

Q

Q

Q

Q

Q

Q

Q

Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Engine stalls when traveling or engine speed drops excessively

SEN03947-01

H-4 Engine stalls when traveling or engine speed drops excessively Ask the operator about the following: q Was there any problem before? o Dirt in HST pump, motor related equipment

Cause HST HST Others pump motor 2

E X

E X

E X

Q

Q

1

Engine stalls when traveling or engine speed drops excessively

Q

2

Machine moves when the directional lever is at F or R and engine is at Lo

Q


c


Diagnosis

b Inclination stopper solenoid valve (SOL b)

Remedy

a

DA valve

Inspection before diagnosis q Is the any external oil leak found around the hydraulic piping, pump and motor?

No.

1

40-500

11

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-5 Shift range is not shifted

H-5 Shift range is not shifted a a

1

Cause If the speed range switch and the monitor display do not match, check the electrical wiring. HST HST Others When the travel speed is slow, carry out troubleshooting for H-2 first. motor 2 motor 1

Shift range is not shifted

40-500

12

Clutch

Diagnosis

d

Clutch solenoid

1

Remedy

c


No.

b

Inclination stopper solenoid valve (SOL b)

a

E X

E X

E X

E X

Q

Q

Q

Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-6 The steering wheel does not turn

SEN03947-01

H-6 The steering wheel does not turn

1

d

e

f

2-way restrictor valve

Emergency steering valve (*1)

Internal defective steering cylinder (Defective piston seal)

c

Orbit-roll

Diagnosis

b

Relief valve

Remedy

a

Spool

No.

Others

E X

X

X

X

E E E X X X

Q

Q

Q

Q

Q

Q

Q

Q

1

Steering wheel does not turn in both directions (left and right)

Q

2

In condition in Item 1, movement of work equipment is abnormal

Q

3

In condition in Item 1, movement of work equipment is normal

4

Steering wheel turns only in one direction (left or right)

5

Steering wheel is heavy and does not turn

6

Oil pressure of steering circuit is low or there is no pressure

7

Emergency steering does not function in both directions (left and right)

Priority valve

Defective hydraulic pump or PTO Steering pump and switch pump

Inspection before diagnosis q Are the oil level in the hydraulic tank and the oil type appropriate? q Has the lock bar been removed from frame?

Cause Hydraulic pump

Steering

Ask the operator about the following: Did the problem suddenly start? o Breakage of steering related equipment q Was there previously any symptom, such as heavy steering? o Internal wear of steering related equipment, defective seal q

Q Q

Q

Q

Q Q Q

a

There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is felt in the steering, check the operation of the work equipment also. a If the steering pump is abnormal (broken), check the priority valve at the same time. *1. This warning is given only when the emergency steering is installed.


40-500

13

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-7 The steering wheel is heavy

H-7 The steering wheel is heavy

1

d

e

f

Clogging of hydraulic oil return filter, defective bypass valve

Clogging of oil cooler

c

E X

E E E E E X X X X X A C C

Steering wheel is heavy when turned in both directions (left and right)

Q

Q

Q

Diagnosis

Steering wheel is heavy when turned in one direction (left and right)

3

Steering wheel is heavy particularly when engine is running at low speed

4

Lift arm lifting speed is slow when engine is running at full speed

Q

5

Steering wheel is heavy and there is jerking

Q

6

Hydraulic oil overheats

7

Oil pressure of steering circuit is low or there is no pressure

8

Pressure rises in return piping of steering cylinder

14

Spool

Relief valve Q

Q

2

40-500

Priority valve

Internal defective steering cylinder (Defective piston seal)

b

Orbit-roll internal defect

Others

E X

Check for abnormalities Measure operating effort of steering wheel and time taken to turn steering, and check standard judgement value table to see if there is any abnormality.

q

1

Valve

Remedy

Inspection before diagnosis Are the oil level in the hydraulic tank and the oil type appropriate? q Is there any abnormality in Orbit-roll, steering column linkage? q Is the any external oil leak found around the hydraulic piping, valve and cylinder? q Is there any gouging of center hinge pin bearing and steering cylinder pin, bushing? q Is the tire inflation pressure correct? q

No.

Cause

The steering pump is defective The hydraulic pump is defective

Ask the operator about the following: q Did the problem suddenly start? Hydraulic pump o Breakage of steering related equipment q Was there previously any symptom, such as heavy steering? a o Internal wear of steering related equipment, defective seal

Q

Q

Q Q

Q

Q

Q Q Q Q

Q

Q

Q Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Steering wheel shakes or jerks

SEN03947-01

H-8 Steering wheel shakes or jerks

1

Cause Checks before troubleshooting Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves q Is there any play in the center hinge pin bearing or steering cylinder pin or a b c d bushing? q Is there any variation in the tire inflation pressure? q Is the steering wheel play correct?

Defect inside Orbit-roll

Defective 2-way restrictor valve

Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)

Defective cushion valve

q

E X

X

E X

E X

Check for abnormalities q Operate at a safe place and check how the steering wheel shakes and under what conditions. a In cases where the steering wheel is heavy but does not shake, go to “H-7 The steering wheel is heavy”.

No.

Remedy Diagnosis

1

Chassis shakes when traveling on rough road surface

Q

2

Shakes when steering is suddenly turned during operation or travel

Q

3

Chassis shakes when accelerating during travel operations

Q

4

Chassis shakes when engine is started

Q

5

Excessive shock when steering wheel is turned back

Q

Q

Q

Q Q

Q Q

H-9 Machine deviates naturally to one side when traveling

1

Causes: Defective steering q Defective operation of safety valve q Oil leakage inside steering cylinder q Variation in tire inflation pressure


40-500

15

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-10 The brake does not work or does not work well

H-10 The brake does not work or does not work well Ask the operator about the following: q Has the brake come not to work suddenly? o Breakage of brake equipment q Has the brake come not to work gradually? o Wear of lining and disc, defective seal

1

When the brake pedal is stepped on, only a little resistance is felt

2

When the brake pedal is stepped on, a strong resistance is felt

3

When the brake works, an abnormal noise occurs from the axle brake

4

When the four wheels are jacked up, the axle is placed on a table and the brake is applied at the first forward speed, only a specific wheel rotates

5

An airflow is observed in bleeding air from brake circuit, and the brake returns to normal after the bleeding

6

Brake oil leaks abnormally from the axle during inspection

7

Much metal powders are mixed in the axle oil

8

The brake pedal leg-power and stroke are normal, but the brake does not work well

9

The brake does not work often when the engine is stopped

X

E E E X X

X

E X

X

E X

A

Q

Q

Q

40-500

16

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q Q Q Q

Q Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

10 The accumulator is not charged, and a buzzer sounds 11 The brake works after some time lag

k

Defective brake linkage

Diagnosis

j

Defective brake pump (For charge)

Remedy

i

Defective operation of accumulator charge valve

Metal contact due to complete wear of brake lining in axle

Check abnormality Measure the braking force and check referring to the standard value table if the brake does not work practically.

q

h Defective seal of accumulator piston, insufficient gas pressure

g

Defect inside brake valve

f

Mixing of air in brake circuit

e

Wear or abnormality of brake lining in axle

E E X X

d

Defective slack adjuster

c

Defective operation of brake piston in axle

Inspection before diagnosis Is the oil level in the hydraulic tank appropriate? q Is the play of brake pedal appropriate? q Oil leak from brake tube and connector, deformation of tube. q Tire air pressure and state of tire tread.

b

Defective brake piston seal in axle

Cause a

q

No.

1

Q

Q

Q

Q

Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-11 The brake is not released or is dragged

SEN03947-01

H-11 The brake is not released or is dragged

1

Ask the operator about the following: q Has the brake pedal returned completely? q Is the parking brake released completely?

No.

Diagnosis

c

d

Defective operation of brake piston in axle

Defective slack adjuster

Wear or abnormality of brake lining in axle

Check abnormality q Abnormal heat of brake. q Does the machine travel smoothly inertia on a level ground?

b

Defective brake piston seal in axle

Cause a

Remedy E E E E X X X X

1

The brake pedal is released, but the brake is still applied

Q

2

When the brake pedal is released, oil is drained from the air bleeder, the circuit oil pressure drops and the brake is released

Q

3

When the four wheels are jacked up, the axle is placed on a table, the engine is stopped, the parking brake is released and the tires are rotated by hand but a specific tire hardly rotates


Q

Q

Q Q

Q

Q

40-500

Q

17

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-12 The lift arm does not rise or lower

H-12 The lift arm does not rise or lower

1

Q

The bucket cannot operate and the lift arm cannot rise

2

The bucket operates but the lift arm cannot rise

3

The lift arm can rise without load but cannot rise when loaded

Q

Q

Q

4

The hydraulic pump causes an abnormal noise

Q

Q

Q

5

Large hydraulic drift of lift arm cylinder

6

When the engine is at full throttle, the steering opera- Q tion is heavy and slow

40-500

18

Q

Q

Q

Q

Damage of lift arm cylinder piston seal

Q

1

Breakage inside valve body (Lift arm spool)

E X

Defective operation of main relief valve

Defective low-pressure relief valve

X

Defective work equipment pump

Remedy C E E E E X X X

Defective steering pump

Defective operation of spool

Diagnosis

Defective HST charge pump

No.


Inspection before diagnosis Is the oil level in the hydraulic tank appropriate? q Is the stroke of the lift arm control lever appropriate? q Is the engine speed appropriate? q

Clogging of pump suction port or mixing of much air in oil

Cause Ask the operator about the following: q Has the lift arm come not to work suddenly? Work Priority HST PPC Tank to Pump equip- Cylinder o Seizure or breakage of each equipment valve pump valve ment valve Did any abnormal noise occur at the time (And where)? a b c d e f g h i j q Was there the phenomenon that the lift arm worked slowly? o Wear of parts or deformation of spring

E X

E X

X

X

Q

Q

Q

Q Q

Q Q

Q

Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-13 The lift arm moves slowly or the lift arm rising force is insufficient

SEN03947-01

H-13 The lift arm moves slowly or the lift arm rising force is insufficient 1

g

Remedy C E E X

E X

E X

E X

Q

Q

A X

X

E X

Q

Q

1

The bucket tilting force and speed are abnormal, and the lift arm rising speed is slow

2

The bucket tilting force and speed are normal, and the lift arm rising speed is slow

3

When the oil temperature rises in item 1, the lift arm speed becomes very slow

4


5

Large hydraulic drift of lift arm cylinder

6

The relief oil pressure from the relief valve of the work equipment valves is low

Q

7

The relief oil pressure from the relief valve of the work equipment valves is too high

Q


Q

Q

Q Q

Q Q

h

Damage of lift arm cylinder piston seal

f

Wear or breakage inside valve body (Lift arm spool)

e

Defective operation or improper adjustment of main relief valve

d


c

Defective low-pressure relief valve

Diagnosis

b


No.

a

Defective work equipment pump and steering pump

Check of abnormality q Rising force and speed problem are closely related, and this problem occurs as insufficient rising speed at first. Measure the lift arm rising speed when the lift arm is loaded and make sure referring to the criterion table that the speed is abnormal.


Cause Inspection before diagnosis q Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment Cylinder Pump valve pump valve valve ate?

Q

Q Q

40-500

Q

19

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-14 When rising, the lift arm comes to move slowly at specific height

H-14 When rising, the lift arm comes to move slowly at specific height

1

Inspection before diagnosis q Deformation of lift arm cylinder in appearance Cause Expansion of lift arm cylinder tube or damage inside a For other abnormal phenomena during lift arm rise, see “H-13. The lift arm moves slowly or the lift arm rising force is insufficient.”

q

H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)

1

See “H-13. The lift arm moves slowly or the lift arm rising force is insufficient.” Inspection before diagnosis q Is the stroke of the lift arm control lever appropriate? Cause q Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve q Oil leak from lift arm cylinder piston seal

H-16 Hydraulic drifts of the lift arm occur often

1

Ask the operator about the following: q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts q Have hydraulic drifts come to occur often gradually? o Wear of parts Inspection before diagnosis q Is the lift arm spool at the neutral position? o The spool detent is defective Diagnosis and Cause Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective

q

H-17 The lift arm wobbles during operation

1

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm control lever in the “HOLD” position. Diagnosis and Cause Check at first the hydraulic drift and if the lift arm cylinder can lift the machine 1. When the hydraulic drift is more than the standard value, see “H-16. Hydraulic drifts of the lift arm occur often.” 2. When the lift arm cylinder cannot lift the machine, see “H-15. The lift arm cylinder cannot hold down the bucket.” 3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vacuum generated inside the cylinder a

40-500

Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective

20


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily

SEN03947-01

H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily

1

Check of Phenomenon q When the control lever is switched from “HOLD” to “RAISE” gradually at low idle of the engine, the lift arm falls temporarily due to its own weight. When the control lever is completely set to “RAISE,” the lift arm returns to normal. Cause q Improper adhesion of lift arm spool check valve of the work equipment valve


40-500

21

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-19 The bucket does not tilt back

SEN03947-01

H-19 The bucket does not tilt back

1

Q

Q

The lift arm cannot operate and the bucket cannot tilt back

2

The bucket can lift the machine but cannot tilt back, or the lift arm operates but the bucket cannot tilt back

3

The bucket can tilt back without load but cannot in digging or scooping up

Q

Q

4


Q

Q Q

5

Large hydraulic drift of bucket cylinder

6

When the engine is at full throttle, the steering operation is heavy and slow

40-500

22

Q

i

j

Damage of bucket cylinder piston seal

Q Q

1

h

Breakage inside valve body (Bucket spool)

E X

Cylinder

Defective operation of main relief valve

X

Work equipment valve

The spool is defective

The low-pressure relief valve is defective

E E X X

The hydraulic pump is defective


Diagnosis

Remedy C E

The HST charge pump (which is used as PPC pump, too) is defective

No.

The steering pump is defective

Inspection before diagnosis Is the stroke of the bucket and lift arm control levers appropriate?

q


Cause Ask the operator about the following: q Has the bucket come not to work suddenly Priority HST PPC Tank to Pump valve pump valve o Seizure or breakage of each equipment a b c d e f g Did any abnormal noise occur at the time (And where)? q Was there the phenomenon that the bucket worked slowly? o Wear of parts or deformation of spring

E X

A X

X

X

Q

Q

Q

Q

Q

Q

Q

Q

Q Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-20 The bucket moves slowly or the tilting-back force is insufficient

SEN03947-01

H-20 The bucket moves slowly or the tilting-back force is insufficient

2

The lift arm rising force and speed are normal, and the bucket tilting force and speed are abnormal

3

When the oil temperature rises in item 1, the bucket speed becomes worse

Q

4

The hydraulic pump is causing an abnormal Q noise

Q

5

Large hydraulic drift of bucket cylinder

6

The relief oil pressure from the relief valve of the work equipment valves is low

7

The relief oil pressure from the relief valve of the work equipment valves is too high

Damage of bucket cylinder piston seal

Q

Q

Wear or breakage inside valve body (Bucket spool)

Q

Q

Defective operation of safety valve (With suction valve) on bucket cylinder bottom side

E X

Defective operation or improper adjustment of main relief valve


i

Defective operation of low-pressure relief valve

h


g

E X

The lift arm rising force and speed are abnormal, and the bucket tilting force and speed are abnormal


f

E X

1

Work equipment valve Cylinder

e

The hydraulic pump and the steering pump are defective

Diagnosis

Cause PPC valve

Remedy C E E X

Check of abnormality q Make sure in an actual operation that the tilting-back force is insufficient. q Measure the operating speed of the bucket, and make sure referring to the criterion value table that the speed is abnormal

No.


Inspection before diagnosis q Is the stroke of the bucket control lever Tank to Priority HST Pump valve pump appropriate? q Seizure of work equipment linkage a b c d bushing (Does any abnormal noise occur?)

A X

E X

X

X

Q

Q

Q

Q

Q

Q

Q Q

1

Q

Q

Q

Q

Q

40-500

23

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-21 The bucket comes to operate slowly in the midst of tilting-back

H-21 The bucket comes to operate slowly in the midst of tilting-back

1

Inspection before diagnosis q Deformation of bucket cylinder in appearance Cause Expansion of bucket cylinder tube or damage inside q For other abnormal phenomena during bucket operation, see “H-20. The bucket moves slowly or the tilting-back force is insufficient.” q

H-22 The bucket cylinder cannot hold down the bucket

1

See “H-20. The bucket moves slowly or the tilting-back force is insufficient.” Inspection before diagnosis q Is the stroke of the bucket control lever appropriate? Cause Defective seat of suction valve on the bucket cylinder rod side of work equipment valve q Oil leak from bucket cylinder piston seal q

H-23 Hydraulic drifts of the bucket occur often

1

Ask the operator about the following: q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts q Have hydraulic drifts come to occur often gradually? o Wear of parts Inspection before diagnosis Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is defective

q

Check of Abnormality q Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically Cause Oil leak in bucket cylinder q Improper adhesion of safety valve (With suction valve) on the bottom side q Improper oil tight of bucket spool q

H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)

1

Inspection before diagnosis q Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?) Cause q Defective seal of bucket cylinder piston q Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to diagnoses for relevant abnormal phenomena.

40-500

24


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily

SEN03947-01

H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily

1

Check of Phenomenon q When the control lever is switched from “HOLD” to “TILT” gradually at low idle of the engine, the bucket falls temporarily due to its own weight. When the control lever is completely set to “TILT,” the bucket returns to normal. Cause q Improper adhesion of bucket spool check valve of the work equipment valve

H-26 The control levers of the lift arm and bucket do not move smoothly and heavy 1 Check of Abnormality q Refer to the criterion value table and check if the lever operating efforts are large practically.

Cause PPC valve Defective operation of spool

a

No.

Remedy Diagnosis

C E

1

Becomes heavy in some places during operation regardless of oil pressure and oil temperature

Q

2

Becomes heavy overall during operation regardless of oil pressure and oil temperature

Q


40-500

25

SEN03947-01

500 Troubleshooting of hydraulic and mechanical system (H-mode) H-27 The ECSS does not operate and machine pitches and bounces

H-27 The ECSS does not operate and machine pitches and bounces

Sensor

a

b

c

d

X

Defective travel speed sensor

Remedy Troubleshooting

Controller

Malfunction of controller

No.

Accumulator

Gas leakage from accumulator or defective seal

Check before troubleshooting Check that the hydraulic tank is filled with oil of a proper type up to a proper level. q Check that the ECSS switch is set properly. q

Cause Solenoid valve

Malfunction of solenoid valve

Check the following points with the operator. q Did the machine starts pitching and bouncing suddenly? o Breakage of related device Did abnormal sound come out when the machine started pitching and bouncing? From what part did the abnormal sound come out? q Did the machine starts pitching and bouncing gradually? o Wear of related device or defective seal

X

X

X

Q

Q

1

Travel speed to start operation of ECSS (6 km/h) changes largely

2

ECSS does not work while machine is loaded

Q

Q

3

ECSS does not work while machine is empty

Q

Q

4

Lift arm lowers more than 30 cm at maximum when ECSS operated while machine is loaded

5

ECSS does not work at all

40-500

26

1

Q Q

Q

Q

Q


500 Troubleshooting of hydraulic and mechanical system (H-mode) H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)

SEN03947-01

H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)

2

Fan hunts

Q

Q

3

Fan does not revolve

Q

X

E E E E X X X X

Q

Q

X Q

Q

Q

Q

4

Fan always revolves in reverse

Q

5

Fan does not revolve in reverse

Q


Note

Q

Q Q

k

Lowering of engine performance

Q

Malfunction of controller

Q

j

Seized forward-reverse selector valve

Q

Malfunction of suction safety valve

Fan speed is low (in fan 100% mode)

Troubleshooting

Remedy C E

Malfunction of EPC solenoid valve

1

No.

i

Seized ON/OFF solenoid valve

Malfunction of relief valve

X

E E X X

(Note): If “Lowering of engine performance” is judged, go to the troubleshooting for the engine system (S mode).

Others

Defective fan motor

Defective fan pump

Check before troubleshooting q Check the level and type of the oil in the hydraulic tank. q Check the hydraulic hoses, pump and motor for oil leakage. q Check the fan for damage.

Seized brake circuit selector spool

Check for abnormality q Measure the fan speed to check for abnormality.

Clogging or sucked air on pump suction side

Cause Check the following with the operator. q Did the fan start making the abnormal sound sud- Tank to Charge Fan motor Pump valve denly? o Damage of the devices related to the fan and a b c d e f g h fan motor q Did the engine overheat after the fan had started making the abnormal sound? o Internal wear of the devices related to the fan pump and fan motor, lowering of sealing performance or dirt

1

Q

Q

Q

Q

40-500

27

SEN03947-01



40-500

28

SEN03948-01




40 Troubleshooting

40

600 Troubleshooting of engine (S-mode) Method of using troubleshooting charts .......................................................................................................... 2 S-1 Starting performance is poor .................................................................................................................... 6 S-2 Engine does not start ............................................................................................................................... 8 S-3 Engine does not pick up smoothly...........................................................................................................11 S-4 Engine stops during operations .............................................................................................................. 12 S-5 Engine does not rotate smoothly ............................................................................................................ 13 S-6 Engine lacks output (or lacks power) ..................................................................................................... 14 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16 S-9 Oil becomes contaminated quickly ......................................................................................................... 17 S-10 Fuel consumption is excessive............................................................................................................. 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19 S-12 Oil pressure drops ................................................................................................................................ 20 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22 S-15 Abnormal noise is made....................................................................................................................... 23 S-16 Vibration is excessive ........................................................................................................................... 24


40-600

1

SEN03948-01

Method of using troubleshooting charts

600 Troubleshooting of engine (S-mode) Method of using troubleshooting charts

1

The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Items to be simply checked by the serviceman to narrow down causes. They correspond to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections.

40-600

2



SEN03948-01

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E : Causes to be referred to for questions and check items Q : Causes related to questions and check items w : Causes highly probable among ones marked with Q a When narrowing the “causes“, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)


40-600

3

SEN03948-01


Exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

40-600

4



SEN03948-01

If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.


40-600

5

600 Troubleshooting of engine (S-mode) S-1 Starting performance is poor

SEN03948-01

S-1 Starting performance is poor

1

General causes why starting performance is poor q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck, seized supply pump plunger

Clogged fuel filter, element

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Defective contact of valve and valve seat

Clogged air cleaner element

Causes

Confirm recent repair history Degree of use of machine Operated for long period

E

E

Q w w

Q

E w

Engine starts easily when warm

w

Q Q Q

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w

w Q Q w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally

w w w

During operation, charge level monitor indicates abnormal charge w

Dust indicator is red

w

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

w

When priming pump is operated, it makes no reaction or it is heavy

w Q

Q w

Starting motor cranks engine slowly

Check items

While engine is cranked with starting motor,

If air bleeding plug of fuel filter is removed, fuel does not flow out

w w

Much fuel returns from the injector

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q Q

Engine does not pick up smoothly and combustion is irregular

w Q w Q

There is hunting from engine (rotation is irregular) w

Blow-by gas is excessive q

Inspect air cleaner directly

q q

When compression pressure is measured, it is found to be low

q

Troubleshooting

When air is bled from fuel system, air comes out

q

Inspect fuel filter, strainer directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q

When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle?

q

Yes

q

No

q

40-600

6

Replace

Replace

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Clean

Remedy

Replace

When specific gravity of electrolyte and voltage of battery are measured, they are low

Replace

Questions

Starting performance

Became worse gradually


600 Troubleshooting of engine (S-mode) S-1 Starting performance is poor

SEN03948-01

*1: Failure codes [CA559] and [CA2249] in the display of code


40-600

7

600 Troubleshooting of engine (S-mode) S-2 Engine does not start

S-2 Engine does not start

1

Degree of use of machine

Operated for long period

Condition of horn when starting switch is turned ON

Horn does not sound

Defective starting motor (motor section)

Defective safety relay

Defective starting switch

E E Q

Q Q w

Makes grating noise

w w

Soon disengages again

Q Q

q

Inspect flywheel ring gear directly

q

When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E

q

When terminal B and terminal C of starting switch are connected, engine starts

q

When terminal B and terminal C at safety relay outlet are connected, engine starts

q

Replace

Replace

Remedy

Replace

q Replace

When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace

q

Replace

Even if terminal B and terminal C at safety relay outlet are connected, engine does not start

Carry out troubleshooting in E-mode

Q

Makes rattling noise and does not turn

8

w

w

w

Speed of rotation is low

40-600

Q

w

When starting switch is turned to START, starting pinion does not move out

Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

w

w

When starting switch is turned ON, there is no operating sound from battery relay

When starting switch is turned to START, starting pinion moves out, but

Q

w

Horn volume is low

Battery terminal is loose

Check items

Defective battery relay

Confirm recent repair history

Battery electrolyte is low

Troubleshooting

Defective connection of battery terminal

Defective or deteriorated battery

Broken flywheel ring gear

Causes

Correct

Questions

a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See “S-4 Engine stops during operations” q Defective electrical system q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

Defective steering circuit wiring

SEN03948-01

—



SEN03948-01

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Defective fuel injector

Defective common rail pressure limiter

Defective operation of overflow valve (Does not close)

Defective supply pump IMV (IMA)


Broken supply pump shaft

Seized, abnormally worn feed pump

Clogged fuel filter element



Insufficient fuel in tank

Use of improper fuel

Causes

Questions

Confirm recent repair history Degree of use of machine

E E


w Q w w

Exhaust smoke suddenly stopped coming out (when starting again) Replacement of filters has not been carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty

w

Air breather hole of fuel tank cap is clogged

Q w

Rust and water are found when fuel tank is drained w

Check items

When fuel filter is removed, there is not fuel in it

w

E

Q E

E E

Fuel is leaking from fuel piping

w


w Q

If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

w

Q

Q

w Q

Q

w w w

Q

q


q

Inspect fuel filter directly Troubleshooting

E

w

Fuel other than specified one is used

q

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q q

Carry out troubleshooting according to “Abnormality in supply pump IMV (IMA) (*2)” in display of code

q q

Inspect pressure relief valve directly

q Replace

Replace

Replace

Replace

Replace

Replace

Replace

Correct

Replace

Clean

Add

Remedy

Replace

Fuel flows out when pressure limiter return piping is disconnected

40-600

9

*1: Failure codes [CA559] and [CA2249] in the display of code *2: Failure codes [CA271] and [CA272] in the display of code



SEN03948-01

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor, wiring harness

Defective, deteriorated battery

Clogged injector, defective spray


Clogging of fuel filter

Leaking or clogged fuel system, entry of air


Use of improper fuel


Worn dynamic valve system (Valve, rocker lever, etc.)


Causes

Confirm recent repair history E


E

w

Suddenly failed to start

E w

Q

Q Q


w

w w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally

w w


Q


w

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

w


w Q w

Check items

Starting motor cranks engine slowly w

When engine is cranked, abnormal sound is generated around cylinder head If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

w q


q

Inspect dynamic valve system directly Troubleshooting

w

q


q


q

Inspect fuel filter directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q q

When specific gravity of electrolyte and voltage of battery are measured, they are low

q

Coolant temperature gauge does not indicate normally

q Replace

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Replace

Clean

Remedy

Replace

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions


*1: Failure code [CA559] and [CA2249] in the display of code

40-600

10


600 Troubleshooting of engine (S-mode) S-3 Engine does not pick up smoothly

SEN03948-01

S-3 Engine does not pick up smoothly

1

General causes why engine does not pick up smoothly Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

Clogged injector, defective spray






Improper valve clearance



Seized turbocharger, interference of turbocharger

Causes

q

Confirm recent repair history E E


E w

Engine pick-up suddenly became worse

E Q Q

Q w w w


w

w w

Oil must be added more frequently w


w


w

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

w


w Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

Q w w

Blue under light load w Q

Black

w w

When engine is cranked, interference sound is generated around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied

Q

w

There is hunting from engine (rotation is irregular)

Q

Q

Q

w



q

When compression pressure is measured, it is found to be low Troubleshooting

w

w

When engine is cranked, abnormal sound is generated around cylinder head

q q

Inspect valve clearance directly

q

When turbocharger is rotated by hand, it is found to be heavy

q


q

Inspect fuel filter, strainer directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q q Replace

Replace

Correct

Clean

Replace

Adjust

Replace

Clean

Remedy

Correct


Replace

Questions




40-600

11

600 Troubleshooting of engine (S-mode) S-4 Engine stops during operations

SEN03948-01

S-4 Engine stops during operations

1

General causes why engine stops during operations Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in hydraulic pump

Defective starting switch wiring

Defective engine controller power supply wiring

Defective hydraulic pump

Broken auxiliary equipment (pump, compressor, etc.)


Broken supply pump shaft

Broken, seized feed pump

Clogging feed pump gauze filter

Clogging of fuel filter, strainer

Leaking, clogged fuel piping



Broken, seized gear train

Broken, seized crankshaft bearing

Broken, seized piston, connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes

q

Confirm recent repair history E E

Operated for long period w w w w

Q w Q w w

w Q

Engine overheated and stopped

Q

Engine stopped slowly

w

Q Q

There was hunting and engine stopped

w Q

Q Q Q

Non-specified fuel is being used

Q Q Q

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w

Fuel level monitor indicates low level

w

When fuel tank is inspected, it is found to be empty

w w


w w

Rust and water are found when fuel tank is drained Metal particles are found when oil pan is drained

w w

Does not turn at all

w w

Q Q

w

Turns in opposite direction

w

Moves by amount of gear backlash

w w

Supply pump shaft does not turn

w

Engine turns, but stops when load is applied to machine q

Inspect dynamic valve system directly

q

Inspect piston, connecting rod directly

q

Inspect crankshaft bearing directly

q

Troubleshooting

Inspect gear train directly

q

Inspect fuel filter, strainer directly

q

Inspect feed pump gauze filter directly

q

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q q

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

q

Check controller power supply wiring Replace

Replace

Replace

Replace

Clean

Clean

Clean

Correct

Add

Replace

Replace

Replace

Remedy

Replace

Check starting switch wiring

q q Correct

Check items

Q

w


When engine is cranked by hand

Q Q Q Q

Carry out troubleshooting in H-mode

Condition when engine stopped

—

Questions

Abnormal noise was heard and engine stopped suddenly

Correct



40-600

12


600 Troubleshooting of engine (S-mode) S-5 Engine does not rotate smoothly

SEN03948-01

S-5 Engine does not rotate smoothly

1

General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Defective G speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Clogged injector, defective spray (dirt in injector)





Causes



Q Q

Occurs at a certain speed range Q

Occurs even when speed is raised

Q Q

w

Occurs on slopes

w

Replacement of filters has not been carried out according to Operation and Maintenance Manual w

When fuel tank is inspected, it is found to be empty Check items


w


w Q

Troubleshooting

w



q

Q

Rust and water are found when fuel tank is drained

q


q


q

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in display of code

q Replace

Replace

Replace

Add

Remedy

Clean

Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in display of code

Replace

Hunting

Q Q Q Q Q

Occurs at low idle

Replace

Questions


*1: Failure code [CA689] in the display of code *2: Failure code [CA778] in the display of code


40-600

13

600 Troubleshooting of engine (S-mode) S-6 Engine lacks output (or lacks power)

SEN03948-01

S-6 Engine lacks output (or lacks power) General causes why engine lacks output Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1

Clogged fuel spill piping

Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor (air leakage)

Defective drive of injector (signal, solenoid)

Clogged injector, defective spray (dirt in injector)



Leaking, clogged fuel piping





Air leakage from air intake piping



Causes

q


E

E

Q

Q

Q

Q w

Suddenly Q

Gradually

Q


w Q

Q

w w


w


w w

Fuel is leaking from fuel piping w

Output becomes insufficient after short stop of operation

w

Black

w w

Blue under light load

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items

Q Q

w

Oil must be added more frequently

w w w

When engine is cranked, interference sound is generated around turbocharger

w


Q

High idle speed is too high Q

High idle speed under no load is normal, but speed suddenly drops when load is applied w w

Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular)

w

Blow-by gas is excessive

w Q Q

Q Q

w

Q Q Q

Q Q

w

q


q

Inspect air intake piping directly

q q q

When boost pressure is measured, it is found to be low

q


q q

Inspect valve clearance directly Troubleshooting

Q Q

Q Q Q


Color of exhaust gas is

Q

q

Inspect fuel piping

q


q

Inspect spill port check valve directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q


q q q

Inspect boost pressure sensor mount directly Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)” in display of code

Correct

Replace

Replace

Replace

Replace

Clean

Correct

Replace

Adjust

Replace

Replace

Clean

Correct

Remedy

q Replace

Power was lost

E


Replace

Questions



40-600

14


600 Troubleshooting of engine (S-mode) S-7 Exhaust smoke is black (incomplete combustion)

SEN03948-01

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black q Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1

Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Abnormally worn injector

Clogged, seized injector



Crushed, clogged muffler

Leakage of air between turbocharger and cylinder head





Causes



Questions


E

E

w

Suddenly became black

w

w

Gradually became black

Q

Q w


Q Q

Non-specified fuel is being used w

Oil must be added more frequently Power was lost

E Q Q Q

w

Suddenly Q

Gradually

Q Q

Q

Q Q Q

w


w

Muffler is crushed w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items


Q w w


w


Q

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal

Q

w

Engine does not pick up smoothly and combustion is irregular

Q

Q Q Q

Q Q w w

Blow-by gas is excessive

w

Much fuel returns from the injector q


q

When turbocharger is rotated by hand, it is fount to be heavy

q

Troubleshooting


q q


q

When muffler is removed, exhaust sound improves Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q

q q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in display of code

q

Replace

Replace

Replace

Replace

Replace

Replace

Correct

Adjust

Correct

Clean

Replace

Remedy

Replace

q q

Confirm with monitoring function

Replace




40-600

15

600 Troubleshooting of engine (S-mode) S-8 Oil consumption is excessive (or exhaust smoke is blue)

S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system

1

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn, damaged rear oil seal


Broken piston ring

Clogged breather, breather hose

Turbocharger Worn seal at blower end

Worn seal at turbine end

Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes Oil leakage from oil pan, cylinder head, etc.

SEN03948-01

E E E


E w

Oil consumption suddenly increased

Q


w

Oil becomes contaminated quickly

Q Q w

Q w w w w w

Outside of engine is dirty with oil w

There are loose piping clamps in intake system

w

Inside of turbocharger intake outlet pipe is dirty with oil Q w

w

There is oil in coolant w

Oil level in damper chamber is high w w

Exhaust smoke is blue under light load Q

Excessive

w w w

q

When intake manifold is removed, dust is found inside

q

When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting

Q

None

q q

Excessive play of turbocharger shaft

q

Check breather and breather hose directly

q q


q

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q q

40-600

16

Replace

Replace

Correct

Replace

Clean

Replace

Replace

Replace

Correct

Remedy

Correct

There is external leakage of oil from engine

Correct

Amount of blow-by gas

Correct

Check items

Inside of turbocharger exhaust outlet pipe is dirty with oil

Correct


Correct

Questions



600 Troubleshooting of engine (S-mode) S-9 Oil becomes contaminated quickly

SEN03948-01

S-9 Oil becomes contaminated quickly

1


Exhaust smoke is bad

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

E E E



Q


w

Metal particles are found when oil filter is drained

Q Q

Inside of exhaust pipe is dirty with oil

w

Q w w

Color of exhaust gas is Amount of blow-by gas

w


w

Black Q Q w

Excessive

Q w

None q

Excessive play of turbocharger shaft

q q


q

Check breather and breather hose directly

See S-7

Check items

Clogged oil filter


Engine oil temperature rises quickly

Troubleshooting

Clogged oil cooler

Clogged breather, breather hose


Worn valve, valve guide

Defective seal at turbocharger turbine end

Causes

q

Inspect oil cooler directly

q

Inspect oil filter directly

q

Spring of oil filter safety valve is hitched or broken

q


Replace

Replace

Clean

Clean

Replace

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

40-600

Clean

Questions

General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

—

17

600 Troubleshooting of engine (S-mode) S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive

1

General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective fuel supply pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Causes Defective coolant temperature sensor, wiring harness

SEN03948-01



Condition of fuel consumption

Gradually increased

E E

E Q

More than for other machines of same model Q Q Q

Suddenly increased

w

There is external leakage of fuel from engine

w

Combustion is irregular w

w


w Q

Low idle speed is high

Q

HST stall speed is high

Q Q

Q

White

q

Remove head cover and inspect directly

q

Inspect fuel supply pump oil seal directly

q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code

q


q

Much fuel returns from the injector Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in display of code

q

Replace

Replace

Replace

Correct

Correct

Remedy

q Replace

q


Replace


Q Q

Black

Correct

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q Q

Replace

Questions



40-600

18


600 Troubleshooting of engine (S-mode) S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)

SEN03948-01

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler

Broken oil cooler core, O-ring

Holes caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Degree of use of machine Oil level

E E

Operated for long period Q

Suddenly rose

Q Q Q Q Q w

w

There are excessive air bubbles in radiator, coolant spurts back Hydraulic oil or power train oil on applicable machine side is milky

w

When hydraulic oil or power train oil is drained, water is found

w q

Pressure-tightness test of cylinder head shows there is leakage

q q

Inspect cylinder block directly

Replace

Replace

Remedy


Check directly q

Pressure-tightness test of oil cooler shows there is leakage Replace

Check items

Oil level has risen and oil is milky

Troubleshooting

Q

Q Q

Gradually rose

Hard water is being used as coolant

Replace

Questions


—

40-600

19

600 Troubleshooting of engine (S-mode) S-12 Oil pressure drops

S-12 Oil pressure drops

1

General causes why oil pressure drops q Leakage, clogging, wear of lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective regulator valve

Defective oil pump

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Coolant, fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes Defective oil level sensor, wiring harness

SEN03948-01


E


E

E Q w

Oil pressure monitor indicates low oil pressure Q

Non-specified oil is being used

Q


w w

Indicates pressure drop at low idle Oil pressure monitor

Indicates pressure drop at low, high idle

Q

Indicates pressure drop on slopes

w

w w w Q w

w

Oil level in oil pan is low

w

Q w w

External hydraulic piping is leaking, crushed w

Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

w


w

Metal particles are found in oil filter

q

Q

Inspect oil pan strainer, pipe directly

See S-13

Troubleshooting

Check items

Sometimes indicates pressure drop Oil level monitor indicates oil level drop

Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly

q q q q q q

40-600

20

Correct

Replace

Adjust

Replace

Clean

—

Clean

Add

Remedy

Replace

If oil level sensor is replaced, oil level monitor indicates normally

Replace

Questions



600 Troubleshooting of engine (S-mode) S-13 Oil level rises (Entry of coolant or fuel)

SEN03948-01

S-13 Oil level rises (Entry of coolant or fuel)

1

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”


Check items

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Broken oil cooler core, O-ring

Worn, damaged rear oil seal



E


E E

E

w

Fuel must be added more frequently

w

Coolant must be added more frequently

Q

There is oil in coolant

Q Q Q Q

Q w

w

Oil smells of diesel fuel Oil is milky

Q

When engine is started, drops of water come from muffler

Q

w Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back

Q Q

Exhaust smoke is white

w

Oil level in damper chamber is low

w

Oil level in hydraulic tank of machine is low q

When compression pressure is measured, it is found to be low Troubleshooting

Broken injector, O-ring


q

Remove injector and inspect O-ring.

q q


q

Inspect rear oil seal directly

q

Pressure-tightness test of oil cooler shows there is leakage

q

Remove and inspect supply pump directly

q


40-600

Replace

Replace

Correct

Replace

Replace

Replace

Remedy

Replace

Inspect seal of auxiliary equipment directly

Replace

Questions


Causes

21

600 Troubleshooting of engine (S-mode) S-14 Coolant temperature becomes too high (overheating)

SEN03948-01

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Rise in oil temperature in power train o Carry out troubleshooting on applicable machine

1

Rise in power train oil temperature

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken fan pulley bearing

Lack of coolant

Clogged, broken oil cooler




Causes

Questions

Confirm recent repair history Degree of use of machine Condition overheating

E


E

E E Q w

Sudden overheated Always tends to overheat

Q

Rises quickly

Q

Q

Radiator coolant level monitor indicates drop of coolant level

Q

w

Engine oil level has risen, oil is milky

w w Q

Coolant temperature gauge

Q Q w w

Q

w w

Does not go down from red range

w

Fan belt tension is low w

When fan pulley is turned, it has play Q Q w

Milky oil is floating on coolant w

Check items

There are excessive air bubbles in radiator, coolant spurts back

w

When light bulb is held behind radiator core, no light passes through

w

Radiator shroud, inside of underguard are clogged with dirt or mud

w

w

Coolant is leaking because of cracks in hose or loose clamps

w

Coolant flows out from radiator overflow hose

w

Fan belt whines under sudden acceleration Power train oil temperature enters red range faster than engine coolant temperature

w

q


q q


q

When operation of thermostat is carried out, it does not open at cracking temperature

Check directly

q

Temperature difference between upper and lower tanks of radiator is large

q q

Temperature difference between upper and lower tanks of radiator is slight

q

Inspect radiator core directly

q

When operation of radiator cap is carried out, its cracking pressure is low

q

Inspect fan belt, pulley directly

q

40-600

22

Correct

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Replace

Remedy

Replace

When coolant temperature is measured, it is found to be normal

Replace

Troubleshooting

Inspect oil cooler directly

—


600 Troubleshooting of engine (S-mode) S-15 Abnormal noise is made

SEN03948-01

S-15 Abnormal noise is made

1

General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan belt

Removed, seized bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder


Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of machine Condition of abnormal noise


E

Gradually occurred

Q Q Q

Suddenly occurred

Q Q

Non-specified fuel is being used w


w


w

w

Air leaks between turbocharger and cylinder head

w


w


w w

When engine is cranked, beat noise is generated around muffler Check items

Q

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

w Q w

Blue under light load Q w

Black

Q w

Engine does not pick up smoothly and combustion is irregular Q

Abnormal noise is loud when engine is accelerated

Q Q

w


When turbocharger is rotated by hand, it is found to be heavy

q


q

When muffler is removed, abnormal noise disappears Troubleshooting

Q

q


q


q q


q

Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Abnormal noise is heard only when engine is started

q


Replace

Replace

Correct

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Remedy

Replace


40-600

Replace

Questions


23

600 Troubleshooting of engine (S-mode) S-16 Vibration is excessive

S-16 Vibration is excessive

1

General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for “S-15 Abnormal noise is made“, too.

Misalignment between engine and devices on applicable machine side

Loose engine mounting bolts, broken cushions

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Worn camshaft bushing

Improper gear train backlash

Worn main bearing, connecting rod bearing

Stuck dynamic valve system (valve, rocker lever)

Causes

Broken output shaft, parts in damper on applicable machine side

SEN03948-01

E

E

E

Q

Q

Q

Non-specified oil is being used

Q

Q


w

w

Metal particles are found when oil pan is drained

w

w

Oil pressure is low at low idle

Q

Q

Degree of use of machine Condition of vibration

Operated for long period Q

Suddenly increased Gradually increased

Q

Vibration occurs at mid-range speed Q

Vibration follows engine speed Exhaust smoke is black

w


q

Q

Q Q Q Q

q

Inspect main bearing and connecting rod bearing directly Troubleshooting

Q

q


q

Inspect camshaft bushing directly

q


q

Inspect engine mounting bolts and cushions directly

q

When alignment is checked, radial runout or facial runout is detected

q

40-600

24

Adjust

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Inspect output shaft or inside of damper directly

Replace

Check items

Questions



600 Troubleshooting of engine (S-mode) S-16 Vibration is excessive


SEN03948-01

40-600

25

SEN03948-01



40-600

26

SEN03949-01




50 Disassembly and assembly

1

100 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools ...............................................................................................................................11


50-100

1

100 General information on disassembly and assembly How to read this manual

SEN03949-01

How to read this manual 1.

(Rev. 2009.01)1

Removal and installation of assemblies Special tools q Special tools which are necessary for r e mo v a l or i n s ta l l at i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

* *** ****

Removal q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : Amount of oil or coolant to be drained 4:

Weight of part or component

Installation Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. q

k

: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque

a

5

: Amount of oil or coolant to be replenished

Sketches of special tools Various special tools are illustrated for the local manufacture.

q

50-100

2


100 General information on disassembly and assembly How to read this manual

2.

SEN03949-01

Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).

* *** ****

Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k

: Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained

a

Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k

: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque

a

5

: Amount of oil or coolant to be replenished

Sketches of special tools q Various special tools are illustrated for the local manufacture.


50-100

3

100 General information on disassembly and assembly Coating materials list

SEN03949-01

Coating materials list a a

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 manual.

Category

Komatsu code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.

LT-3 Adhesive

(Rev. 2009.02)1

790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)

LT-4

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

ThreeBond 1735

Gasket sealant

• Used to stick and seal metal, glass, and plastics.

Polyethylene • Used to seal plugs. container Tube

• Heat-resistant seal used to repair engines.

50 g

• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.

Aron-alpha 201

790-129-9130

2g

Loctite 648-50

79A-129-9110

50 cc

• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.

1 kg

• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-5

790-129-9080

LG-6

790-129-9160

200 g

Tube

• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.

LG-7

790-129-9170

1 kg

Tube

• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.

LG-8 ThreeBond 1207B

50-100

790-129-9140

Can

4

419-15-18131

100 g



Gasket sealant

CateKomatsu code gory

Molybdenum disulfide lubricant

Container


790-129-9310

200 g

Tube

• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.

ThreeBond 1211

790-129-9090

100 g

Tube

• Gasket sealant used to repair engine.

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.

Can

• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the drive shaft splines, needle bearings, pins and bolts of various links, etc.

—

Can

• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

Various

• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.

—

LC-G NEVER-SEEZ

09940-00040

09995-00250

—

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)

Grease

Q'ty

LG-9 ThreeBond 1206D

LM-P

Seizure prevention compound

Part number

SEN03949-01

Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)

Hyper White Grease G2-T, G0-T (*)

SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*)


200 g

190 g

• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg

400 g 16 kg

• Bellows-type container Can •

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.

Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.

50-100

5


SEN03949-01

Grease

G2-S ThreeBond 1855

G2-U-S ENS grease

Part number

—

427-12-11871

SUNSTAR PAINT PRIMER 580 SUPER

SUNSTAR PAINT PRIMER 435-95

Container


Tube

• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.

2 kg

Can

• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

20 ml

Glass container

• Used as primer for cab side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side. (Using limit: 4 months after date of manufacture)

20 ml

Glass container

200 g

417-926-3910

22M-54-27230

• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)

SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”

417-926-3910

320 ml

Polyethylene container

• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml


• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml


SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml


• Used to seal front window. (Using limit: 6 months after date of manufacture)

Cartridge

• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

50-100

6

22M-54-27220

333 ml

Adhesive for cab glass

Caulking material

Adhesive

Primer

SUNSTAR GLASS PRIMER 580 SUPER

Q'ty

Adhesive for cab glass

CateKomatsu code gory

• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)


100 General information on disassembly and assembly Special tool list

SEN03949-01

Special tool list a a

a

Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See “Sketches of special tools”).

Component

Symbol

Part No.

Part name

Necessity Q'ty New/Remodel Sketch

a

1

Nature of work, remarks

Engine front oil seal

1

795-799-6400 Seal puller

t 1

Installation of engine front oil seal

Engine rear oil seal

2 3

795-799-6500 Seal puller 795-799-6700 Puller

t 1 t 1

Installation of engine rear oil seal Removal of fuel injector

4 5

795-799-1131 Gear 795-799-8150 Remover

t 1 q 1

Positioning of crankshaft Removal of inlet connector

6

790-331-1120

q 1

7

795-790-4510 Gauge

q 1

Angle tightening of bolt Judgment of cylinder head bolt length

8 1

791-415-2002 Remover 790-201-2840 Spacer

q 1 t 1

2

793T-417-1110 Push tool 790-101-5201 Push tool kit

t 1 t 1

Cylinder head assembly, fuel injector assembly A Cylinder head assembly, engine front oil seal assembly Cooling fan assembly

3

4

Transfer assembly and D parking brake assembly

Wrench (Angle)

790-101-5311 • Plate 790-101-5221 • Grip

Removal of cooling fan Press fitting of output shaft Q bearing

1 1

Press fitting of oil seal of parking brake case

01010-51225 • Bolt 793T-417-1120 Push tool

1 t 1

790-101-5221 Grip 01010-81225 Bolt

t 1 t 1

Press fitting of dust seal of parking brake case Operation test of transfer clutch

5

799-301-1500 Oil leak tester

t 1

6 7

799-401-3200 Adapter 02789-00315 Cap

t 1 t 1

8 9

799-101-5160 Nipple 790-190-1500 Pump assembly

t 1 t 1

10 790-201-3260 Bolt (12 x 1.75 mm)

q 2

Q

Removal and installation of parking brake cylinder rod pin

11 792-735-2420 Collar

t 1

Removal and installation of parking brake assembly, cage assembly and front case Removal of HST motor 1 shaft

12 792-104-1130 Collar 13 790-101-3101 Bearing puller

t 1 q 1

Disassembly of output shaft and gear assembly

14 790-101-2501 Puller 15 790-102-2900 Puller

q 1 q 1

16 790-201-1320 Spacer

t 1

Disassembly of HST motor 2 gear and bearing assembly

17 790-101-3501 Gear puller

q 1

Removal of HST motor 1 gear and outer race


Removal of carrier assembly

50-100

7

Component

Symbol

Part No.

Part name

q 1

Disassembly of HST motor 1 gear and outer race

19 79G-17L-1000 Bar

t 1

20 795-100-1291 Sleeve driver

t 1

Removal of HST motor 1 gear shaft and bearing Removal of clutch housing

21 796-430-1110

t 1

Push tool

t 2

Adapter

t 1

Torque wrench

q 1

Press fitting of cage and bearing Measurement of output shaft and rotation torque

27 790-434-1470 Push tool

q 1

793T-623-1170 Push tool

t 1

Installation of parking brake and plate Press fitting of axle shaft bearQ ing inner race

793T-422-1440 Push tool 793T-422-1410 Seal support

t 1 t 1

Q Q

793T-422-1420 Seal support 01016-50860 Bolt

t 1 t 6

Q Axle shaft oil seal support

3

793T-659-1110 Push tool 790-201-2750 Spacer

t 1 t 1

Q

4

793T-422-1430 Holder

t 1

Q Adjustment of axle shaft bearing shim

790-101-5201 Push tool kit

t 1

5 Axle housing assembly 6 7 8

790-101-5271 790-101-5221

• Plate • Grip

1 1

01010-51225 • Bolt 790-101-3101 Bearing puller

1 q 1

790-101-3501 Gear puller 791T-465-1130 Push tool

q 1 t 1

790-201-2670 Plate

t 1

799-501-1120

t 1

Axle shaft bearing inner race

Removal of axle shaft

Removal of axle shaft bearing Q Removal of ring gear

10 790-445-5980 Guide bar

t 1

Installation of planetary carrier roll pin Removal and installation of pinion gear shaft

11 Commercially Dial gauge available 79A-264-0021 12 or commerPush-pull scale cially available

q 1

Measurement of planetary carrier end play

q 1

Measurement of housing starting torque

13 799-301-1500 Oil leak tester

t 1

14 797-101-1211

Wrench

t 1

Operation check of clutch piston Removal and installation of pinion shaft nut

15 793-615-1100

Wrench

t 1

No-load operation torque of limited slip differential

9

8

Installation of HST motor 1 gear shaft and bearing Installation of front case

t 1

25 791-126-0211 Commercially 26 available

2

50-100

Disassembly of HST motor 1, 2 gear and bearing assembly Assembly of HST motor 1 gear and outer race

t 1

24 79G-05V-1400 Bar

1

Differential assembly


18 790-101-3401 Bearing puller

Transfer assembly and D 22 790-470-1410 Collar parking brake assembly 23 796-667-1310 Collar

H



SEN03949-01

Pin

16 790-201-2840 Push tool

t 1

17 797T-423-1320 Push tool

t 1

18 792T-413-1130 Push tool

t 1

Press fitting of pinion shaft bearQ ing Press fitting of pinion shaft cage Q oil seal



Differential assembly

Symbol

H


q 3

Installation of brake piston and check for brake oil leak

20 790-190-1500 Pump assembly 21 799-101-5210 Nipple

t 1 t 1

Check for brake oil leak

22 793T-422-1611 Plate 23 791T-465-1210 Push tool

t 1 t 1

24 790-201-3280 Bolt (14 x 2.0 mm)

q 4

25 790-201-3260 Bolt (12 x 1.75 mm)

q 2

26 791-615-2130 Sleeve

t 1

27 790-101-2501 Puller

t 1

Removal of pinion gear assembly Removal of carrier bearing

28 79G-05V-1400 Bar

t 1

Removal of differential case bearing outer race

Commercially 29 available

q 1

Selection of plate thickness

30 Commercially Torque wrench available 31 791T-630-2230 Push tool

q 1

Measurement of no-load operation torque of sun gear shaft Q Installation of carrier bearing

32 Commercially available

q 1

Depth gauge

t 1

Q Q Removal of shaft Removal of cage assembly Removal and installation of upper cover and bearing carrier

33 790-201-2830 Spacer

t 1

Measurement of backlash of bevel gear Installation of long cage shaft bearing

34 791-126-0211

t 1

Installation of long cage shaft assembly

2 3

U

Part name

19 793-520-2202 Installer

1

Hydraulic cylinder assembly

Part No.


Component

SEN03949-01

4

Dial gauge

Adapter

790-502-1003 Repair stand

t 1

790-101-1102 Hydraulic pump 790-102-2303 Wrench assembly or 790-102-3802 (for steering)

t 1

Disassembly, assembly of hydraulic cylinder

t 1

Removal, installation of cylinder head

790-302-1340 Socket (for steering)

t 1

Removal, installation of piston nut


t 1

790-101-5021 01010-50816

• Grip • Bolt

1 1

790-201-1821

• Push tool (Lift)

1

790-201-1831 790-201-1741

• Push tool (Bucket) • Push tool (Steering)

1 1

790-201-1500 Push tool kit 790-101-5021 • Grip 5


Press fitting of cylinder head bushing

t 1 1

01010-50816 790-201-1630

• Bolt • Plate (Lift)

1 1

790-201-1640 790-201-1550

• Plate (Bucket) • Plate (Steering)

1 1

Installation of dust seal

50-100

9

Component

Symbol

6

Hydraulic cylinder assembly

7 U

8

Operator's cab glass (stuck glass)

X

50-100

10

q 1

796-720-1680 Ring (Lift, Bucket) 07281-01589 Clamp (Lift, Bucket)

q 1 q 1

796-720-1740 Ring (Steering) 07281-00809 Clamp (Steering)

q 1 q 1

790-102-4300 Wrench assembly (Lift, Bucket) 790-102-4310 Pin

t 1

3 793-498-1110

1

Y

Part name

790-720-1000 Expander

1 793-498-1120 1 2 793-498-1130

2

Center hinge pin

Part No.



SEN03949-01

t 2 t 2

Magnet

t 2 t 2

790-101-5201 Push tool kit 790-101-5281 • Plate

t 1 1

• Grip • Bolt

Installation of piston ring

t 2

Clear plate Plate

793-498-1210 Lifter (Suction cup)

790-101-5221 01010-51225


1 1

Adjustment of clearance of window glass Removal, installation of window glass Removal of bearing of front frame lower hinge

2

793-840-1410 Push tool

t 1

Removal of bearing of front frame upper hinge

3

793-840-1420 Push tool

t 1

4

793-415-1180

t 1

Press fitting of bearing of front frame upper hinge Press fitting of bearing of front frame lower hinge

Push tool


100 General information on disassembly and assembly Sketches of special tools

Sketches of special tools

SEN03949-01

1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. D2 Push tool

9JF00891

D4 Push tool

9JF00892


50-100

11


SEN03949-01

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. H1-1 Push tool

a

Use this tool with tool H1-2 jointed to it.

H1-2 Push tool

a

Use this tool with tool H1-1 jointed to it.

50-100

12



SEN03949-01

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. H2 Seal support

H2 Seal support


50-100

13


SEN03949-01

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. H3 Push tool

9JF00899

H4 Holder

50-100

14



SEN03949-01


COW16159

H17 Push tool


50-100

15


SEN03949-01


9JF00901

H22 Plate

50-100

16



SEN03949-01


H31 Push tool


50-100

17

SEN03949-01



50-100

18

SEN03950-02





1

200 Engine and cooling system Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ......................................................................................... 4 Removal and installation of cylinder head assembly .................................................................................... 12 Removal and installation of engine hood assembly ...................................................................................... 24 Removal and installation of radiator.............................................................................................................. 27 Removal and installation of air aftercooler .................................................................................................... 30 Removal and installation of hydraulic oil cooler assembly ............................................................................ 32 Removal and installation of engine assembly ............................................................................................... 34 Removal and installation of engine front oil seal assembly .......................................................................... 40 Removal and installation of engine rear oil seal assembly ........................................................................... 43 Removal and installation of cooling fan and fan motor assembly ................................................................. 46 Removal and installation of fuel tank assembly ............................................................................................ 49


50-200

1

200 Engine and cooling system Removal and installation of fuel supply pump assembly

SEN03950-02

Removal and installation of fuel supply pump assembly

5.

Disconnect fuel return hose (7) from fuel supply pump (4). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (5). a Plug the disconnected hose to prevent fuel leakage.

6.

Disconnect fuel supply hose (8) from fuel supply pump (4). [*1]

7.

Remove boot (9).

8.

Remove the 2 clamps of fuel high-pressure pipe (10) between the supply pump and common rail.

9.

Disconnect fuel high-pressure pipe (10) from fuel supply pump (4). [*2] a Remove the boot on the common rail side of high-pressure pipe (10) and loosen the sleeve nut.

1

Removal k

k

k

1.

2.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Open and fix right engine side cover (1). a Check that the cover is locked securely.

Remove fuel prefilter and bracket assembly (2). a Fix fuel prefilter and bracket assembly (2) to the machine with ropes.

3.

Disconnect wiring harness connector CN-CP3 (3) from fuel supply pump (4).

4.

Disconnect fuel filter hoses (5) and (6) from fuel supply pump (4).

50-200

2


200 Engine and cooling system Removal and installation of fuel supply pump assembly

10. Remove 3 mounting nuts at part (A) and fuel supply pump assembly (11). [*3]

a

SEN03950-02 [*2] q

How to install high-pressure pipe (10)

1.

Tighten the sleeve nut with the fingers.

2.

Check that the high-pressure pipe is installed correctly and tighten the sleeve nut to the following torque. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} k Be sure to use the genuine fuel highpressure pipe clamp and strictly observe the specified tightening torque.

3.

Install boot (9). a Direct the slit of the boot down. a The boot is installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason.

Remove fuel supply pump assembly (11) and the gear together. The gear does not have a positioning mark (missing tooth), etc.

[*3] a If too much grease is applied to O-ring (13), it will ooze out. Accordingly, do not apply grease so much. (Apply grease to the O-ring groove area of part (B).) a When installing new fuel supply pump mounting stud bolts (14) to replace the existing ones, apply LOCTITE (LT-2) to them. Install fuel supply pump (12). 3

Fuel supply pump mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

Installation q

Carry out installation in the reverse order to removal. a The internal parts of the fuel hose adapter may be damaged when it is removed. Accordingly, do not reuse the fuel hose but use new one when assembling again, as a rule.

[*1]

3

Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

q


Bleeding air Bleed air from the fuel system. For details, see Testing and adjusting, “Bleeding air from fuel system”.

50-200

3

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN03950-02

Removal and installation of fuel injector assembly

A

Part name


Part No.

3

795-799-6700 Puller

t 1

4

795-799-1131 Gear

t 1

5

795-799-8150 Remover

q 1

Remove 4 muffer mounting bolts (2) and (3) from the left and from the right respectively.

5.

Lift off muffer (4). a Take care that the muffer will not interfere with water drain tube (5).

1

Special tools

Symbol

4.

4

Muffer assembly: 40 kg

6.

Remove muffer mounting bracket (6) from the right.

7.

Disconnect engine intake air heater wiring harness terminal CN-E07B (7). [*1]

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant. Drain the coolant from the radiator. 6 6

Radiator: Approx. 26 l

2.

Remove the engine hood assembly. For details, see “Removal and installation of engine hood assembly”.

3.

Remove muffer cover (1).

50-200

4



SEN03950-02

8.

Remove clamps (8) and (9).

[*2]

9.

Remove air hose (10) and air inlet elbow (11) together.

10. Remove mounting bolt (12a) and then remove the engine intake air heater (electrical intake air heater). [*3]

11. Remove 2 wiring harness clamps (13). 12. Disconnect wiring harness connector (14). a While pressing the lock of wiring harness connector (14), pull the connector in the direction of the arrow. 13. Disconnect 3 wiring harness connectors (15). [*4] a While pressing the lock of the wiring harness connector with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Move wiring harness (16) toward the intake manifold.


14. Using hexagonal wrench (width across flats: 3 mm), remove blow-by duct (17). [*5] 15. Remove 6 mounting nuts (18) and cylinder head cover (19). [*6]

50-200

5


SEN03950-02 16. Remove 6 boots (20).

[*7]

17. Remove 6 high-pressure pipes (21).

[*8]

18. Position the crankshaft according to the following procedure. 1) Remove plug (22) under the starting motor and set tool A4. 2) Rotate the crankshaft forward (counterclockwise seeing from the flywheel side) to set marks (M1) and (M2). Mark (M1): Top of projection of front cover Mark (M2): A wide slit on slitted revolution sensor disc at rear of crankshaft pulley Mark (M3): Yellow paint on vibration damper (on prolongation of wide slit (M2)) a Set the projection top of mark (M1) within the wide slit (M2). a When the marks are set as above, the piston of the No. 1 or No. 6 cylinder is 76 – 88° before the top dead center. a See Testing and adjusting, “Adjusting valve clearance”. a Use tool A4 to rotate the crankshaft.

50-200

6

19. Remove the 12 mounting bolts and rocker arm (23). a Loosen locknut (24), and then loosen adjustment screw (25) by 2 – 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed.

20. Remove 12 crossheads (26). a Record the installed positions and the shapes of holes (a) and (b) of the crossheads. (When assembling, install each crosshead to the intake/exhaust valve from which it was removed.)



SEN03950-02 Do not remove the connector of injector harness from rocker housing unless it is necessary.

21. Remove retaining nuts (27) and 6 inlet connectors (28). a Before removing, clean the inlet connectors carefully so that mud, etc. sticking around them will not enter their holes. a Tool A5 is set for removal of inlet connector (28). (See the special tools list.)

22. Remove 2 wiring harness mounting nuts (30) from fuel injector assembly (29). Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6


23. Remove 2 mounting bolts (31) of fuel injector assembly (29).

24. Using tool A3, remove fuel injector assembly (29). a Take care that dirt and foreign matter will not enter the fuel injector assembly mounting area.

50-200

7


SEN03950-02 Installation a

1.

The internal parts of the fuel hose adapter may be damaged when it is removed. Accordingly, do not reuse the fuel hose but use new one when assembling, as a rule. When replacing the fuel injector assembly with new one, be sure to replace the inlet connector with new one, too.

6)

7)

Apply engine oil (EO30) to O-ring (35) of inlet connector (28) and the mounting hole on the cylinder head side. Insert inlet connector (28) securely, while setting part (B) to the groove on the cylinder head side.

Fuel injector assembly a Check that the fuel injector sleeve is free from flaw and dirt. 1) Fit O-ring (32) and gasket (33) to fuel injector (29). 2) Apply engine oil (EO30) to O-ring (32) of fuel injector (29) and the mounting hole on the cylinder head side. 3) While setting convex and concave parts (A), install holder (34) to fuel injector (29). 8)

Secure inlet connector (28) by tightening retaining nut (27) lightly. 3 Retaining nut (27): 15 ± 5 Nm {1.5 ± 0.5 kgm} 9) Tighten 2 mounting bolts (31) of fuel injector (29) alternately. 3 Fuel injector mounting bolt (31): 8.0 ± 0.8 Nm {0.8 ± 0.08 kgm} 10) Tighten retaining nut (27). 3 Retaining nut (27): 50 ± 5 Nm {5.1 ± 0.5 kgm}

4)

5)

Insert fuel injector (29) in the cylinder head, directing its fuel inlet hole toward the air intake manifold. Tighten 2 mounting bolts (31) of fuel injector (29) by 3 – 4 turns.

11) Install the wiring harnesses to fuel injector (29) and tighten 2 mounting nuts (30). 3 Wiring harness mounting nut (30): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a Installed positions of wiring harnesses

50-200

8

Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6



SEN03950-02 q

a

When the connector of injector harness is removed. When assembling the injector harness connector (42) to the housing, apply gasket sealant (LG-7) to the Oring portion (43) and the flange face of connector (44). When applying gasket sealant (LG-7) to the O-ring portion, be sure to apply a string of LG-7 f 3 mm in diameter until O-ring groove is completely filled. If the O-ring is damaged, replace as a harness assembly. 3 Connector flange mounting bolt (45): 10 ± 2 Nm {1 ± 0.2 kgm}


Precautions for installing inlet connector 1) When replacing the fuel injector assembly with new one, be sure to replace inlet connector, too. 2) Check the inlet connector visually. If it has any of the following faults, replace it. 1] There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector. 2] There is foreign matter in the edge filter at rear end (c) of the inlet connector. 3] The O-ring at upper part (d) of the inlet connector is cracked or deteriorated.

3)

Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal face has fine streaks or cracks.

50-200

9


SEN03950-02 2.

Crosshead and rocker arm assembly 1) Install the crosshead and rocker arm. a The shapes of holes (a) and (b) of each crosshead are different. Accordingly, when reusing the crossheads, install each of them to the same intake/exhaust valve in the same direction as it has been installed. 2) Check that the ball of adjustment screw (25) is set in the push rod socket securely and then tighten mounting bolts (36). 3 Rocker arm mounting bolt (36): 36 ± 5 Nm {3.7 ± 0.5 kgm} 3) Adjust the valve clearance. For details, see Testing and adjusting, “Adjusting valve clearance”. 3 Locknut (24): 24 ± 4 Nm {2.4 ± 0.4 kgm}

q

Carry out the following installation in the reverse order to removal.

[*1]

3

Wiring harness terminal CN-E07B (7): 4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}

[*2]

3 3

Clamp (8): 7 ± 1 Nm {0.71 ± 0.1 kgm} Clamp (9): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]

3

Engine intake air heater mounting bolt (12a): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*4]

k

Install each fuel high-pressure pipe and wiring harness at least 10 mm apart from each other.

[*5]

3

Blow-by duct (17) mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm}

[*6]

3

Cylinder head cover mounting nut (18): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*7], [*8] k Do not bend the fuel high-pressure pipe to correct before installing. k Be sure to use the genuine fuel high-pressure pipe clamps and observe the tightening torque. a If the taper seal area of the fuel high-pressure pipe has any of the following defects, replace the fuel high-pressure pipe. q There is visible lengthwise slit (b) or spot (c) in range (a) of 2 mm from the end. q Taper seal end (d) at 2 mm from the end has stepped-type wear which your nail can feel.

50-200

10



1)

2)

3)

SEN03950-02

Temporarily install fuel high-pressure pipes (36) – (41). 3 Sleeve nut: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten fuel high-pressure pipes (36) – (41) in the following order. 1] Tighten the cylinder head side of fuel high-pressure pipes (36) and (41). 2] Tighten the common rail side of fuel high-pressure pipes (36) and (41). 3] Tighten the cylinder head side of fuel high-pressure pipes (37), (38), (39) and (40). 4] Tighten the common rail side of fuel high-pressure pipes (37), (38), (39) and (40). 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} Install 6 boots (20) to the fuel high-pressure pipes. a Direct the slit of the boot out and down. a The boots are installed so that fuel will not spout over the hot parts of the engine to catch fire when it leaks for some reason.

q


q

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5

Total amount of coolant: 26.5 l (For details, see “Table of fuel, coolant and lubricants”)


50-200

11

200 Engine and cooling system Removal and installation of cylinder head assembly

SEN03950-02

Removal and installation of cylinder head assembly

A

Part name


Part No.

3

795-799-6700 Puller

t 1

4

795-799-1131 Gear

t 1

5

795-799-8150 Remover

q 1

6

790-331-1120 Wrench (angle)

q 1

7

795-790-4510 Gauge

q 1

Remove 4 muffler mounting bolts (2) on the left and 4 (3) on the right.

5.

Lift off muffler (4). a Take care that the muffler will not interfere with water drain tube (5).

1

Special tools

Symbol

4.

4

Muffler assembly: 40 kg

6.

Remove right muffler mounting bracket (6).

7.

Disconnect engine intake air heater wiring harness terminal CN-E07B (7). [*1]

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant. Drain the coolant from the radiator. 6


2.


3.

Remove muffer cover (1).

50-200

12



SEN03950-02

8.

Remove clamps (8) and (9).

[*2]

9.

Remove air hose (10), and intake air inlet elbow (11) as a set.

10. Remove mounting bolt (12a) and engine intake air heater (electrical intake air heater). [*3]

11. Remove the air conditioner compressor assembly according to the following procedure. 1) Loosen air conditioner compressor assembly mounting bolt (13). 2) Loosen air conditioner compressor drive belt adjustment bolt (14) and remove belt (15). [*4]

3) 4) 5) a

Disconnect wiring harness connector (16). Remove bracket (17). Remove air conditioner compressor [*4] assembly (18). Fix air conditioner compressor assembly (18) to the machine with ropes.

12. Disconnect fuel filter hoses (19) and (20). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (20). a Plug the disconnected hoses to prevent fuel leakage. 13. Disconnect fuel return hose (21). 14. Remove fuel prefilter hose clamp (22). 15. Remove 2 air conditioner compressor hose clamps (23). 16. Remove fuel filter and bracket assembly (24).


50-200

13

SEN03950-02


17. Remove 2 clamps (25).

21. Remove 2 wiring harness clamps (29).

18. Disconnect engine coolant temperature sensor connector (26).

22. Disconnect wiring harness connector (30). a While pressing the lock of wiring harness connector (30), pull the connector in the direction of the arrow.

19. Disconnect ambient air pressure sensor connector (27) according to the following procedure. 1) Slide lock (L1) in the direction of the arrow. 2) Pull out connector (27) in the direction of the arrow while pressing lock (L2). 20. Disconnect intake air pressure sensor connector (28).

23. Disconnect 3 wiring harness connectors (31). [*5] a While pressing the lock of the wiring harness connector (31) with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Move wiring harness (32) toward the intake manifold.

50-200

14



SEN03950-02

24. Remove the fuel high-pressure pipe according to the following procedure. 1) Disconnect fuel drain hose (33). [*6] 2) Remove 6 bolts (34). [*7] 3) Disconnect fuel high-pressure pipe (35).[*8] 4) Remove 6 high-pressure pipes (36). [*9] a Loosen the sleeve nut on the common rail side of each high-pressure pipe.

28. Disconnect heater hose (40). 29. Disconnect corrosion resistor hose (41). 30. Remove corrosion resistor and bracket assembly (42).

31. Remove heat insulation plate (43). 25. Disconnect radiator upper hose (37).

[*10] 32. Remove bracket (44).

26. Disconnect air aftercooler upper hose and tube [*11] assembly (38).

33. Remove cover (45).

27. Remove heat insulation cover (39).

34. Remove the alternator assembly according to the following procedure. 1)


Disconnect wiring harness terminals CNE02 (46) and CN-E03 (47).

50-200

15

SEN03950-02 2)

3)

Remove fan belt (49). q Put the wrench in the concave section (width across flats: 12.7 mm) of tensioner assembly (48) and turn it in the unwinding direction to decrease the tension of fan belt (49). k Set the wrench securely to the concave section of tensioner assembly (48) before turning it. (The spring of tensioner assembly (48) is strong. If the wrench is set incompletely and turned, it comes off and that is very dangerous.) k After removing belt (49), return tensioner assembly (48) slowly and carefully. k Take care not to catch your finger between the pulley and fan belt (49) during work. Remove alternator assembly (50).


2)

Remove mounting bolts (54) of exhaust manifold (53), leaving some of them installed. [*13]

3)

Temporarily sling exhaust manifold and turbocharger assembly (55) and remove the remaining mounting bolts. Lift off exhaust manifold and turbocharger assembly (55). 4 Exhaust manifold and turbocharger assembly: 40 kg

4)

35. Remove the turbocharger assembly according to the following procedure. 1) Disconnect turbocharger lubricating oil inlet tube (51) and drain hose (52). [*12] 36. Remove the fuel infector assembly according to the following procedure. 1) Using hexagonal wrench (width across flats: 3 mm), remove blow-by duct (56). [*14] 2) Remove 6 mounting nuts (57) and cylinder head cover (58). [*15]

50-200

16



3)

Position the crankshaft according to the following procedure. 1] Remove plug (59) under the starting motor and set tool A4.

Rotate the crankshaft forward (counterclockwise seeing from the flywheel side) to set marks (M1) and (M2). Mark (M1): Top of projection of front cover Mark (M2): A wide slit on slitted revolution sensor disc at rear of crankshaft pulley Mark (M3): Yellow paint on vibration damper (on prolongation of wide slit (M2)) a Set the projection top of mark (M1) within the wide slit (M2). a There is yellow paint mark (M3) on the prolongation of wide slit (M2). a When the marks are set as above, the piston of the No. 1 or No. 6 cylinder is 76 – 88° before the top dead center. a See Testing and adjusting, “Adjusting valve clearance”. a Use tool A4 to rotate the crankshaft.

SEN03950-02 4)

Remove the 12 mounting bolts and rocker arm (60). a Loosen locknut (61), and then loosen adjustment screw (62) by 2 – 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed.

5)

Remove 12 crossheads (63). a Record the installed positions and the shapes of holes (a) and (b) of the crossheads. (When assembling, install each crosshead to the intake/ exhaust valve from which it was removed.)

2]


50-200

17


SEN03950-02 6)

Remove retaining nuts (64) and 6 inlet connectors (65). a Before removing, clean the inlet connectors carefully so that mud, etc. sticking around them will not enter their holes. a Tool A5 is set for removal of inlet connector (65). (See the special tools list.)

9)

Using tool A3, remove fuel injector assembly (66). a Take care that dirt and foreign matter will not enter the fuel injector assembly mounting area.

37. Remove push rods (69). 38. Remove 7 mounting bolts (70) and rocker housing (71). 7)

8)

Remove 2 wiring harness mounting nuts (67) from fuel injector assembly (66). Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

Remove 2 mounting bolts (68) of fuel injector assembly (66).

39. Remove 26 mounting bolts (72) and lift off cylinder head assembly (73). 4

Cylinder head assembly: 75 kg

40. Remove cylinder head gasket (74).

50-200

18



SEN03950-02

Installation a

1.

2)

The internal parts of the fuel hose adapter may be damaged when it is removed. Accordingly, do not reuse the fuel hose but use new one when assembling as a rule. When replacing the fuel injector assembly with new one, be sure to replace the inlet connector with new one, too.

3) 4)

Cylinder head assembly 1) Using tool A7, measure stem length (a) of each cylinder head mounting bolt and check that it is shorter than using limit (b). (See the special tools list.) q Using limit length of bolt (b): 132.1 mm a If a bolt is longer than the using limit, replace it.

q


Set cylinder head gasket (74). a Check that there is no dirt and foreign matter on the cylinder head mounting surface and in the cylinders. a Check that the holes of the cylinder head gasket are matched to the holes of the cylinder head. Set cylinder head (73) on the cylinder block. Tighten 26 mounting bolts (72) 2 – 3 turns with the fingers, and then tighten them according to the following procedure. 2 Threaded part and seat of mounting bolt: Engine oil (EO30)

Tightening procedure for mounting bolts (63). 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] Check the tightening torque of 90 ± 3 Nm {9.2 ± 0.3 kgm}. 3] 90 ± 5° (Use the angle tightening tool) a Tighten the mounting bolts in the following order. a Tool A6 is set for angle tightening. (See the special tools list.)

50-200

19

SEN03950-02 q


When not using angle tightening tool 4] After steps 1] and 2], make marks on the cylinder head and each bolt with a paint. 5] Tighten the bolt by 90 ± 5°.

6)

7) 2.

Fuel injector assembly a Check that the fuel injector sleeve is free from flaw and dirt. 1) Fit O-ring (75) and gasket (76) to fuel injector (66). 2) Apply engine oil (EO30) to O-ring (75) of fuel injector (66) and the mounting hole on the cylinder head side. 3) Install holder (77), while setting its concave part to convex part (A) of fuel injector (66).

8)

9)

4)

5)

50-200

Insert fuel injector (66) in the cylinder head, directing its fuel inlet hole toward the air intake manifold. Tighten 2 mounting bolts (68) of fuel injector (66) by 3 – 4 turns.

Apply engine oil (EO30) to O-ring (78) of inlet connector (65) and the mounting hole on the cylinder head side. Insert inlet connector (65) securely, while setting part (B) to the groove on the cylinder head side.

Install rocker housing (71). 3 Rocker housing mounting bolt (70): 24 ± 4 Nm {2.4 ± 0.4 kgm} Install push rods (69).

20



10) Secure inlet connector (65) by tightening retaining nut (64) lightly. 3 Retaining nut (64): 15 ± 5 Nm {1.5 ± 0.5 kgm} 11) Tighten 2 mounting bolts (68) of fuel injector (66) alternately. 3 Fuel injector mounting bolt (68): 8.0 ± 0.8 Nm {0.8 ± 0.08 kgm} 12) Tighten retaining nut (64). 3 Retaining nut (64): 50 ± 5 Nm {5.1 ± 0.5 kgm}

13) Install the wiring harnesses to fuel injector (66) and tighten 2 mounting nuts (67). 3 Wiring harness mounting nut (67): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a Installed positions of wiring harnesses Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6


SEN03950-02 q

Precautions for installing inlet connector 1) When replacing the fuel injector assembly with new one, be sure to replace inlet connector, too. 2) Check the inlet connector visually. If it has any of the following faults, replace it. 1] There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector. 2] There is foreign matter in the edge filter at rear end (c) of the inlet connector. 3] The O-ring at upper part (d) of the inlet connector is cracked or deteriorated.

3)

Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal face has fine streaks or cracks.

50-200

21


SEN03950-02 3.

Crosshead and rocker arm assembly 1) Install the crosshead and rocker arm. a The shapes of holes (a) and (b) of each crosshead are different. Accordingly, when assembling, install each crosshead to the intake/exhaust valve from which it was removed. 2) Check that the ball of adjustment screw (80) is set in the push rod socket securely and then tighten mounting bolts (81). 3 Rocker arm mounting bolt (81): 36 ± 5 Nm {3.7 ± 0.5 kgm} 3) Adjust the valve clearance. For details, see Testing and adjusting, “Adjusting valve clearance”. 3 Locknut (79): 24 ± 4 Nm {2.4 ± 0.4 kgm}

q


[*1]

3

Wiring harness terminal CN-E07B (7): 4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}

[*2]

3 3

Clamp (8): 7 ± 1 Nm {0.71 ± 0.1 kgm} Clamp (9): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]

3

Engine intake air heater mounting bolt (12a): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*4] Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting, “Adjusting air conditioner compressor belt tension”. [*5]

k

Install each fuel high-pressure pipe and wiring harness at least 10 mm apart from each other.

[*6], [*7], [*8], [*9] k Do not bend the fuel high-pressure pipe to correct before installing. k Be sure to use the genuine fuel high-pressure pipe clamps and observe the tightening torque. a If the taper seal area of the fuel high-pressure pipe has any of the following defects, replace the fuel high-pressure pipe. q There is visible lengthwise slit (b) or spot (c) in range (a) of 2 mm from the end. q Taper seal end (d) at 2 mm from the end has stepped-type wear which your nail can feel.

50-200

22



1)

2)

3)

4)

Temporarily install fuel high-pressure pipes (82) – (87). 3 Sleeve nut: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten fuel high-pressure pipes (82) – (87) in the following order. 1] Tighten the cylinder head side of fuel high-pressure pipes (82) and (87). 2] Tighten the common rail side of fuel high-pressure pipes (82) and (87). 3] Tighten the cylinder head side of fuel high-pressure pipes (83), (84), (85) and (86). 4] Tighten the common rail side of fuel high-pressure pipes (83), (84), (85) and (86). 5] Tighten the pump side of high-pressure pipe (35) and then tighten the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} Install 6 boots (34) to the fuel high-pressure pipes. a Direct the slit of the boot out and down. a The boots are installed so that fuel will not spout over the hot parts of the engine to catch fire when it leaks for some reason. Install fuel drain hose (33). 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}

SEN03950-02 [*12]

3 3

Mounting nut of turbocharger lubricating oil inlet hose (51): 35 ± 5 Nm {3.5 ± 0.5 kgm} Mounting bolt of turbocharger lubricating oil drain tube (52): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*13] Tighten the exhaust manifold mounting bolts according to the following procedure. 3 Exhaust manifold mounting bolts 1st time: Tighten [1] – [12] to 24 ± 4 Nm {2.4 ± 0.4 kgm} in order. 2nd time:Tighten [1] – [12] to 53 ± 6 Nm {5.4 ± 0.6 kgm} in order. 3rd time: Tighten only [1] – [4] to 53 ± 6 Nm {5.4 ± 0.6 kgm} in order.

q

[*14]

3

Blow-by duct mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm}

[*15]

3

[*10]

2

3

Radiator upper hose insertion area: Gasket sealant (ThreeBond 1206E or equivalent) Radiator upper hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Cylinder head cover mounting nut (57): 24 ± 4 Nm {2.4 ± 0.4 kgm}

q


q


Total amount of coolant: 26.5 l

[*11]

3

Air aftercooler upper hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}


50-200

23

200 Engine and cooling system Removal and installation of engine hood assembly

SEN03950-02

Removal and installation of engine hood assembly

4.

Remove partition plate (4).

5.

Disconnect radiator overflow hose (5).

Open and fix right and left engine side covers (2). a Check that the covers are locked securely.

6.

Remove 4 bolts (6), then remove cover (7).

Open radiator grille (3).

7.

Remove 3 air conditioner compressor hose clamps (8).

8.

Remove 4 right and left bolts (9), then remove partition plate (10).

1

Removal k

k

k

1.

2.

3.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Remove exhaust pipe (1).

50-200

24



9.

Remove stay (1) on the right and left.

SEN03950-02 12. Remove right and left fenders (15). 13. Remove right and left covers (16).

a

Put wooden block [1] under striker (12) to prevent the radiator assembly from falling down.

10. Disconnect water separator wiring harness connector CN-E42 (13). 11. Remove fuel prefilter and bracket assembly (14). a Fix fuel prefilter and bracket assembly (14) to the machine with ropes.


14. Remove hose (17) between the air cleaner and turbocharger. [*1]

15. Disconnect 2 washer hoses (18). 16. Remove wiring clamp (19). 17. Remove rubber cover (20).

50-200

25


SEN03950-02 18. Disconnect rear combination lamp connector CN-BR1 (21).

21. Lift off engine hood assembly (24). 4

Engine hood assembly: 240 kg

19. Remove 2 front mounting bolts (22) on each of the right and left sides.

Installation q

Carry out installation in the reverse order to removal.

[*1]

3

Hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

20. Remove 1 rear mounting bolt (23) on each of the right and left sides.

50-200

26


200 Engine and cooling system Removal and installation of radiator

Removal and installation of radiator

SEN03950-02

1

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant.

7.

Remove air conditioner receiver tank (8) and [*1] bracket (9) together.

8.

Disconnect air aftercooler upper hose (10).

Drain the coolant from the radiator. 6


2.


3.


a

9.

4.

Remove 4 bolts (3) and cover (4).

5.

Remove 3 air conditioner compressor hose clamps (5).

6.

Remove 4 bolts (6) on the right and left sides and partition plate (7).


[*2] Remove the air aftercooler upper hose since it interferes with the air conditioner condenser when the latter is removed.

Remove 4 mounting bolts (11) and air conditioner condenser (12). a Move air conditioner condenser (12) and the air conditioner receiver tank to the front of the machine.

50-200

27


SEN03950-02 10. Disconnect radiator upper hose (13).

[*3]

15. Remove 2 radiator mounting bolts (21) on the top.

11. Remove 8 mounting bolts (15) on the right and left sides and bracket (16).

12. Disconnect radiator lower hose (17).

[*4]

13. Fix cooling fan and fan motor assembly (18) open. a Check that the cooling fan and fan motor assembly is locked securely.

16. Remove 2 bolts (19) and cover (20). a This cover needs to be removed since it interferes with bolt (19) when the radiator is removed.

17. Remove radiator (22) from the left side. [*5] a When removing the radiator, take care not to damage the radiator core.

14. Remove 4 wiring harness clamps (14).

50-200

28



Installation q


[*1]

3

Air conditioner receiver tank mounting Uclamp: 10.8 – 26.0 Nm {1.1 – 2.7 kgm}

SEN03950-02 [*5] a Fit grommet (23) to the mounting hole. a Check that projection (A) of the radiator is fitted to grommet (23). a When installing the radiator, set drain hose (24) in mounting hole (B) securely.

[*2]

3


[*3]

2

3

Radiator upper hose insertion area: Gasket sealant (ThreeBond 1206E or equivalent) Radiator upper hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*4]

2

3

Radiator lower hose insertion area: Gasket sealant (ThreeBond 1206E or equivalent) Radiator lower hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

q




50-200

29

200 Engine and cooling system Removal and installation of air aftercooler

SEN03950-02

Removal and installation of air aftercooler

4.

Remove upper 2 air aftercooler mounting bolts (2).

5.

Remove air aftercooler (3) from the left side. [*2] a When removing the air aftercooler, take care not to damage its core.

1

Removal k

k

k k

1.



2.

Remove the radiator. For details, “Removal and installation of radiator”.

3.

Disconnect air aftercooler lower hose (1). [*1] a Since the air aftercooler upper hose was removed in “Removal and installation of radiator”, it is not described here.

50-200

30

see


200 Engine and cooling system Removal and installation of air aftercooler

SEN03950-02

Installation q


[*1]

3

Air aftercooler lower hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2] a Fit grommet (4) to the mounting hole. a Check that projection (A) of the air aftercooler is fitted to grommet (4).

q




50-200

31

200 Engine and cooling system Removal and installation of hydraulic oil cooler assembly

SEN03950-02

Removal and installation of hydraulic oil cooler assembly

4.

Disconnect hydraulic oil cooler lower hose (2). a Plug the disconnected hose to prevent oil leakage.

5.

Remove 2 upper mounting bolts (3) of the hydraulic oil cooler.

6.

Remove 2 lower mounting bolts (4) of the hydraulic oil cooler.

1

Removal k

k

k k

1.



2.

Remove the radiator. For details, “Removal and installation of radiator”.

3.

Disconnect hydraulic oil cooler upper hose (1). a Plug the disconnected hose to prevent oil leakage.

50-200

32

see


200 Engine and cooling system Removal and installation of hydraulic oil cooler assembly

7.

Remove 2 hydraulic oil cooler mounting bolts (5) on the right side.

SEN03950-02 Installation q


q

Refilling with oil (Hydraulic tank) 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. 5

q

8.

Remove hydraulic oil cooler assembly (6) from the right side. a When removing, take care not to damage the hydraulic oil cooler core.


Hydraulic oil (For details, see “Table of fuel, coolant and lubricants”): Only necessary quantity


Total amount of coolant: 26.5 l (For details, see “Table of fuel, coolant and lubricants”)

50-200

33

200 Engine and cooling system Removal and installation of engine assembly

SEN03950-02

Removal and installation of engine assembly

4.

Disconnect fuel prefilter wiring harness clamp (2) and connector CN-E42 (3). a The fuel prefilter was removed and fixed in “Removal and installation of engine hood assembly”.

5.

Remove wiring harness clamp (4).

6.

Disconnect alternator wiring harness terminals CN-E02 (5) and CN-E03 (6).

7.

Remove hose clamp (7).

8.

Disconnect heater return hose (8).

1

Removal k

k

k k

1.



2.


3.

Remove muffler cover (1). a Remove the muffler cover since it will interfere with the engine slings (wire ropes, etc.)

50-200

34



9.

SEN03950-02 15. Remove clamps (15) for the engine wiring harness and air conditioner compressor hose.


10. Disconnect starting motor wiring harness terminal (10).

16. Disconnect starting motor wiring (17). 11. Disconnect engine ground cable (11).

[*1]

17. Disconnect wiring (18). 18. Disconnect connectors CN-ER1 (19), CN-ER2 (20) and CN-ER3 (21).

12. Remove hose clamp (12). 13. Disconnect heater inlet hose (13). 14. Remove engine wiring harness clamp (14).


50-200

35

SEN03950-02 19. Disconnect wiring harness connector (22).


21. Remove hose clamp (28). 22. Disconnect fuel return hose (29).

20. Remove the air conditioner compressor assembly according to the following procedure. 1) Loosen air conditioner compressor assembly mounting bolt (23). 2) Loosen air conditioner compressor drive belt adjustment bolt (23a) and remove belt (24). [*6]

23. Remove 3 fan motor hose clamps (30).

24. Disconnect air aftercooler upper hose (31). [*2] 25. Disconnect radiator upper hose (32). 3) 4) 5)

50-200

[*3]

Disconnect wiring harness connector (25). Remove bracket (26). Remove air conditioner compressor assembly (27).

36



SEN03950-02

26. Remove mounting bracket (33), then remove radiator hose mounting bracket (34).

29. Place bar [1] over the frame. Using lever blocks [3] and [2], sling HST pump assembly (37) temporarily.

27. Disconnect air aftercooler lower hose (35). [*4] 28. Disconnect radiator lower hose (36).


[*5]

30. Remove 12 damper cover mounting bolts (38). [*7] a Do not remove HST pump mounting bolts (39) to disconnect the HST pump. q If the HST pump is disconnected from the engine assembly, you cannot see if the gears are meshed when installing the engine assembly and the damper may be damaged consequently.

50-200

37


SEN03950-02 31. Using the sling, lift up the engine assembly temporarily. 32. Remove right and left engine mounting bolts (40) at the rear of the machine. [*8]

Installation q

33. Remove right and left engine mounting bolts (41) at the front of the machine. [*9]

[*1]

34. Remove 4 engine mounting bolts (42) on each of the right and left side of the front of the machine to remove bracket (43). [*10] a Loosen adjustment bolts (43a) and (43b).

[*2]


3

3

Engine ground cable mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}


[*3]

2

3

Radiator upper hose: Gasket sealant (ThreeBond 1206E or equivalent) Radiator upper hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*4]

3

Air aftercooler lower hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*5] 35. Lift up engine assembly (44) a little and move it toward the rear of the machine to disconnect it from the HST pump assembly. [*11] 36. Lift off engine assembly (44). a Check that all the electric wiring and hydraulic piping are disconnected. a When removing the engine, take care that it will not interfere with the radiator, air aftercooler and hydraulic oil cooler. 4

Engine assembly: 700 kg

2

3

38

Gasket sealant (ThreeBond 1206E or equivalent) Radiator lower hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*6] Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting, “Adjusting air conditioner compressor belt tension”. [*7]

2 3

50-200

Radiator lower hose:

Damper cover mating face: Gasket sealant (LG-6) Damper cover mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}



SEN03950-02

[*8]

3

Right and left engine mounting bolts (40) at rear of machine: 245 – 308.9 Nm {25.0 – 31.5 kgm}

[*9]

3

Right and left engine mounting bolts (41) at front of machine: 245 – 308.9 Nm {25.0 – 31.5 kgm}

[*10]

3

a

Right and left engine mount bracket mounting bolts (42) at front of machine: 98 – 123 Nm {10.0 – 12.5 kgm} Adjust clearances (a) and (b) of right and left engine mount adjustment bolts (43a) and (43b) at front of machine to the following dimensions and lock the adjustment bolts. Clearance (a): 2 mm Clearance (b): 2 mm

q


q



[*11] a When installing the engine assembly, carefully set damper flange (45) to the gear of HST pump boss (46). a Take care not to damage flange (45).


50-200

39

200 Engine and cooling system Removal and installation of engine front oil seal assembly

SEN03950-02

Removal and installation of engine front oil seal assembly

1

2.

Remove 4 bolts (2), then remove cover (3).

3.

Remove 3 air conditioner compressor hose clamp (4).

4.

Remove 4 bolts (5) on the right and left sides, then remove partition plate (6).

5.

Remove cover (7).

Symbol

A

Part No.

Part name


Special tools

1

795-799-6400 Seal puller

t 1

6

790-331-1120 Wrench (angle)

q 1

Removal k

k

k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Open and fix right and left engine side covers (1). a Check that the covers are locked securely.

50-200

40



6.

Put wrench [1] in the concave section (width across flats: 12.7 mm) of tensioner assembly (8) and turn it in the unwinding direction to decrease the tension of fan belt (9). k Set the wrench [1] securely to the concave section of tensioner assembly (8) before turning it. (The spring of tensioner assembly (8) is strong. If the wrench [1] is set incompletely and turned, it comes off and that is very dangerous.) k After removing belt (9), return tensioner assembly (8) slowly and carefully. k Take care not to catch your finger between the pulley and fan belt (9) during work.

SEN03950-02 8.

Installation 1.

7.

Remove engine front oil seal (12).

Using tool A1, install engine front oil seal (12). a Before installing the engine front oil seal, check that crankshaft end corners and seal lip sliding surfaces are free from a housing flaw, burr, fin, rust, etc. a Before installing the engine front oil seal, degrease, clean, and dry the seal contact faces of the crankshaft and the seal lip surfaces to prevent oil leakage. a When installing the engine front oil seal, do not apply oil or grease to the crankshaft and seal lip.

Remove 6 mounting bolts (10) and vibration damper (11).


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41

SEN03950-02


a

a

When not using angle tightening tool 5] After steps 1] – 3], make marks on the vibration damper and each bolt with a paint. 6] Tighten the bolts by 90 ± 5°.

q


q q

2.

The projection and runout of engine front oil seal (12) from cover (13) must be in the following range. Projection (x): Max. 0.38 mm Facial runout (TIR: Total Indicator Reading) (y): Max. 0.25 mm

Vibration damper 1) Install vibration damper (8) to the crankshaft while setting the dowel hole of the former to dowel pin (a) of the latter. 2) Tighten mounting bolts (7) according to the following procedure. 1] Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5 kgm} in the diagonal order. 2] Loosen the bolts by 180°. 3] Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5 kgm} in the diagonal order. 4] Retighten the bolts by 90 ± 5°. a Tool A6 is set for angle tightening. (See the special tools list.)

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42


200 Engine and cooling system Removal and installation of engine rear oil seal assembly

Removal and installation of engine rear oil seal assembly

A

Part name

2 795-799-6500 Seal puller


Part No.

5.

Install eyebolt [1] to the damper mounting bolt hole and sling flywheel assembly (4).

6.

Remove the 2 flywheel mounting bolts and install guide bolts [2].

7.

Remove other 6 mounting bolts (3) and lift off flywheel assembly (4). [*2]

1

Special tools

Symbol

SEN03950-02

4

Flywheel assembly: 45 kg

t 1

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant. Loosen the radiator cap to drain the coolant. 6

Radiator: Approx. 26.5 l

2.


3.

Remove the engine assembly. For details, see “Removal and installation of engine assembly”.

4.

Remove 8 mounting bolts (1) and damper flange (2). [*1]


8.

Engine rear oil seal 1) Install tool A2 to the crankshaft. 2) Tighten tapping screw [3] of tool A2 into the seal carrier of engine rear oil seal (5). 3) Rotate the wrench handle clockwise to remove engine rear oil seal (5).

50-200

43

SEN03950-02


Installation 1.

Keep pilot [4] installed to engine rear oil seal (5) until it is inserted in the crankshaft. a Before installing the engine rear oil seal, check that crankshaft end corners and seal lip sliding surfaces are free from a housing flaw, burr, fin, rust, etc. a Before installing the engine rear oil seal, degrease, clean, and dry the seal contact faces of the crankshaft and the seal lip surfaces to prevent oil leakage. a When installing the engine rear oil seal, do not apply oil or grease to the crankshaft and seal lip.

2.

Insert pilot [4] in crankshaft (6) and push engine rear oil seal (5) into flywheel housing (7).

q

3.

Push in engine rear oil seal (5) further and then pull out pilot [4].

4.

Using tool A2, install engine rear oil seal (5) to flywheel housing (7). a When installing engine rear oil seal (5), take care not to bend it. a Projection of engine rear oil seal (5) (x): Max. 0.38 mm


[*1] a When installing damper flange (2), direct part (a) as shown below.

2

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44

3

Damper flange mounting bolt (1): Adhesive (LT-2) Damper flange mounting bolt (1): 44.1 – 53.9 Nm {4.5 – 5.5 kgm}



[*2] a Tighten the 8 flywheel assembly mounting bolts in the following order shown below. a Using a bar, lock the flywheel. 3 Flywheel mounting bolt: 137 ± 7 Nm {13.97 ± 0.71 kgm}

SEN03950-02 q

a

a

q

a

Measuring facial runout Facial runout: Max. 0.20 mm 1) Install the stand to dial gauge [6] and install them to flywheel housing [7]. 2) Set the dial gauge so that its probe will be perpendicular to end face (c) of the flywheel near the periphery. 3) Rotate the flywheel by 1 turn and measure the difference between the lowest and highest values indicated by the dial gauge. After rotating the flywheel by 1 turn, check that the dial gauge indicates the value at the start of rotation.

Measuring radial runout Radial runout: Max. 0.13 mm 1) Install the stand to dial gauge [6] and install them to flywheel housing [7]. 2) Set the dial gauge so that its probe will be perpendicular to spigot portion (b) or periphery of the flywheel. q


q


3)


Rotate the flywheel by 1 turn and measure the difference between the lowest and highest values indicated by the dial gauge. a After rotating the flywheel by 1 turn, check that the dial gauge indicates the value at the start of rotation.


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45

200 Engine and cooling system Removal and installation of cooling fan and fan motor assembly

SEN03950-02

Removal and installation of cooling fan and fan motor assembly

A

Part name

8 791-415-2002 Remover


Part No.

Remove 4 fuel tank breather hose clamps (3).

4.

Remove clip (5) and disconnect hose (4) from breather (6).

5.

Remove breather (6).

6.

Remove 3 wiring harness clamps (7).

7.

Disconnect wiring harness connectors CN-R59 (8) and CN-R29 (9).

8.

Disconnect P port hose (10), TC port hose (11) and T port hose (12). a Plug the disconnected hoses and ports to prevent oil leakage.

1

Special tools

Symbol

3.

q 1

Removal k

k

k

1.

2.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Open radiator grille (1).

Remove cover (2).

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46



9.

Move the lock portion of stopper link (13) to hole (A) of bracket (14) to remove it from the bracket.

10. Remove mounting bolt (16), stopper plate (15) and nut (17). [*1]

SEN03950-02

12. Remove 4 mounting bolts (19) and remove fan [*3] motor assembly (21) from bracket (20).

Installation q


[*1]

3

Nut (17): 98.0 – 127.5 Nm {10 – 13 kgm} Set the installed position of stopper plate (15) in the tightening direction of nut (17). 2 Mounting bolt (16): Adhesive (LT-2) 3 Mounting bolt (16): 59 – 74 Nm {6.0 – 7.5 kgm}

a

11. Using tool A8, remove cooling fan assembly (18). [*2]


[*2] a Check that key (22) is fitted securely to the key way on the shaft of fan motor assembly (21). a When installing cooling fan assembly (18), set its key way to key (22).

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47

SEN03950-02


[*3] a Before installing fan motor assembly (21), add hydraulic oil from port (23) (for details, see “Table of fuel, coolant and lubricants”) until it flows over and then install the plug.

q


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48


200 Engine and cooling system Removal and installation of fuel tank assembly

Removal and installation of fuel tank assembly

SEN03950-02

k

k

1.

Disconnect fuel level gauge wiring harness connector CN-R21 (7).

7.

Remove hose clamp (8).

8.

Disconnect fuel return hose (9) and supply hose (10). a Plug the disconnected hoses to prevent fuel leakage.

9.

Remove power train oil cooler hose clamp (11) under the front of the radiator.

1

Removal k

6.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Drain the fuel from the fuel tank. 6

Fuel tank: Approx. 245 l (When full)

2.


3.


4.

Remove 4 breather hose clamps (3) of the fuel tank.

5.

Remove clip (5) and disconnect hose (4) from breather (6).


10. Remove hydraulic oil cooler hose clamps (12) and (13) under the front of the hydraulic oil cooler.

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49


SEN03950-02 11. Support the fuel tank bottom with the transmission jack. 12. Remove fuel tank front mounting bolts (14) on the right and left sides. [*1]

Installation q


[*1], [*2] 3 Fuel tank mounting bolts (14) and (15): 245 – 309 Nm {25.0 – 31.5 kgm} q

Refilling with fuel (Fuel tank) 5

Fuel: 245 l (When full)

13. Remove fuel tank rear mounting bolt (15) from the counterweight bottom. [*2]

14. Lower transmission jack [1] gradually and remove fuel tank assembly (16). a Take care extremely that the fuel tank will not come off the transmission jack. 4

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Fuel tank assembly: 130 kg (excluding fuel)

50




SEN03950-02

50-200

51

SEN03950-02



50-200

52

SEN03951-00





50

310 Power train, Part 1 Removal and installation of transfer................................................................................................................ 2 Disassembly and assembly of transfer assembly ........................................................................................... 5 Removal and installation of parking brake assembly .................................................................................... 24 Disassembly and assembly of parking brake assembly ............................................................................... 25


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1

310 Power train, Part 1 Removal and installation of transfer

SEN03951-00

Removal and installation of transfer

5.

Disconnect motor 1 drain hose (1) and motor 2 drain hose (2).

6.

Disconnect accumulator charge valve drain hose (3).

7.

Disconnect PA-port hose (4) and PB-port hose (5) from the brake valve.

8.

Disconnect clutch valve P-port hose (6).

9.

Disconnect transfer cooler hose (7).

1

Removal k k

k

k

q

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Press the brake pedal at least 100 times to release the residual pressure in the brake accumulator circuit. Disconnect the cable from the negative (–) terminal of the battery. Precautions for handling refrigerant k Collect refrigerant (R134a) beforehand. a Ask professional traders for collecting and filling the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant (R134a) gets inside ones eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person. k If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant is cooled, and then drain the coolant.

1.

Recover the refrigerant (R134a).

2.

Loosen the radiator cap to drain the coolant. 6

[*1]


3.

Remove the operator's cab assembly. For details, see “Removal and installation of operator's cab”.

4.

Remove the HST pump and 4-gear pump assembly. For details, see “Removal and installation of HST pump and 4-gear pump assembly”.

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2



SEN03951-00 13. Sling the transfer assembly temporarily and remove 2 transfer cushions (13) on right and left sides. [*4]

10. Disconnect clamps (8), (9), and (10).

14. remove the 2 transfer mounting bolts on right and left sides. [*5] a After removing the right cushion, remove accumulator and bracket assembly (14).

11. Disconnect front drive shaft (11) from the transfer side. [*2]

15. Remove the 2 mounting bolts and bracket (15).

12. Remove rear drive shaft (12).

[*3]

16. Lift off transfer assembly (16). a Check that all the wires and pipes are disconnected, and then sling the assembly slowly. 4


Transfer and HST motor assembly: 420 kg

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3


SEN03951-00 Installation q


[*1] a When installing the hoses of the air conditioner circuit, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner hose, check that O-ring (17) is fitted to it. a Check O-ring (17) for a flaw and deterioration. a When connecting each refrigerant pipe, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8 or ZEXEL ZXL100PG (equivalent to PAG46)) to O-ring (17). 3

3

3

[*4]

3

[*5]

3

q

Threaded part of hose (M24 × 1.5): 30 – 35 Nm {3.0 – 3.5 kgm}

Transfer mount mounting bolt: 610 – 765 Nm {62.5 – 78.0 kgm}


Threaded part of hose (M16 × 1.5): 12 – 15 Nm {1.2 – 1.5 kgm} Threaded part of hose (M22 × 1.5): 20 – 25 Nm {2.0 – 2.5 kgm}

Transfer cushion mounting bolt: M10 bolt: 59 – 74 Nm {6.0 – 7.5 kgm} M12 bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

q


q

Hydraulic oil (for details, see “Table of fuel, coolant and lubricants”): Only necessary quantity


Charging with refrigerant (R134a) Charge the air conditioner circuit with refrigerant (R134a).

[*2], [*3] 3 Drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} a

Precautions for installing rear drive shaft 1) Check that the key of the spider cap is fitted to the key way of the mating yoke and then tighten the mounting bolts. 2) Check that the lateral runout of the rear axle and transfer from each other is 3 mm or less. 3) If the runout in 2) is 3 mm or larger, adjust the transfer cushion and transfer mount to reduce the runout.

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4


310 Power train, Part 1 Disassembly and assembly of transfer assembly

SEN03951-00

Disassembly and assembly of transfer assembly

Disassembly 1

1.

Special tools

Part No.

Part name

1

790-201-2840 Spacer

t 1

2

793T-417-1110 Push tool

t 1


t 1

3

4

D

6


Symbol

Transfer assembly Drain the transfer oil.

790-101-5311 • Plate

1

790-101-5221 • Grip

1

01010-51225

1

• Bolt

793T-417-1120 Push tool

t 1

790-101-5221 Grip

t 1

01010-81225

t 1

Bolt

5

799-301-1500 Oil leak tester

t 1

6

799-401-3200 Adapter

t 1

7

02789-00315

t 1

8

799-101-5160 Nipple

t 1

9

790-190-1500 Pump assembly

t 1

Cap

10 790-201-3260 Bolt (12 x 1.75 mm)

q 2

11 792-735-2420 Collar

t 1

12 792-104-1130

t 1

Collar


q 1

14 790-101-2501 Puller

q 1

15 790-102-2900 Puller

q 1

16 790-201-1320 Spacer

t 1

17 790-101-3501 Gear puller

q 1


q 1

19 79G-17L-1000 Bar

t 1

20 795-100-1291 Sleeve driver

t 1

21 796-430-1110

t 1

Push tool

22 790-470-1410 Collar

t 1

23 796-667-1310 Collar

t 1

24 79G-05V-1400 Bar

t 2

25 791-126-0211

Adapter

t 1

Commercially 26 available

Torque wrench

q 1

27 790-434-1470 Push tool


Q

2.

Transfer oil: 7.2 l

Brake accumulator 1) Remove the speed sensor from the transfer case top. 2) Disconnect wiring connectors T06 (1) and T11 (2).

Q

3)

Disconnect wiring connectors T10 (3) and T07 (4).

4) 5)

Disconnect clutch port hose (5). Remove the 6 mounting bolts and bracket assembly (6).

q 1

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5


SEN03951-00 3.

HST motor 1) Remove the 4 mounting bolts and lift off HST motor 1 (7). 2) Remove the 4 mounting bolts and lift off HST motor 2 (8).

4.

Oil supply pipe and hose 1) Remove oil supply pipe (9). 2) Remove hose (10) from the transfer case strainer.

5.

3)

6.

Remove the mounting bolts. Using tool D10, remove parking brake assembly (15). a For disassembly and assembly of the parking brake assembly, see “Disassembly and assembly of parking brake assembly”.

Hub 1) Remove snap ring (16). 2) Remove hub (17).

Parking brake assembly 1) Set the transfer assembly to a block with the parking brake side up. 2) Remove coupling (14) on the parking brake side.

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6



7.

SEN03951-00

Belleville springs 1) Turn over the case and remove cage (18) from the HST motor 1 mounting section. a Loosen the mounting bolts evenly and gradually to release the belleville springs, and then remove the cage. q Free height of belleville springs (7-piece set): 57.4 mm q Installed height of belleville springs (7-piece set): 44.8 mm q Installed load of belleville springs (7-piece set): 21,500 N {2,190 kg}

3)

8.

2)

Remove 7 belleville springs (19). a Check the directions of the belleville springs. a The 1st belleville spring (The one on the top) has a yellow mark. a When any belleville spring needs to be replaced, replace all of the 7 springs as a set.

Piston and spacer 1) Remove piston (20).

Remove snap ring (89). Using tool D25, remove bearing (88).

2)


Put copper plate [1] in the O-ring groove and remove spacer (21) with a flat-head screwdriver.

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7


SEN03951-00 9.

Clutch discs, plates, and springs 1) Remove 7 discs (22), 8 plates (23), and 7 wave springs (24).

2)

Remove end plate (25).

10. Coupling 1) Remove the mounting bolts and holder (26). 2) Remove coupling (27).

11. Cage assembly 1) Remove the mounting bolts. Using tool D10, remove cage assembly (28).

2)

Remove shims (29). a Check the thickness and quantity of the shims.

3)

Remove dust seal (30) and oil seal (31) from cage (32). Remove outer race (33).

4)

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8



12. Spacer Remove spacer (34).

13. Front case Remove the mounting bolts. Using tool D10 and screwdrivers, remove front case (35). a Take care not to forget to remove the bolts on the rear case side (5 pieces). a When using screwdrivers, take care not to scratch the case mating face.

SEN03951-00 15. Disassembly of HST motor 1 shaft and ring gear assembly 1) Remove snap ring (37) and sun gear (38).

2)

Remove snap ring (39).

3)

Supporting ring gear (40) and using tool D11 and a press, push out HST motor 1 shaft (41).

14. Removal of HST motor 1 shaft and ring gear Remove HST motor 1 shaft and ring gear assembly (36).


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9


SEN03951-00 4) 5)

Remove bearing (42) and spacer (43) from ring gear (40). Remove snap ring (44) and bearing (45).

16. Removal of output shaft and gear assembly 1) Remove 2 mounting bolts (47) of cover (46). 2) Remove output shaft and gear assembly (49) and cover (46).

17. Disassembly of output shaft and gear assembly 1) Using tool D12, remove rear bearing (50). 2) Remove gear (51) and spacer (52).

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10

3)

Using tool D13, remove front bearing (53).

18. Removal of carrier assembly 1) Remove 6 bolts (54). 2) Using tool D14, remove carrier assembly (55).

19. Disassembly of carrier assembly 1) Remove shaft (56) and ball (57) from carrier (58). a Keep the ball carefully. 2) Remove 2 thrust washers (59), planetary gear (60), and bearing (61) (at 3 places).



20. Holder 1) Remove mounting bolt (62) and holder (63).

2)

Remove seal rings (64) and (65) and Oring (66) from holder (63).

SEN03951-00 22. Disassembly of HST motor 2 gear and bearing assembly 1) Using puller D15 and tool D16, remove 2 bearings (69) from HST motor 2 gear (68).

23. Removal of HST motor 1 gear and outer races Do not remove HST motor 1 gear shaft (70). (If it is removed forcibly and reused, it can cause a trouble.) 1) Using puller D17, remove bearing (71) and HST motor 1 gear (72).

21. Removal of HST motor 2 gear and bearing assembly Remove HST motor 2 gear and bearing assembly (67). a


If the claws of puller D17 are so thick that they cannot be inserted between the gear and case, screw 3 bolts [2] (M14) into the carrier mounting holes of HST motor 1 gear (72) by 15 mm. Then, using 3-claw puller D17, remove bearing (71) and HST motor 1 gear (72).

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11

SEN03951-00 24. Disassembly of HST motor 1 gear and outer races 1) Using puller D18, remove 2 outer races (73) from HST motor 1 gear (72), and then remove spacer (74). 2) Remove seal ring (75).

25. Bearing 1) Remove 2 plugs (76) from shaft (70).

2) 3)

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26. Rear case Remove outer race (80) from rear case (79).

27. Clutch housing 1) Using tool D20, remove clutch housing (81) and 3 pins (82). 2) Remove snap ring (83) from clutch housing (81). 3) Remove snap ring (84).

Remove spacer (77). Insert 2 tools D19 in the plug holes and hit them evenly to remove bearing (78) from shaft (70). a Do not remove shaft (70).

12



Assembly a a

1.

2.

SEN03951-00 3.

Installation of HST motor 2 gear and bearing assembly Install HST motor 2 gear and bearing assembly (67).

4.

Assembly of HST motor 1 gear and outer races 1) Install spacer (74) to HST motor 1 gear (72). 2) Using tool D22, press fit 2 outer races (73) to HST motor 1 gear (72). 3) Install seal ring (75) to HST motor 1 gear (72). 3 Seal ring: Grease (G2-LI)

5.

Bearing and HST motor 1 gear 1) Using tool D23 and the press, press fit bearing (78).

Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with power line oil (TO10) before installing. Before icing a bearing in dry ice for expansion fit, drop about 6 cc of power line oil (TO10) onto it and rotate it 10 turns. Rear case Press fit outer race (80) of the output shaft to rear case (79).

Assembly of HST motor 2 gear and bearing assembly Using push tool D21, press fit 2 bearings (69) to HST motor 2 gear (68). a After press fitting the bearings, apply transfer oil to them and rotate them.


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13


SEN03951-00 2)

Install spacer (77).

3) 4)

Install HST motor 1 gear (72). Using push tool D21 and the press, press fit bearing (71). q Projection of bearing from shaft: 0.92 – 2.13 mm

2)

7.

6.

Install holder (63) and tighten the mounting bolt. a Set the hole 2 mm in diameter (g) on the top of the holder horizontally [Set it at 90° to the hole 4.5 mm in diameter (h) on shaft (70)]. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 88.2 – 107.8 Nm {9 – 11 kgm}

Assembly of carrier assembly 1) Set planetary gear (60), bearing (61), and 2 thrust washers (59) to carrier (58) (at 3 places). 2) Install pinion shaft (56) to carrier (58), matching their ball holes to each other, and then install ball (57).

Holder 1) Install seal rings (64) and (65) and O-ring (66) to holder (63). 2 Seal ring and O-ring: Grease (G2-LI)

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14



8.

9.

Installation of carrier assembly 1) Install carrier assembly (55), matching it to the dowel pin of the HST motor 1 gear. 2) Tighten mounting bolts (54). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 137 – 196 Nm {14 – 20 kgm}

SEN03951-00 3)

Install spacer (43) and set bearing (42). a Take care of the setting direction of the bearing (flanged).

4)

Using push tool D21 and the press, press fit bearing (42).

5)

Install snap ring (39).

Assembly of HST motor 1 shaft and ring gear assembly 1) Install bearing (45) to ring gear (40), and then install snap ring (44).

2)

Set ring gear (40) to HST motor 1 shaft (41). Using push tool D21 and the press, press fit bearing (45).


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15


SEN03951-00 6)

Install sun gear (38) and snap ring (37).

10. Installation of HST motor 1 shaft and ring gear Install HST motor 1 shaft and ring gear assembly (36).

2) 3)

Rotate the shaft and set spacer (52). Install output gear (51). 2 Gear spline: Grease (LM-G)

4)

Using tool D2 and the press, press fit rear bearing (50). a After press fitting the bearing, apply transfer oil to it and rotate it.

11. Assembly of output shaft and gear assembly 1) Using tool D1 and the press, press fit front bearing (53) until it touches output shaft (85). a After press fitting the bearing, apply transfer oil to it and rotate it.

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16



12. Installation of output shaft and gear assembly 1) Put cover (46) over the gear and install output shaft and gear assembly (49) to the rear case. 2) Secure cover (46) with bolts (47). a Check that cover (46) does not interfere with the inside of the gear. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

SEN03951-00 14. Front case a Use the front case and rear case as an assembly. a When installing the cases, match the match marks on their tops to each other. 1) Apply gasket sealant to the rear case according to the following procedure. a Apply the gasket sealant to forcing screw contact part (a), similarly to the dimensions for each bolt hole. a Apply the gasket sealant so that dimensions (b) and (c) will be the same respectively. a Apply the gasket sealant so that dimension (e) x dimension (f) will be 2 – 5 mm. 2 Gasket sealant: ThreeBond 1207B or equivalent

13. Clutch housing 1) Install snap ring (84) to the front case. 2) Install clutch housing (81) and 3 pins (82).

2)

3)

Set tool D24 and install front case (35). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

Install snap ring (83)


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17


SEN03951-00 3)

Install snap ring (86) on the HST motor 2 side.

4)

Install spacer (34) of the output shaft.

2)

Install 7 discs (22), 7 wave springs (24), and 8 plates (23). a Soak the discs in clean transfer oil for at least 2 minutes before installing them.

16. Spacer and piston 1) Install the O-ring and spacer (21). 2 O-ring: Grease (G2-LI)

15. Clutch discs, plates, and springs 1) Install end plate (25).

2)

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18

Install the O-ring and piston (20). 2 O-ring: Grease (G2-LI)



17. Belleville springs 1) Set the 1st one (bottom one) of the 7 belleville springs (19) with the convex side up. 2) Set the 2nd, 4th, and 6th belleville springs in the opposite direction to the 1st one and set the 3rd and 5th ones in the same direction as the 1st one. (There are no marks on the 1st – 6th springs.) 3) Set the 7th belleville spring with the yellow mark side up. a When any belleville spring needs to be replaced, replace all of the 7 springs as a set.


SEN03951-00 18. Cage 1) Install cage (18). a Tighten the mounting bolts evenly and gradually. q Installed load of belleville springs (7-piece set): 21,500 N {2,190 kg} 3 Mounting bolt: 245 – 308 Nm {25 – 31.5 kgm} 2) After installing cage (18), press fit bearing (88) with tool D25 and install snap ring (89).

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19

SEN03951-00 19. Operation test of transfer clutch Using tool D5, apply oil pressure to transfer clutch disengagement port (m). a When the oil pressure is applied, if the transfer clutch is disengaged, it is operating normally. q Clutch disengaging oil pressure: 1.52 MPa {15.5 kg/cm2}

20. Cage assembly 1) Press fit outer race (33) to cage (32). 2) Using tools D3 and D4, press fit oil seal (31) and dust seal (30) to cage (32). 2 Lips and clearances of oil seal and dust seal: Silicone grease (ThreeBond 1855 or equivalent)

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20


21. Adjusting pre-load on output shaft taper roller bearing 1) Install cage (28) without inserting any shim. 3 Mounting bolt: 4.80 ± 0.98 Nm {0.5 ± 0.1 kgm} 2) Rotate the output shaft 20 turns and check the tightening torque of the mounting bolts tightened in step 1). a If the tightening torque has changed, repeat steps 1) and 2), and then check again. 3) If the tightening torque has not changed, measure the clearances at 3 places (j) of cage (28) and obtain average (k). a To confirm that the bearing is not leaning, check that the dispersion of clearances at 3 places (j) is 0.15 mm or less. If the dispersion is large, the bearing is not installed normally or there is another cause. In this case, eliminate the cause and reduce the dispersion to 0.15 mm or less.



4)

5) 6)

7) 8)

Calculate shim thickness (t). q Shim thickness (t) = Average of clearance (k) + 0.15 mm to 0.20 mm Insert selected shim (29) between cage assembly (28) and the front case. Tighten the cage mounting bolts. 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

Install holder (26) and the holder mounting bolt to the output shaft. Set tool D26 to the holder mounting bolt and measure the rotating torque of the output shaft. a Measure the rotating torque without installing the front and rear couplings. q Rotating torque of output shaft: 4.9 – 6.7 Nm {0.5 – 0.7 kgm}


SEN03951-00 22. Coupling 1) Install coupling (27) on the cage side. 2 Spline of coupling: Lubricant containing molybdenum disulfide (LM-G) 2) Install holder (26) and tighten the mounting bolt. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}

23. Hub 1) Turn over the transfer assembly and install hub (17). 2) Install snap ring (16). 2 Spline of output shaft: Lubricant containing molybdenum disulfide (LM-G)

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21

SEN03951-00 24. Parking brake assembly 1) Remove 2 dowel pins (87) from the parking brake assembly. a The dowel pins may be left on the transfer case side.

2)

3)

50-310

Install parking brake assembly (15). a After the all internal teeth of the disc are meshed with the spline and the clearance between the parking brake housing and transfer case is eliminated, tighten the mounting bolts. a If the mounting bolts are tightened while there is clearance between the parking brake housing and transfer case and the internal teeth of the disc are shifted from the spline, the disc will be broken. Accordingly, remove the dowel pins and check securely in advance that there is not clearance. a Do not reuse the gasket but fit new one to the case side. Drive in the dowel pins and tighten the mounting bolts. 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

22


25. Coupling Install coupling (14). 2 Spline of coupling: Lubricant containing molybdenum disulfide (LM-G)

26. Oil supply pipe and hose 1) Connect hose (10) to the transfer case strainer. 2) Install oil supply pipe (9).

27. HST motor 1) Sling and install HST motor 2 (8). 2 Spline of HST motor 2: Lubricant containing molybdenum disulfide (LM-G) 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm} 2) Sling and install HST motor 1 (7). a Do not apply LM-G to the spline of HST motor 1. 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}



28. Transfer oil filter 1) Install transfer oil filter bracket assembly (6) with the 6 mounting bolts. 2) Connect clutch port hose (5).

3)

SEN03951-00 4)

Connect wiring connectors T06 (1) and T11 (2).

5)

Install the speed sensor to the transfer case top.

Connect wiring connectors T10 (3) and T07 (4).


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23

310 Power train, Part 1 Removal and installation of parking brake assembly

SEN03951-00

Removal and installation of parking brake assembly

k

k

7.

Remove the parking brake mounting bolts. Then, using tool D10, remove parking brake assembly (10). [*3]

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Keep in mind that “the parking brake is removed” = you cannot apply the parking brake.

1.

Turn the parking brake OFF (Release it).

2.

Drain the transfer oil. 6

3.

Disconnect transfer lubricating oil pump hose (9).

1

Removal k

6.

Transfer case: 7.2 l

Remove cotter pin (2) and pin (3) of the parking brake cylinder. [*1] a The parking brake cylinder is at the front of the inside of the left rear wheel.

4.

Remove rear drive shaft (7).

5.

Remove coupling (8).

Installation q

[*2]


[*1] a After inserting cotter pin (2) in pin (3), open it to 180°. [*2]

3

a

Rear drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}

Precautions for installing rear drive shaft 1) When installing the drive shaft, check that the key way of the spider cap is fitted in the key way of the mating yoke, and then tighten the mounting bolts. 2) When installing the rear drive shaft, check that misalignment between the rear axle and transfer in the lateral direction is not larger than 3 mm. 3) If misalignment checked in 2) is larger than 3 mm, adjust the positions of the transfer cushion and transfer mount.

[*3] a Using guide bolts, install the parking brake. 3 Parking brake mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} q

Refilling with oil (Transfer case) 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. 6

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24

Transfer case: 7.2 l WA320, 320PZ-6 (KA SPEC.)

310 Power train, Part 1 Disassembly and assembly of parking brake assembly

Disassembly and assembly of parking brake assembly

SEN03951-00 2. 1

Sketch

Part Name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

Plates, discs, and springs 1) Remove 2 clamping bolts (3) and 2 spacers (4). a Since the spring tension is applied, loosen the 2 clamping bolts evenly.

t 1

790-101-5201

Push tool kit

790-101-5301

• Plate

1

790-101-5221

• Grip

1

01010-51225

• Bolt

1

793T-417-1120

Push tool

t 1

Grip

t 1

Bolt

t 1

3 D

4 790-101-5221 01010-81225

Q

2)

Disassembly 1.

Remove 5 plates (5), 4 wave springs (6), and 4 discs (7).

Strainer 1) Remove cover (1).

3. 2)

Cam plate Remove cam plate (8).

Remove strainer (2).


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25


SEN03951-00 4.

5.

Ball Remove 6 balls (9).

6.

Pin Remove pin (12).

7.

Dust seal and oil seal Remove dust seal (13) and oil seal (14).

8.

Oil seal and bearings 1) Remove oil seal (15). 2) Remove 2 bearings (16) from parking brake case (17).

Lever 1) Remove the mounting bolt and lever (10).

2)

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Remove lever (11).

26



SEN03951-00

Assembly a a

1.

2.

Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with transfer oil (EO10-CD) before installing. Do not reuse the gasket but remove it completely. Oil seal and bearings 1) Install 2 bearings (16) to parking brake case (17). 2) Install oil seal (15). 2 Oil seal: Grease (G2-LI)

3.

Pin Install pin (12). a Install the pin with the grooved part outward. a Check that dirt is not sticking to the ball groove and inside of the housing.

4.

Lever Install levers (11) and (10).

Oil seal and dust seal Using tools D3 and D4, press fit oil seal (14) and dust seal (13). 2 Lips and clearances of oil seal and dust seal: Silicone grease (ThreeBond 1855 or equivalent)


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27


SEN03951-00 a

5.

Balls Install 6 balls (9). a Check that dirt is not sticking to the balls.

6.

Cam plate Install cam plate (8). a Check that dirt is not sticking to the ball grooves, inside of parking brake housing, cam plate, discs, and plates.

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a

When installing the levers (11) and (10), match their match marks (a) and (b). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 27 – 34 Nm {2.8 – 3.5 kgm}

28

a

7.

Move cam plate (8) several times so that balls (9) will be fitted to grooves (c) of cam plate (8). Check that the cam plate does not hitch on the housing.

Plates, disc, and springs 1) Install 4 discs (7), 4 wave springs (6), and 5 plates (5). a Soak the disc in clean transfer oil for at least 2 minutes before installing them. a Check that dirt is not sticking to the discs and plates.



2)

8.

Using tool D27, press plate (5) lightly with a press and install 2 spacers (4) and 2 clamping bolts (3). a Take care not to press plate (5) too much and not to damage it. a Press plate (5) until it is flush with the parking brake case. a Move the lever and check that it returns normally. 2 Clamping bolt: Adhesive (LT-2) 3 Clamping bolt: 19.6 – 27.4 Nm {2.0 – 2.8 kgm}

SEN03951-00 2)

Install the O-ring and cover (1). 2 O-ring: Grease (G2-LI) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

Strainer 1) Install strainer (2).


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29

SEN03951-00



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30

SEN03952-00





50

320 Power train, Part 2 Removal and installation of front axle assembly ............................................................................................. 2 Removal and installation of rear axle assembly.............................................................................................. 4 Disassembly and assembly of axle housing assembly ................................................................................... 7 Disassembly and assembly of differential assembly..................................................................................... 19


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1

320 Power train, Part 2 Removal and installation of front axle assembly

SEN03952-00

Removal and installation of front axle assembly

3.

Remove work equipment valve upper cover (2).

4.

Disconnect wiring connector F14 (3) and clamp (10).

5.

Disconnect brake hose (4).

1

Removal k

k

k

k

1.

2.

Stop the machine on a level ground and install the lock bar to the frame to lock the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Release the remaining pressure in the brake accumulator circuit. For details, see Testing and adjusting, “Releasing remaining pressure in hydraulic circuit”. Set the support stand to the frame securely. Raise the front part of the chassis with the work equipment and set support stand [1] under the frame at the rear of the front wheel to float the front part of the chassis.

Lift off front wheel (1). [*1] a Lift off the front wheel on the other side similarly. 4 Front wheel (1 side): 340 kg

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2


320 Power train, Part 2 Removal and installation of front axle assembly

6.

Disconnect front drive shaft (5).

SEN03952-00 [*2]

Installation q


[*1]

3

Front wheel mounting bolt: 824 – 1030 Nm {84 – 105 kgm}

[*2] a When installing the drive shaft, check that the key way of the spider cap is fitted to the key way of the mating yoke, and then tighten the mounting bolts. 3 Front drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} 7.

Sling front axle assembly (6) temporarily and support it on jack [2]. Remove the 4 mounting bolts on both sides and front axle assembly (6). [*3] 4

[*3]

3

Front axle mounting bolt: 1325 – 1470 Nm {135 – 150 kgm}

Front axle assembly: 730 kg q


Bleeding air Bleed air from the brake system. For details, see Testing and adjusting, “Bleeding air from brake system”.

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3

320 Power train, Part 2 Removal and installation of rear axle assembly

SEN03952-00

Removal and installation of rear axle assembly

4.

Lift off rear wheel (1). [*1] a Lift off the rear wheel on the other side similarly. 4 Rear wheel (1 side): 340 kg

5.

Disconnect brake hose (2) from the axle.

6.

Disconnect 2 grease tubes (3).

7.

Change the outlet direction of oil pan drain hose (4).

1

Removal k

k k

k

1.

Stop the machine on a level ground and install the lock bar to the frame to lock the front and rear frames. Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the brake accumulator circuit. For details, see Testing and adjusting, “Bleeding air from brake accumulator circuit”. Set the support stand to the frame securely. Raise the chassis with the work equipment (See Removal and installation of front axle assembly, 1.) and set support stand [1] under the rear frame in front of the rear wheel.

2.

Lower the work equipment to the ground horizontally and raise the rear part of the chassis, and then support the counterweight on support stand [1] and jack [2].

3.

Set support stand [3] between top of each side of the rear axle and the rear frame and fix the rear wheel so that it will not lean.

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4



8.

Remove rear drive shaft (5). [*2] a Remove coupling (6) to avoid damaging dust seal (8) in step 11.

9.

Remove bracket (8) of relay assembly (7). [*3]

SEN03952-00 11. Pull out the rear axle assembly backward to disconnect it from the rear frame assembly. a When disconnecting the rear axle assembly, take care not to damage dust seal (8) of rear frame (12).

12. Lower the crane and jack [3] simultaneously to remove rear axle assembly (9). 4

Rear axle and support assembly: 780 kg

10. Sling rear axle assembly (9) temporarily, support it on jack [3], and remove the mounting bolts (11) of support (10). [*4]


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5

SEN03952-00


Installation q


[*1]

3

Rear wheel mounting bolt: 824 – 1030 Nm {84 – 105 kgm}

[*2] a Check that the radial runout of the rear axle from the transfer in lateral direction is not larger than 3 mm. If it is larger than 3 mm, reduce it by moving the transfer mount. a When installing the drive shaft, check that the key way of the spider cap is fitted to the key way of the mating yoke, and then tighten the mounting bolts. 3 Rear drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} [*3] a When removing and installing the mounting bolts of support (10), take care not to hit the removed electronic parts with a tool, a bolt, etc. [*4]

3

q

Support mounting bolt: 1325 – 1470 Nm {135 – 150 kgm}

Bleeding air Bleed air from the brake system. For details, see Testing and adjusting, “Bleeding air from brake system”.

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6


320 Power train, Part 2 Disassembly and assembly of axle housing assembly

Disassembly and assembly of axle housing assembly

SEN03952-00

1

Symbol

1

2

3 4

5 H

Part No.

Part name


Special tools

793T-623-1170 Push tool

t 1

Q

793T-422-1440 Push tool

t 1

Q

793T-422-1410 Seal support

t 1

Q

793T-422-1420 Seal support

t 1

Q

01016-50860

t 6

Bolt

793T-659-1110 Push tool

t 1

790-201-2750

t 1

Spacer

793T-422-1430 Holder

t 1

790-101-5201

Push tool kit

t 1

790-101-5271

• Plate

1

790-101-5221

• Grip

1

01010-51225

• Bolt

6

790-101-3101

Bearing puller

q 1

7

790-101-3501

Gear puller

q 1

2)

Sling rear support (30) temporarily and remove cover (31).

Remove thrust plate (32) and rear support (30). Remove brake tube and hose assembly (33).

Q Q

1

791T-465-1130 Push tool

t 1

790-201-2670

Plate

t 1

799-501-1120

Pin

t 1

10 790-445-5980

Guide bar

t 1

3)

11 Commercially available

Dial gauge

q 1

4)

8 9

79A-264-0021 12 or commerPush-pull scale cially available

Q

q 1

Disassembly a

The following photos and illustrations show the rear axle housing as an example.

1.

Draining oil 6

2.

Axle (Each of front and rear axles): 24 l

Axle assembly 1) Set the axle assembly on block [1] and jack [30]. a Set jack [30] so that the axle assembly will not lean when the housing assembly on one side is removed.


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7


SEN03952-00 3.

Axle housing assembly 1) Sling axle housing assembly (1) temporarily and remove the housing mounting bolts and axle housing assembly (1). a When removing both axle housing assemblies, make match marks on the housings and differential case so that the housing assemblies will not be mistaken.

2) k

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4.

Brakes a Remove both brakes according to the following procedure. 1) Remove 2 inside hexagon bolts (34).

2)

Remove 2 plates (35), 2 discs (36), and 2 wave springs (37).

3) 4)

Remove end plate (38). Remove sun gear shaft (39).

Set axle housing assembly (1) with the brake side up. When working, take extreme care that the axle housing assembly will not fall down.

8



5.

Planetary carrier assembly 1) Remove axle shaft mounting bolt (2).

2)

SEN03952-00 6.

Axle shaft 1) Sling axle housing assembly (5) about 20 mm.

Remove planetary carrier assembly (3). 2)

3)

Apply push tool H5 to the end of axle shaft (6) and hit it with copper hammer [2] to drive out the shaft. a The bearing on the planetary carrier side will be removed.

Remove shim (4). a Record the thickness and quantity of the shims.


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9


SEN03952-00 7.

Axle shaft bearing a Do not heat the bearing to remove it or cut it with gas. 1) When removing bearing (7) from axle shaft (6), evenly push in part (a) around the oil seal and sleeve (8) with a screwdriver toward the flange. 2) Make clearance (b) at the contact part of bearing (7) and sleeve (8a) to hitch the claws of the puller. 3) Install tool H6 securely to clearance (b). 4) Tighten the bolts of tool H6 to remove bearing (7). 5) Remove oil seal (8).

8.

Axle housing 1) Remove 3 pins (10) from axle housing (11). (You can pull them out with the hand.) 2) Using tool H7, pull up ring gear (9) evenly to remove it from axle housing (11). a Install tool H8 to the bolt end of tool H7 to adjust the height. a Take care that the claws of the puller will not come off the ring gear.

3)

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10

Remove outer races (12) and (13) from axle housing (11).



9.

Planetary carrier 1) Using tool H9, drive in roll pin (15) of planetary carrier (14) until it is in the range of shaft (16). a Take care not to drive in the roll pin too deep.

SEN03952-00 3)

Pull roll pin (15) out of removed shaft (16).

4)

Remove pinion gear (17) and 2 bearings (18) from planetary carrier (14). Similarly, remove the 2nd and 3rd pinion gears (17) and 2 sets of shaft (16), roll pin (15), and bearing (18) from planetary carrier (14). Remove spacer (19) from planetary carrier (14).

5)

6)

2)

Using tool H10, push out shaft (16) with a press.


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11


SEN03952-00 10. Rear axle support (Rear axle only) 1) Remove thrust washer (50) and retainer (51) from rear axle support (30).

2)

50-320

Remove bushing (52) from rear axle support (30) and remove packing (53) from the retainer side.

12

Assembly 1.

Axle housing and axle shaft 1) Press fit bearing outer races (12) and (13) to axle housing (11).

2)

Using tool H1, press fit seal (8) and bearing (7) to axle shaft (6) simultaneously. a Press fit the seal and bearing until oil seal sleeve (8a) is flush with shaft end (c), and then check that there is not clearance between oil seal sleeve (8a) and bearing (7).

3)

Install tool H2 under oil seal (8). a Adjust tool H2 so that its top will lightly touch oil seal (8) and the clearance will be even.



2.

Axle shaft bearing 1) Erect axle shaft (6) on the block and fix it securely. k Perform the work carefully so that the axle shaft will not fall. 2) Sling axle housing (11) vertically, and then lower it slowly. a Insert the axle housing by utilizing its weight. 2 Fitting part of oil seal and bearing: Axle oil (AXO80) a After installing the housing, leave tool H2 installed until step 4). 3) Using tool H3, press fit bearing (20) to axle shaft (6). a Press fit the bearing, turning the axle housing with the hand. 2 Outside of bearing: Axle oil (AXO80) 4) Remove tool H2 horizontally. a Check that oil seal (8) does not lean. a Fit the end face of axle housing (11) to the flange of oil seal (8) (Reduce the clearance to below 0.2 mm.)

SEN03952-00 3.

Selecting shims 1) After bearings (7) and (20) are fitted well, measure the turning force of hole (d) of axle housing (11). a Carry out this work before installing the planetary carrier. q Turning force (Not static friction, but dynamic friction) (Common to front and rear) (Including seal resistance) 25.5 – 49 N {2.6 – 5.0 kg} a a

If the turning force is below the standard value, press fit the bearings again and perform the work in step 1). If the turning force exceeds the standard value, adjust it according to following steps 2) – 4).

9JS01378

9JF00886


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13


SEN03952-00 2)

3)

4)

Hold 2 parts of axle shaft and housing assembly (5) and sling it by 20 – 30 mm, as you installed the axle housing. Rotating axle shaft (6), hit the flange with a copper hammer in the direction of the arrow several times to drive out axle shaft (6). Adjust the turning force to the standard value according to step 1).

9JS01379

4.

Planetary carrier

1)

5)

6)

7)

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Put 2 bearings (18) in 1st gear (17) and install them to planetary carrier (14). a Using tool H10 and matching pin holes (f), press fit shaft (16). 2 Shaft: Axle oil (AXO80)

Install planetary carrier (14) to the spline of axle shaft (6) without the gear and place tool H4. a Just place tool H4 on planetary carrier (14). Do not tighten the bolt. Using a depth micrometer, measure distance (e) from the end of tool H4 to the end of the axle shaft. a Subtract thickness (t) of tool H4 from distance (e), and let the result be (e – t). q Shim thickness = (e – t) +0.05 +0 After determining the shim thickness, remove planetary carrier (14).

14



a

2)

3)

SEN03952-00

Matching the holes of shaft (16) and roll pin (15), drive roll pin (15) through push tool H9 so that it will be flush with planetary carrier (14).

5.

Ring gear Install ring gear (9) to axle housing (11) and insert 3 pins (10). a Match the pin holes of the housing and ring gear.

6.

Planetary carrier assembly 1) Install shim (4) selected in steps 3 to the end of the axle shaft.

Install spacer (19) in planetary carrier (14). a Insert the spacer from (g) side of planetary carrier (14) before installing 2nd gear (17).

Similarly to 1), install 2nd and 3rd gears (17) to planetary carrier (14). a Using tool H9 and matching pin holes (f), press fit shaft (16). a Matching the holes of shaft (16) and roll pin (15), drive roll pin (15) through tool H9 so that it will be flush with planetary carrier (14). a Hit the end of shaft (16) and the differential side of gear (17) lightly to push back the bearing and check that the gear rotates smoothly.


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15

SEN03952-00 2)

Sling and install planetary carrier assembly (3). k When installing the planetary carrier, take care not to catch your fingers in the gear.

3)

Tighten mounting bolt (2). a Degrease and clean the bolt hole of the axle shaft and mounting bolt. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm} a Clean the shaft end and planetary c ar rier s pline thoroughly before installing.

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16


4)

Install dial gauge [9] to axle housing (11) and measure the end play of the planetary carrier. q End play of planetary carrier: 0 – 0.1 mm a If the end play is out of the standard range, change the thickness of the shim in 1) and repeat the above procedure referring to “3. Selecting shims”.

5)

Rotate axle housing (11) 10 or more turns to fit it. Then, using push-pull gauge [10], measure the starting effort at the mounting bolt hole of the axle housing assembly. q Starting effort (Common to front and rear) (Including resistance of seal and planetary carrier) 25.5 – 68.6 N {2.6 – 7.0 kg} a If the starting effort exceeds the above range, adjust it again, referring to “3. Selecting shims” above.



7.

SEN03952-00

Brake 1) Install end plate (38). 2) Install sun gear shaft (39).

4)

3)

Install 2 discs (36), 2 wave springs (37), and 2 plates (35) in order from the bottom, observing the following precautions. a Match the notches of the 2 springs to each other and set them in the range marked with A. The range marked with A is on the left side of wear gauge (41) in the left axle (as shown in the photo) and on the right side of wear gauge (41), or symmetrically opposite to the photo, in the right axle. a When the axle is installed, the notches of the springs, A, and brake port must be set as shown in the following figure. a Match the concave lug of lower plate (40) to wear gauge (41). a Match the convex lug of upper plate (35) to wear gauge (41). a Wear gauge (41) is seen before upper plate (35) is set but not seen after upper plate (35) is set.


8.

Install 2 inside hexagon bolts (34).

Axle housing assembly 1) Degrease and clean the mating faces of the axle housing and differential housing and dry them in air. 2) Apply a string of gasket sealant 2 – 3 mm in diameter to part (P) of differential housing (1). a Take care that gasket sealant will not project into hollow parts (r) of the housing. 2 Mating faces of housings: Gasket sealant (LOCTITE 515 or equivalent)

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17


SEN03952-00 3)

2)

Sling axle housing assembly (1) horizontally and install it carefully, matching it to the spline grooves of the sun gear shaft.

3)

4)

Tighten the axle housing mounting bolts in the diagonal order. 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm} 4)

9.

Sling and install rear axle support (30) and install thrust plate (32). 2 Periphery of pivot mounting part: Grease (G2-LI) 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm} Install brake tube and hose assembly (33).

Rear axle support 1) Fit packing (53) to retainer (51) and install bushing (52), thrust washer (50), and retainer (51) to rear axle support (30). a Clean and dry the inside of the support to insert the bushing. a Press fit the bushing with a press having a surface plate and keep the support and bushing in parallel. a Secure clearance of 0.5 mm between the end of the bushing and the bottom of the mounting part. a Set thrust washer (50) with the groove up (Direct the grove toward the retainer). a Direct the lip of the packing toward the outside of the rear axle support (toward the axle). 2 Inside of packing: Grease (G2-LI) (Apply thinly)

q

Install cover (31). 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

Refilling with oil (Axle housing) Tighten the drain plug and add oil through the oil filler to the specified level, and then check the oil level. 3 Drain plug: 127.4 – 176.4 Nm {13 – 18 kgm} 3 Oil filler plug: 93.1 – 122.5 Nm {9.5 – 12.5 kgm} 5

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18

Axle oil (AXO80) (Each of front and rear): 24 l


320 Power train, Part 2 Disassembly and assembly of differential assembly

SEN03952-00

Disassembly and assembly of differential assembly

2.

Removal of long cage assembly (For only front differential) 1) Set the axle assembly on block [1] and jack [30]. 2) Remove coupling (23). a Remove the coupling protector only when it needs to be removed. 3) Remove long cage assembly (24).

3.

Disassembly of long cage assembly (For only front differential) 1) Remove oil seal (25).

1

Symbol

Part No.

Part name


Special tools

13 799-301-1500 14 797-101-1211

Oil leak tester Wrench

t 1 t 1

15 793-615-1100 16 790-201-2840

Wrench Push tool

t 1 t 1

17 797T-423-1320 Push tool 18 792T-413-1130 Push tool

t 1 t 1

19 793-520-2202 Installer 20 790-190-1500 Pump assembly

q 3 t 1

21 799-101-5210 Nipple 22 793T-422-1611 Plate

t 1 t 1

23 791T-465-1210 Push tool 24 790-201-3280 Bolt (14 x 2.0 mm)

t 1 q 4

H 25 790-201-3260 26 791-615-2130

Q Q

Q Q

Bolt (12 x 1.75 mm) q 2 Sleeve t 1

27 Commercially Puller available 28 79G-05V-1400 Bar

q 1

29 Commercially available Commercially 30 available

Depth gauge

q 1

Torque wrench

q 1

t 1

31 791T-630-2230 Push tool Commercially 32 available Dial gauge

t 1

33 790-201-2830 34 791-126-0211

t 1 t 1

Spacer Adapter

Q

q 1

Disassembly of front differential 1.

Draining oil 6

a q

q

a

2)

Using tool H23, push shaft (26) with a press to remove it from long cage (27).

Axle (Each of front and rear axles): 24 l

When disassembling the rear differential Perform “Disassembly and assembly of axle housing assembly” up to 3. 1) to remove the rear axle support, brake tube, hose assembly, and right and left axle housings. Perform the procedure in “6. Differential assembly” and after. Perform following steps 2 – 5 when disassembling the front differential.


50-320

19


SEN03952-00 3)

4.

Remove snap ring (28) and ring (29), and then remove bearing (30) from long cage (27).

Removal of front cage assembly (Front differential) 1) Using tool H14, loosen nut (31) before removing the cage assembly.

2) 3)

4) 5)

50-320

Remove cover (10). Remove the axle oil temperature sensor (which is hidden by cover (10)) and wiring harness (11) together. Remove brake tube assembly (12). Remove the mounting bolts of front cage assembly (32).

20

6)

Using tool H24, remove front cage assembly (32). a Record the thickness and quantity of the shims.

5.

Axle housing a Referring to Disassembly and assembly of axle housing assembly, “3. Axle housing assembly, 1)”, remove the right and left axle housings.

6.

Differential assembly 1) Place and stabilize differential assembly on block [1]. a The photo shows the rear differential. a Remove the right and left rear differentials according to the same procedure. 2) Remove 2 slack adjusters (22). 3) Remove 2 bleeder screws (19). 4) Remove piston (20). 5) Remove coupling (18). a Perform this step for only rear differential. 6) Remove the mounting bolts of top cover (21).



7.

7)

Using tool H25, remove top cover (21).

8)

Remove seal (87) from piston (20).

SEN03952-00 2)

Using tool H26, push out pinion gear assembly (81) with a press.

3)

Using bearing puller [31] and tool H26, push bearing (35) out of pinion gear (36) with a press.

4)

Remove bearing (37), outer races (38) and (39) from cage (40).

Disassembly of front cage assembly (For front differential) 1) Remove nut (31) and holder (33).


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21

SEN03952-00 8.

9.

Removal of rear cage assembly (For rear differential) Remove the mounting bolts. Using tool H24, remove rear cage assembly (42). a Record the thickness and quantity of the shims.


10. Bearing carriers 1) Sling differential carrier assembly (43) temporarily.

2)

Remove the mounting bolts and both bearing carriers (44), using tool H25. a Make marks on both bearing carriers so that they will not be mistaken. a Record the thickness and quantity of the shims.

3)

Remove seal (84) and ring (85) from each bearing carrier (44). a Keep the seal, ring, and shim as a set.

Disassembly of rear cage assembly (For rear differential) 1) Remove oil seal (82).

2)

50-320

For the further disassembly procedure for the rear cage assembly, see steps 2) – 4) in “7. Disassembly of front cage assembly” shown above.

22



4)

Using tools H6 and H27, remove bearing (86) from each bearing carrier (44).

11. Removal of differential carrier assembly 1) Lift off differential carrier assembly (43) from differential housing (45). a Take care that the sling will not come off. a Do not damage the differential carrier assembly by hitting it against the differential case. 2) Remove the 4 mounting bolts and gear cover (42).


SEN03952-00 12. Disassembly of standard differential carrier assembly a When keeping the parts on both sides, make marks on them so that they will not be mistaken. 1) Before disconnecting the bevel gear and case, make match marks on them.

2)

Remove 20 mounting bolts (46) and bevel gear (47).

3)

Reverse the case and disconnect cases (48) and (49). a Before disconnecting, make match marks on the cases.

50-320

23

SEN03952-00 4) 5)

Remove washer (51) from case (48). Remove side gear (52) from case (49).

6)

Remove pinion gear assembly (53) from case (49).

7)

50-320

Remove 4 spherical washers (54) and 4 pinion gears (55) from spider shaft (56).

24


8)

Remove side gear (57) from case (49).

9)

Remove washer (58) from case (49).

10) Using a puller, remove outer race (61) from case (49). a Remove the outer race of case (48) on the opposite side similarly.



13. Disassembly of limited slip differential assembly (If equipped) a If the machine is equipped with the limited slip differential assembly, disassemble it according to the following procedure. a When keeping the parts on both sides, make marks on them so that they will not be mistaken. 1) Before disconnecting the bevel gear and case, make match marks on them.

2)

3)

SEN03952-00 4)

Remove washer (66).

5)

Remove 2 plates (67) and 2 discs (68).

6)

Remove pressure ring (69). a Insert a finger in the hole on the side of the case to raise the pressure ring.

Remove 20 mounting bolts (46) and bevel gear (47).

Place the case upside down and remove cover (63). a Before disconnecting the cover, make match marks on it and case.


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25

SEN03952-00


7)

Remove side gear (70).

10) Remove side gear (74).

8)

Remove pinion gear assembly (71).

11) Remove pressure ring (75).

9)

Remove 4 pinion gears (72) from spider shaft (73).

12) Remove 2 plates (76) and 2 discs (77).

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26



SEN03952-00

13) Remove washer (78).

a

Removed parts

Assembly a

Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with axle oil (AXO80) before installing.

1.

Assembly of limited slip differential assembly (if equipped) 1) Install outer race (79) to case (64). 2) Similarly, install outer race (79) to cover (63).

14) Using tool H28, remove outer race (79) from inside of case (64). Similarly, using tool H28, remove the outer race from inside of cover (63).

3)


Install washer (78).

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27

SEN03952-00 4)

5)

6)

50-320

Install 2 plates (76), 2 discs (77), 2 plates (76), and 2 discs (77) in order from the bottom. 2 Before installing the discs and plates, soak them in axle oil (AXO80).


7)

Install 4 pinion gears (72) to spider shaft (73).

8)

Install pinion gear assembly (71).

9)

Install side gear (70).

Install pressure ring (75).

Install side gear (74).

28



SEN03952-00

10) Install pressure ring (69).

11) Install 2 discs (68), 2 plates (67), 2 discs (68), and 2 plates (67) in order from the bottom. 2 Before installing the discs and plates, soak them in axle oil (AXO80).

12) Selection of thickness of plate i) Using tool H29, measure distance (d) between the end of case (64) and plate (67). a Distance (dd) [(d) – 4.8 mm] is the clearance between the case and plate. ii) Select the thickness of the plate so that distance (dd) [(d) – 4.8] will be 0.2 – 0.6 mm. a Replace the plates on both sides so that their thickness (total of 2 pieces) will be the same and assemble them according to the procedure in and after 4) shown above. q Varieties of plate thickness: 3.0 mm, 3.1 mm


13) Fit washer (66) to cover (63), and then install cover (63) temporarily. a There are grooves on both sides of the washer. a Apply axle oil or grease thinly to the washer so that it will stick to the cover. a When installing the cover, match the ma tch mark s made when it was removed.

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29

SEN03952-00 14) Adjust the clearance of the side gear in the axial direction. i) Measure clearance (e) between the side gear and washer through the shaft holes on both sides of the limited slip differential. q Clearance (e): 0.15 – 0.35 mm (on each side) a If the clearance is out of the standard range, replace the washer with new one. a There are washers 2.0 mm and 2.1 mm thick.


15) Install cover (63) to case (64). 2 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

16) Turn over the assembly and install bevel gear (47). a When installing the bevel gear, match the match marks made when it was removed. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

a

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30

Referring to “Disassembly and assembly of axle housing assembly”, disassemble the brakes of the right and left axle housings and take out sun gear shafts (14) which will be used in the next step.



17) Measure the no-load operation torque. i) Install sun gear shafts (14) to both sides of limited slip differential assembly (83). ii) Fix the sun gear shaft on one side and install tool H15 to the sun gear shaft on the other side. iii) Install tool H30 to tool H15 and measure the no-load operation torque. a When measuring, let the case rotate freely. q No-load operation torque: Max. 10 Nm {Max. 1.0 kgm} q If the no-load operation torque exceeds the standard value, disassemble the limited slip differential again and perform 12) “Selection of thickness of plate” and 14) “Adjustment of side gear in axial direction”.

2.

Assembly of standard differential carrier assembly 1) Install outer race (61) to case (49) on the bevel gear side. 2) Similarly, install outer race (61) to the case (48) on the opposite side.


SEN03952-00 3)

Install washer (58) to case (49) on the bevel gear side. a Install the washer with the dimpled side up (toward the side gear).

4)

Install side gear (57) to case (49).

5)

Install 4 pinion gears (55) and 4 spherical washers (54) to spider shaft (56).

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31


SEN03952-00 6)

Install pinion gear assembly (53) to case (49).

7) 8)

Install side gear (52) to case (49). Install washer (51) to case (48). a Install the washer with the dimpled side up (toward the side gear). a Apply axle oil or grease thinly to the washer so that it will stick to the case.

10) Turn over the assembly and install bevel gear (47). a When installing the bevel gear, match the match marks made when it was removed. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

3.

9)

50-320

Installation of differential assembly 1) Install gear cover (42). 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} 2) Sling differential carrier assembly (43) and set it to the mounting section of differential case (45). a Take care that the sling will not come off. a Do not damage the differential carrier by hitting it against the differential case.

Install case (48) to case (49). a When installing the case, match the m atch mar ks mad e when it wa s removed. 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

32



SEN03952-00 a

4)

4.

Rotate the bearing several turns to spread the axle oil to every part of the bearing. Using tool H12, measure the starting torque of the bevel gear in the tangential direction. q Starting torque: 6.9 – 19.6 N {0.7 – 2.0 kg} a If the starting torque is out of the standard range, adjust it by increasing or decreasing the shim thickness. q Varieties of shim thickness: 0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm a Limit the shim thickness after the adjustment to 0.3 – 1.25 mm on each side.

Bearing carrier 1) Using tool H31 and a press, press fit bearing (86) to bearing carrier (44). 2) Install ring (85) and seal (84) to bearing carrier (44).

5.

3)

Assembly of front cage assembly (For front differential) 1) Install outer races (39) and (38) to cage (40).

Apply axle oil to the bearing. Using H25, install shims (87) and bearing carriers (44) on both sides. a Install the shims of the thickness and quantity checked when disassembled to each bearing carrier. a Turning the bevel gear, tighten the mounting bolts. 2 Bearing: Axle oil (AXO80) 3 Mounting bolt: 98 – 122.5 Nm {10.0 – 12.5 kgm}


50-320

33


SEN03952-00 2)

Using tool H16 and a press, install bearing (35) to pinion gear (36).

6. 3) 4)

5) 6)

7)

50-320

Erect pinion gear assembly (81) and install cage assembly (88). Install bearing (37) to pinion gear assembly (81). a Install the bearing by shrink fit at temperature below 100°C or by using tool H17 and a press.

Assembly of rear cage assembly (For rear differential) 1) Referring to “5. Assembly of front cage assembly”, steps 1) – 4), assemble the rear cage assembly. 2) Apply axle oil to the bearing and rotate the cage several turns to spread the axle oil to every part of the bearing. 2 Bearing: Axle oil (AXO80) 3) Install coupling (41). 2 Contact surfaces of coupling and bearing: Lubricant containing molybdenum disulfide (LM-G or LM-P) 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}

Install holder (33) and nut (31). a Replace nut (31) with new one. Using tool H14 (See 4. Removal of front cage assembly), tighten nut (31) to the specified torque. a Secure assembly by gripping the outside of the pinion gear in a vise. 3 Mounting nut: 441 – 539 Nm {45 – 55 kgm} Apply axle oil to the bearing and rotate the cage several turns to spread the axle oil to every part of the bearing, and then measure the following. 2 Bearing: Axle oil (AXO80) q End play: 0 – 0.165 mm q Starting torque at cage mounting hole (A): 0 – 60.8 N {0 – 6.2 kg} a If the cage is heavy to rotate, replace the bearing, and then check the starting torque again.

34



4)

5)

6)

7.

SEN03952-00

Rotate the cage several turns to spread the axle oil to every part of the bearing, and then measure the following. q End play: 0 – 0.165 mm q Starting torque at cage mounting hole (A): 0 – 60.8 N {0 – 6.2 kg} a If the cage is heavy to rotate, replace the bearing, and then check the starting torque again. Remove coupling (41). Using tool H18, press fit oil seal (82). 2 Oil seal: Grease (G2-LI)

8.

Installation of rear cage assembly (For rear differential) Install tool H24 to the differential case assembly, and then install shim (90), O-ring, and rear cage assembly (42). a For the adjustment of the shims and tightening torque, see “7. Installation of front cage assembly”.

9.

Adjusting backlash Measure the backlash of the bevel gear with tool H32. q Standard backlash: 0.20 – 0.33 mm a Measure the backlash at 3 places on the periphery of the bevel gear and check that the dispersion of the measured values is 0.1 mm or less.

Install coupling (41). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}

Installation of front cage assembly (For front differential) Install tool H24 to the differential case assembly, and then install shim (89), O-ring, and front cage assembly (32). a Install the shims of the thickness and quantity checked when disassembled to each bearing carrier. a Install the shims with the thinnest one on the cage side. q Adjustment allowance of shims: 0.74 – 1.4 mm q Varieties of shim thickness: 0.05 mm, 0.2 mm, 0.3 mm, 0.6 mm 3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}


50-320

35

SEN03952-00 1)

If the measured backlash is out of the standard range, adjust it by moving a part of the shims on either side to the opposite side. a Do not change the total thickness of the shims on both sides. a If the backlash is insufficient, move a part of shims (g) to the shims (f). (Move the bevel gear in direction (A), or to the right in the figure.) a If the backlash is too large, move a part of shims (f) to the shims (g). (Move the bevel gear in direction (B), or to the left in the figure.)


10. Testing tooth contact Apply red lead thinly to the surfaces of the bevel gear teeth and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. a The center of the tooth contact must be as follows. q Middle of tooth height q Point on tooth at which distance of (x) from small end (C) is 24 ± 4 mm a Width (y) of the tooth contact must be 31 ± 3 mm. a Check that there is not a strong contact at tip (A), bottom (B), small end (C), or large end (D).

9JF01500

11. Adjusting tooth contact 1) If the tooth contact pattern is not proper, adjust the tooth contact. a Adjust the tooth contact by increasing or decreasing the shims on both sides of the bearing carrier (to move the bevel gear) and the shims of the cage assembly (to move the bevel pinion). a After adjusting the tooth contact, check the backlash again. 2) If the bevel pinion is too far from the bevel gear, the tooth contact pattern is as follows. In this case, adjust the tooth contact according to the following procedure. q Decrease the shims of the cage assembly (on the bevel pinion side) to move the cage assembly in the direction (C). q Adjust the shims on both sides of the bearing carrier to move bevel gear in the direction of (D) far from the bevel pinion. a Do not change the total thickness of the shims on both sides of the bearing carrier.

50-320

36



3)

SEN03952-00 4)

If the bevel gear is too close to the bevel pinion, the tooth contact pattern is as follows. In this case, adjust the tooth contact according to the following procedure. q Decrease the shims of the cage assembly (on the bevel pinion side) to move the cage assembly in the direction (C). q Adjust the shims on both sides of the bearing carrier to move bevel gear in the direction of (D) far from the bevel pinion. a Do not change the total thickness of the shims on both sides of the bearing carrier.

5)

If the bevel gear is too far from the bevel pinion, the tooth contact pattern is as follows. In this case, adjust the tooth contact according to the following procedure. q Increase the shims of the cage assembly (on the bevel pinion side) to move the cage assembly in the direction (E). q Adjust the shims on both sides of the bearing carrier to move bevel gear in the direction of (F) close to the bevel pinion. a Do not change the total thickness of the shims on both sides of the bearing carrier.

If the bevel pinion is too close to the bevel gear, the tooth contact pattern is as follows. In this case, adjust the tooth contact according to the following procedure. q Increase the shims of the cage assembly (on the bevel pinion side) to move the cage assembly in the direction (E). q Adjust the shims on both sides of the bearing carrier to move bevel gear in the direction of (F) close to the bevel pinion. a Do not change the total thickness of the shims on both sides of the bearing carrier.


50-320

37

SEN03952-00


12. Brake a Install both brakes according to the same procedure. 1) Install seal (87) to piston (20). 2 Thinly apply axle oil to the piston and piston mounting section.

2)

Using tool H19, press fit piston (20) evenly. a Press fit the piston until it touches the housing. a Do not hit the piston with a plastic hammer, etc. to press fit it. (If it is press fitted so, it and its O-ring will be damaged.)

3) 4)

Install bleeder screw (19). Install tool H22. a You may install tool H22 when checking for brake oil leakage. a Tool H22: Fit the O-ring without fail. 3 Tool H22 mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} Set installer [24] (equivalent to tool H19). Using tool H13, supply air into the brake oil port to fit the piston. k If the air is supplied without setting installer [24], the piston will jump out, and that is dangerous.

5)

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38

13. Brake oil leakage test a Action of the piston of the slack adjuster lowers pressure during the low-pressure leakage test. To prevent this, use tool H22. 1) Keep installer [24] (equivalent to tool H19) set. k If the brake oil leakage test is performed without setting installer [24], the piston will jump out, and that is dangerous. 2) Install tool H22, nipple H21, and pump H20 to the brake port and bleed all air fr o m t h e b r a k e s y s t e m t h r o u g h t h e bleeder. a Tool H22: Fit the O-ring without fail. 3 Tool H22 mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} a Bleed air by operating pump H20.



3)

4)

5)

Perform the low-pressure oil leakage test. a Operate tool H20 to raise the pressure to 98 kPa {1 kg/cm2}. a Leave the system at 98 kPa {1 kg/ cm2} for 5 minutes and check that the pressure does not lower at all. a If the oil leaks (If the pressure drops more than the standard), remove the brake piston and check the seals for damage. a If the hose is moved while the pressure is measured, the pressure fluctuates. Accordingly, do not move the hose. Perform the high-pressure oil leakage test. a If oil leakage is not detected by the low-pressure brake oil leakage test, operate tool H20 to raise the pressure to 4,410 kPa {45 kg/cm2}. a Leave the system at 4,410 kPa {45 kg/cm2} for 5 minutes and check that the pressure does not drop more than 98 kPa {1 kg/cm2}. a If the oil leaks (If the pressure drops more than the standard), remove the brake piston and check the seals for damage. a If the hose is moved while the pressure is measured, the pressure fluctuates. Accordingly, do not move the hose. Remove pump H20, nipple H21, tool H22, and installer [24] (equivalent to tool H19), and then perform the test on the opposite side.


SEN03952-00 14. Top cover 1) Remove bleeder screw (19) temporarily and install top cover (21). 2 Mating face of cover: Adhesive (LOCTITE 515 or equivalent) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} 2) Install slack adjusters (22) to the right and left. a Take care that the O-ring will not come off. 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} 3) Install bleeder screw (19).

15. Axle housing 1) Referring to Disassembly and assembly of axle housing, “8. Axle housing assembly”, install the right and left housings. 2) For the rear differential, perform step 10. in the Disassembly and assembly of axle housing to install the rear axle support and the brake tube and hose assembly. a Perform steps 16 – 18 below for only the front differential.

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39

SEN03952-00 16. Axle oil temperature sensor (For only front differential) 1) Install axle oil temperature sensor and wiring harness assembly (11). a Install the axle oil temperature sensor to the back side of cover (10). 2 Threads: Gasket sealant (LG-5) 3 Axle oil temperature sensor: 29.4 – 49 Nm {3 – 5 kgm} 2)

Install cover (10). 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

3)

Install oil temperature sensor clamps (16) and (17). 3 Mounting bolts (16) and (17): 98 – 123 Nm {10.0 – 12.5 kgm}

4)

Install brake tube assembly (12). 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

50-320

40


17. Disassembly of long cage assembly (For only front differential) 1) Using tool H33, press fit bearing (30) to shaft (26) with a press. a Direct shield side (G) of the bearing down. 2) Using tool H34, press fit shaft and bearing assembly (91) to long cage (27).

3)

Install ring (29) and snap ring (28). a Check that part (G) (the shield side of the bearing) is on the lower side.

4)

Using tool H18, press fit oil seal (25). 2 Oil seal: Grease (G2-LI) a Set top (h) of the oil seal rim flush with end face (i) of the cage.



SEN03952-00

18. Installation of long cage assembly (For only front differential) 1) Sling and install long cage assembly (24). 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm} 2) Install coupling (23). 2 Contact surfaces of coupling and bearing: Lubricant containing molybdenum disulfide (LM-G) or (LM-P) 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}

q

Refilling with oil (Axle housing) Tighten the drain plug and add oil through the oil filler to the specified level. 3 Drain plug: 127.4 – 176.4 Nm {13 – 18 kgm} 3 Oil filler plug: 93.1 – 122.5 Nm {9.5 – 12.5 kgm} 5

Axle oil AXO80 (Each of front and rear): 24 l


50-320

41

SEN03952-00



50-320

42

SEN03953-00





50

400 Undercarriage and frame Removal and installation of center hinge pin .................................................................................................. 2 Removal and installation of counterweight ................................................................................................... 12


50-400

1

400 Undercarriage and frame Removal and installation of center hinge pin

SEN03953-00

Removal and installation of center 1 hinge pin

Symbol

Part No.

Part Name


Special tools

t 1 1

790-101-5201 790-101-5281

Push tool kit • Plate

790-101-5221 01010-51225

• Grip • Bolt

2 3

793-840-1410 793-840-1420

Push tool Push tool

t 1 t 1

4

793-415-1180

Push tool

t 1

1 Y

1 1

Removal k

k

k

1.

2.

k

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Set supports to the frame securely.

3.

Remove operator's cab and floor frame assembly (1). For details, see “Removal and installation of operator's cab and floor frame assembly”.

4.

Remove upper cover (2) of the work equipment valve.

5.

Disconnect all wiring harness clamps (3) between the front frame and rear frame from the rear frame.

Raise the front part of the chassis with the work equipment and set support stands [1] under the right and left sides of the frame at the rear of the front wheels.

Set the work equipment horizontally, raise the counterweight with hydraulic jack [2], and set support stands [3] under the right and left sides of the rear frame. Disconnect the cable from the negative (–) terminal of the battery.

50-400

2



6.

Disconnect brake hose (4).

SEN03953-00 [*1]

9.

Remove brake hose clamp (8).

10. Disconnect PPC hoses (9) – (12) from the work [*3] equipment control valve. a Since oil will leak through the disconnected hoses and tubes, prepare oil receivers. 11. Disconnect port P hose (13) and port T hoses (14) and (15). a Plug the disconnected hoses to prevent oil leakage.

7.

Disconnect front drive shaft (5).

[*2]

8.

Remove 2 hose clamp brackets (6) and (7).

Reference: The photo shows the work equipment valve seen from the rear lower direction.


50-400

3


SEN03953-00 12. Remove pins (11) and hoses (12) and (13) from the bottom side of both steering cylinders to disconnect these cylinders. [*4] a Record the thickness and quantity of the shims.

13. Remove the lower hinge pin. 1) Remove lock bolt (14a). 2) Remove lower hinge pin (14b).

2)

Remove the mounting bolt, cover (15) and shim (17). a Record the thickness and quantity of the shims.

3)

Adjust the height of the front frame and rear frame with the hydraulic jack so that you can pull out the pin easily, and then remove upper hinge pin (16). [*7] Remove upper spacer (18).

[*5]

4)

14. Remove the upper hinge pin. [*6] 1) Remove mounting bolt (14c). a Record the thickness and quantity of the shims.

15. Disconnect the front frame and rear frame. [*8] 1) Set hand lift truck [4] under bucket (19).

AJF00736

50-400

4



2)

Using a bar, etc., raise front frame assembly (20) by 2 – 3 mm to move lower spacer (21) of the upper hinge from rear frame assembly (22). a You may raise the front frame assembly by 2 – 3 mm with a large-sized crane, if available.

SEN03953-00 2)

3)

Remove retainer (24) and shims (25). a Record the thickness and quantity of the shims. Remove dust seal (26) from retainer (24).

AJF00740 9JF00909

4)

3)

Remove bearing (27a) and spacer (27b) with push tool Y1.

Turn the tires to move front frame assembly (20) forward.

AJF00737

16. Disassemble the lower hinge of the front frame. [*9] 1) Remove dust seal (23).

17. Disassemble the upper hinge of the front frame. [*10] 1) Remove lower spacer (28). 2) Remove dust seal (29). 3) Remove retainer (30) and shim (31). a Record the thickness and quantity of the shims. 4) Remove dust seal (32) from retainer (30).

AJF00739


50-400

5


SEN03953-00 5)

Remove bearing (33a) and spacer (33b) with push tool Y2.

Installation Carry out installation in the reverse order to removal.

q

[*1] a Bleed air from the brake. For details, see Testing and adjusting, “Bleeding air from brake circuit”. [*2]

3

a

18. Remove 2 bushings (34) from the lower hinge of the rear frame. [*11]

AJF00743

Front drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} When installing the drive shaft, check that the key way of the spider cap is fitted in the key way of the mating yoke, and then tighten the mounting bolts.

[*3] a Connect PPC hoses (9) – (12) according to their band colors shown below. q Work equipment lever specification: 2 levers No.

Connecting point

Band color

(9)

Bucket DUMP

Blue

(10)

Bucket TILT

Red

(11)

Lift arm LOWER

Orange

(12)

Lift arm RAISE

Yellow

[*4] a Adjust the shim so that the total of the upper and lower clearances between the frame and cylinder will be less than 0.5 mm. q Varieties of shim thickness: 0.5 mm, 1 mm 2 Inside of bushing on cylinder side and dust seal: Lubricant containing molybdenum disulfide (LM-P)

50-400

6



[*5] [*6] [*7] [*8] a Install the upper hinge pin and lower hinge pin according to the following procedure. 1.

Set hand lift truck [4] under the bucket and turn the tires to move the front frame assembly (20) toward the rear frame.

2.

Using a bar, etc., raise front frame assembly (20) by 2 – 3 mm to move spacer (21) to the spacer of rear frame assembly (22). a You may raise the front frame assembly by 2 – 3 mm with a large-sized crane, if available.

9JF00909

3.

SEN03953-00 4.

Insert upper hinge pin (16) and lower hinge pin (14b) to the end.

5.

Install upper spacer (18). a Install the spacer with the chamfered part on the bearing side. 2 Upper spacer: Lubricant containing molybdenum disulfide (LM-P)

6.

Tighten cover (15) of upper hinge pin (16) with 3 bolts of the centre. a Do not insert the shim for the upper hinge pin, 2 Mounting bolt: Adhensive: (Loctite #2701) 3 Mounting bolt: 186 – 226 Nm {19 – 23 kgm}

7.

Measure clearance between the bottom of cover (15) and rear frame top with a clearance gauge, and then select shims so that the maximum clearance will be less than 0.2 mm when shim (17) are inserted. q Standard shim thickness: 1 mm q Varieties of shim thickness: 0.1 mm, 0.5 mm

Align the upper and lower pin holes. a Using a hydraulic jack, adjust the height of the front and rear frames and align the pin holes. k When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.


50-400

7


SEN03953-00 8.

Insert selected shim (17) between cover (15) and rear frame and tighten the 6 mounting bolts. 2 Mounting bolt: Adhensive: (Loctite #2701) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

9.

Install lock bolt (14a) of lower hinge pin (14b).

[*9] [*10] [*11] a Assemble the upper hinge and lower hinge according to the following procedure. 1. Install 2 bushings (34) to the lower hinge of the rear frame.

AJF00743

2.

a

A clearance of 1 mm should be made at (b) between bushing (35) and lower hinge pin (14b).

9JF00917

Assemble the upper hinge of the front frame. 1) Using push tool Y3, press fit bearing (33a) and spacer (33b) to the front frame. a Since the clearance of bearing (33a) and spacer (33b) is adjusted properly, do not change their combination. a Since bearing (33a) and spacer (33b) are an assembly, always replace them as a set. a Press fit bearing (33a) and spacer (33b) securely so that a clearance will not be made between the bearing and frame. 2 Bearing: Grease (G2-LI)

10. Install mounting bolt (14c) of upper hinge pin (16).

50-400

8



2)

3)

Press fit dust seal (29) to the front frame. a Press fit the dust seal with the lip out. 2 Lip of dust seal: Grease (G2-LI) Install lower spacer (28). a Install the spacer with the chamfered part on the bearing side. 2 Lower spacer: Lubricant containing molybdenum disulfide (LM-P)

SEN03953-00 5)

6)

Tighten the 3 mounting bolts of retainer (30) evenly. 3 Retainer mounting bolt: 19.6 ± 10% Nm {2 ± 10% kgm} Measure clearance (a) between retainer (30) and front frame with a clearance gauge, and then select shims so that the maximum clearance will be less than 0.1 mm when the shims are inserted. q Standard shim thickness: 2 mm q Varieties of shim thickness: 0.1 mm, 0.5 mm, 1.0 mm

AJF00741

4)

Press fit dust seal (32) to retainer (30). a Press fit the dust seal with the lip out. 2 Lip of dust seal: Grease (G2-LI) 7)

9JF00913


Insert selected shim (31) and tighten retainer (30) with the 6 mounting bolts. 2 Mounting bolt: Adhensive: (Loctite #2701) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

50-400

9


SEN03953-00 3.

Assemble the lower hinge of the front frame. 1) Using tool Y4, press fit bearing (27a) and spacer (27b) to the front frame. a Since the clearance of bearing (27a) and spacer (27b) is adjusted properly, do not change their combination. a Since bearing (27a) and spacer (27b) are an assembly, always replace them as a set. a Press fit bearing (27a) and spacer (27b) securely so that a clearance will not be made between the bearing and frame. 2 Bearing: Grease (G2-LI)

3)

Press fit dust seal (26) to retainer (24). a Press fit the dust seal with the lip out. 2 Lip of dust seal: Grease (G2-LI)

4)

Tighten the 3 mounting bolts of retainer (24) evenly. 3 Retainer mounting bolt: 19.6 ± 10% Nm {2 ± 10% kgm} Measure the clearance between retainer (24) and front frame with clearance gauge [6], and then select shims so that the maximum clearance will be less than 0.1 mm when the shims are inserted. q Standard shim thickness: 1 mm q Varieties of shim thickness: 0.1 mm, 0.5 mm

5)

2)

Press fit dust seal (23) to the front frame. a Press fit the dust seal with the lip out. 2 Lip of dust seal: Grease (G2-LI)

AJF00739

50-400

10



6)

Insert selected shim (25) and tighten the 9 mounting bolts. 2 Mounting bolt: Adhensive: (Loctite #2701) 3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

SEN03953-00 q



AJF00747


50-400

11

400 Undercarriage and frame Removal and installation of counterweight

SEN03953-00

Removal and installation of counterweight

1

5.

Open the radiator grille and sling it temporarily.

6.

Open the engine left side cover and disconnect wiring connector CN-BR1 (8).

7.

Disconnect both damper gas cylinders (9).

8.

Remove the 4 mounting bolts and lift off the radiator grille (10).

Removal k

k

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires.

1.

Disconnect battery negative (–) terminal (1) from the right side, and then disconnect battery terminal (2).

2.

Disconnect wiring harness connectors CN-R23 (3) and CN-R24 (4).

3.

Disconnect battery terminals (5) and (6) from the left side.

4.

Disconnect wiring harness connector CN-R22 (7).

50-400

12

4

Radiator grille: 25 kg


400 Undercarriage and frame Removal and installation of counterweight

9.

SEN03953-00

Sling counterweight (11) temporarily and remove the mounting bolt, and then remove counterweight (11). [*1] 4

Counterweight and assembly: 2,100 kg


batteries

(both)

Installation q


[*1]

3

Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}

50-400

13

SEN03953-00



50-400

14

SEN03954-00





50

500 Hydraulic system Removal and installation of HST pump and 4-gear pump assembly .............................................................. 2 Disassembly and assembly of HST pump assembly ...................................................................................... 5 Removal and installation of HST motor 1 assembly ..................................................................................... 32 Removal and installation of HST motor 2 assembly ..................................................................................... 34 Disassembly and assembly of HST motor assembly.................................................................................... 36 Removal and installation of work equipment control valve assembly ........................................................... 52 Removal and installation of hydraulic tank assembly.................................................................................... 54 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 56


50-500

1

SEN03954-00

500 Hydraulic system Removal and installation of HST pump and 4-gear pump assembly

Removal and installation of HST pump and 4-gear pump assembly 1 Removal k k

k

k

a a

q

Disconnect the following tubes and hoses. q (1): 4 HST pump discharge hoses q (2): Hose between charge valve port (A) and fan motor (IN) hose

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Slowly loosen the oil filler cap of the hydraulic tank to release the residual pressure in the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. Plug the disconnected hoses to prevent oil leakage. Put tags to the disconnected hoses and pipes and record the installed positions etc. on them. Precautions for handling refrigerant k Collect refrigerant (R134a) beforehand. a Ask professional traders for collecting and filling the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant (R134a) gets inside ones eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person. k If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant is cooled, and then drain the coolant.

1.


2.

Drain the hydraulic oil. 6

3.

4.

q q

q q q q

(3): Hose between charge valve port (P) and brake/fan pump (4): 2 HST filter hoses

(5): (6): (7): (8):

Steering pump suction tube HST pump port (G) hose HST pump port (S) hose Parking brake solenoid port (T) hose

[*1]

Hydraulic tank: 89 l

Remove the operator's cab assembly. For details, see “Removal and installation of operator's cab”.

50-500

2



q q q

(9), (10): HST pump port (PS) hose (11), (12): HST pump port (YS) hose (13): HST pump port (G) hose

6.

SEN03954-00 Sling HST pump and 4-gear pump assembly (22) temporarily, and then remove its 5 mounting bolts and it. [*2] 4

q q q q q q q

5.

HST pump and 4-gear pump assembly: 150 kg

(14): (15): (16): (17):

HST motor M1 port (T2) hose HST motor M2 port (T2) hose Steering priority valve port (P) hose Hose between work equipment pump and cut-off valve port (P) (18): Transfer clutch valve port (T) hose (19): Transfer lubrication hose (20): Transfer cooler inlet hose

Disconnect wiring connector (T05) (21).


50-500

3

SEN03954-00


Installation q


[*1] a When installing the hoses of the air conditioner circuit, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner hose, check that O-ring (70) is fitted to it. a Check O-ring (70) for a flaw and deterioration. a When connecting each refrigerant pipe, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8 or ZEXEL ZXL100PG (equivalent to PAG46)) to O-ring (70). 3 Threaded part of hose (M16 × 1.5): 12 – 15 Nm {1.2 – 1.5 kgm} 3 Threaded part of hose (M22 × 1.5): 20 – 25 Nm {2.0 – 2.5 kgm} 3 Threaded part of hose (M24 × 1.5): 30 – 35 Nm {3.0 – 3.5 kgm}

q


1.

If boss (23) was removed from the HST pump assembly, install it according to the following procedure. a Install boss (23) so that it will be flush with the shaft end of pump (24). q Level difference between boss and pump shaft end: Max. 0.5 mm

2.

Tighten mounting bolt (25) of boss (23). 3 Mounting bolt: 210 Nm {21.4 kgm}

q

Refilling with oil (Hydraulic tank) 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.

[*2]

2 3

Mating face of pump: Gasket sealant (LG-6) Mounting bolt: A: 245 – 309 Nm {25.0 – 31.5 kgm} B: 98 – 123 Nm {10.0 – 12.5 kgm}

5

50-500

4

Hydraulic tank: 89 l WA320, 320PZ-6 (KA SPEC.)

500 Hydraulic system Disassembly and assembly of HST pump assembly

Disassembly and assembly of HST pump assembly

SEN03954-00 2. 1

Low pressure valve assembly 1) Remove low pressure valve assembly (2). a Do not change adjustment screw.

Symbol

Part No.

1 790-201-2720

Part Name

Push tool


Special tools

q 1

790-201-2730

Push tool

t 1

790-201-2830

Push tool

t 1

3 790-201-2740

Push tool

q 1

S 2

Disassembly a a

1.

If the pump body is disassembled, the assembly special tool will be required. See Assembly 3. 5). General view

High pressure relief valve assembly 1) Remove 2 high pressure relief valve assemblies (1). a Do not change adjustment screw. a Control: O-ring, housing. a Do not disassemble the high pressure relief valve assemblies, except the Orings and backup rings.


2)

Disassemble the low pressure relief valve according to the following procedure, if necessary. a Before loosening the adjustment screw, check the adjustment dimension. i) Remove spring (3) and spring seat (4). ii) Remove piston (5). iii) Remove locknut (6). iv) Remove adjustment screw (7) from holder (8).

CJW11904

50-500

5


SEN03954-00 3.

High pressure cut-off valve assembly 1) Remove high pressure cut-off valve assembly (9) a Unscrew setting cartridge completely. a Control: O-ring, housing.

CJW11906

2)

50-500

Disassemble the high pressure cut-off valve according to the following procedure, if necessary. a Before loosening the adjustment screw, check the adjustment dimension. i) Remove spring seat (10) and spring (11) from the pump case. ii) Remove barrel assembly (12) from the pump case. iii) Remove spring seat (13) and shuttle spool (15) from barrel (12). iv) Remove spool (16) and piston (17) from barrel (12). v) Screw a bolt of M3 x 140 or longer one and pull valve seat (14) out of the pump case. vi) Remove locknut (18), and then remove adjustment screw (97) from holder (98).

6

4.

Remove speed-related valve (DA valve) assembly 1) Remove speed-related valve assembly (19).



5.

Directional solenoid valve (34) 1) Remove directional solenoid valve assembly (34).

SEN03954-00 3)

Disassemble the valve housing assembly (35) according to the following procedure. i) Remove 2 springs (37) and 2 collars (38). ii) Remove piston (39). a Do not remove 4 plugs (41) and plug (42) from housing.

CJW12132

2)

Remove 2 solenoid valves (36) from directional solenoid valve assembly (34). a Remove cap (36B) by turning it and remove coil (36A) by pulling it from the solenoid valve, and then remove the tube from the valve housing assembly (35).


50-500

7


SEN03954-00 6.

Charge pump assembly (44) 1) Remove 4 mounting bolts (97) and charge pump assembly (44). 2) Remove wear plate (43). 3) Remove gear (46). 4) Remove coupling (48) and key (49). a Do not remove bearing metal (47) from flange (45).

7.

Port plate assembly (51) 1) Mark the position (angle) of the indexing screw (50), m0. a Record setting measure.(angle) 2) Set the indexing screw to disassembly position (a).(0°.)

CJW12131

50-500

8

3) 4)

Mark position of the port plate, m1. Loosen port plate fixation.

5)

Lift off port plate assembly (51) and control plate (52).



8.

SEN03954-00

Cylinder block and piston assembly (54) 1) Press cylinder (53) to the bottom. 2) Remove fixing indexing screw (50).

3)

Remove cylinder block and piston assembly (54).


50-500

9

SEN03954-00 4)

Disassemble cylinder block and piston assembly (54) according to the following procedure.

i)

ii)

50-500


10

Remove the assembly of pistons (57) and retainer (58) from cylinder block (56). Remove 9 pistons (57) from retainer (58).



iii)

Remove retainer guide (59) from cylinder block (56). iv) Remove shim (60) and spring (61).

SEN03954-00 a

Check of pistons q Check that there are no scratches or metal deposits on sliding surface (b), and there is no axial play (c), (otherwise: pistons must be replaced in sets).

CJW12142

a

Check of cylinder block and control plate. Cylinder bores (d), splines (e).

q

a

When any of cylinder block (56), control plate (52), retainer guide (59), retainer (58), and shim (60) needs to be replaced, replace the whole cylinder block since a dimension of shim (60) must be adjusted. v) Remove snap ring (63) from the cylinder block. k Snap ring (63) will jump out. Take care. vi) Remove spring (62) and 2 shims (65).


Cylinder surface ( f ) free of scoring. Control plate (g) without scoring. Fit faces (f) and (g) (having notch (B) on the ellipse) together.

q q

a

50-500

11

SEN03954-00 9.

Seal 1) Protect drive shaft (66). 2) Remove snap ring (67).

3) 4)

Screw [1] in sheet metal screw into the holes fitted with rubber. Pull out shaft seal (68) with pliers.

5)

Remove snap ring (69).

50-500

12


10. Drive shaft assembly 1) Remove drive shaft assembly (66) with plastic hammer strokes.

2)

Disassemble the drive shaft assembly according to the following procedure. i) Remove snap ring (70). ii) Remove bearing (71) from drive shaft (72). a Check of drive shaft q Splines for damage or fretting. q Running surfaces. q Groove cut by shaft seal.



SEN03954-00

11. Swivel cradle (73), Bearing cups (74) 1) Remove swivel cradle (73). 2) Remove bearing cups (74). a Check q Bearing cups set.

q

4)

3)

Bearing surfaces ( j ) of cradle (76).

Remove lever (75) from cradle (73). a Check of cradle lever (75)

Remove wire (95), articulate pin (96) and bearing (74b) from swivel cradle (73).

12. Servo cylinder assembly 1) Remove plugs (77). 2) Remove joint pins (78). a q

Check of cradle (76) Sliding surface (h) free from scoring.


50-500

13

SEN03954-00 3) 4)

Mark position m2, m3 of covers (80), (81), note measure of “zero position” ( k ) . Loosen nut (79).

5)

Remove covers (80) and (81).

6)

Remove O-rings (101) from both sides.


7)

Remove servo piston assembly (82).

a

Check of groove (A).

8)

Disassemble servo piston assembly (82) according to the following procedure. a Disassemble either side first, then disassemble the other side. i) Using tool S1, push collar (83). ii) Break and remove plastic cap (86). (Prepare new one for assembly.) iii) Remove ring (84). iv) Remove snap ring (85).

v) Remove collar (83). vi) Remove large spring (87) and small spring (88). vii) Remove collar (89).

50-500

14



viii) Disassemble the opposite side similarly. ix) Remove rod (91) from piston (90).

SEN03954-00

Assembly a a a

1.

a

Clean the all parts and remove burrs, etc. Coat the rotary parts and sliding parts with engine oil (EO10-CD) before installing. If the tightening torque of a mounting bolt, nut, or plug is not shown in this manual, see the tightening torque table. Pump case 1) Install guide ring (92).

When any of rod (91), collar (83), snap ring (85), piston (90), and ring (84) needs to be replaced, replace all of the servo piston assembly (82) since a dimension of ring (84) must be adjusted. 2)

Install O-ring (94).

3)

Install seal ring (93) over O-ring (94).

13. Pump case 1) Remove guide ring (92) from the servo cylinder mounting part (100) of pump case. 2) Remove seal ring (93) and O-ring (94).


50-500

15


SEN03954-00 a a

2.

The deformation of the seal has to be done with care so as not to damage the sealing edges. Check the position of seal ring (93). If necessary, straighten using a finger.

v) vi) vii) viii) ix) x)

Using tool S1, push collar (83). Install snap ring (85). Install ring (84). Install new plastic cap (86). Turn over upside down. Assemble the opposite side similarly.

Servo piston assembly (82) a Assemble the servo piston assembly in an oil pan. 1) Dip piston (90), rod (91), springs (87) and (88), collars (83) and (89) in engine oil (EO10-CD). 2) Assemble the servo piston assembly according to the following procedure. i) Install rod (91) to piston (90).

3) 4) 5)

a

Insert guide thorn [4] into the servo piston assembly (82). Grease slightly guide thorn [4]. Install servo piston assembly (82) with guide thorn [4].

Assemble either side first, then assemble the other side. ii) Install collar (89). iii) Install small spring (88) and large spring (87). iv) Install collar (83).

a

50-500

16

When any of rod (91), collar (83), snap ring (85), piston (90), and ring (84) needs to be replaced, replace all of the servo piston assembly (82) since a dimension of ring (84) must be adjusted.



3.

Cradle, Bearing cups 1) Insert bearing cup set (74a). a Fit hole (c) of cup set (74a) to the pin in the case.

2)

SEN03954-00 3)

Swivel cradle (73) Assemble bearing (74b), wire (95), lever (75) and articulating pin (96) to cradle (76).

a

k

a

Insert completely swivel cradle (73) into housing. a Assistance: Devices, e.g. clamp, rubber rings, grease and string. a Pay attention for correct seat of swivel cradle (73) in the housing.

Sliding stone guidance in piston (82).

Remove auxiliary device.

Completed cradle holding device


50-500

17


SEN03954-00 a q

q

Check: Location of the swivel bearing in the bearing. Centralize swivel (73) by using a measuring device (dial gauge or depth measurement [5]) Check points 1 and 2 – they should have the same dimension.

CJW11961

CJW11958

6) k

4)

Hold swash plate in position utilizing the seat screw. Do not use force.

Fit joint pin (78) and plug (77). a Pinch wire (95) in pin (78).

CJW11960

5)

50-500

Make holding devices [6] (2 pieces). a Holding device [6] “swivel cradle”

18



7)

Install second holding device [6] diagonally and fix the swash plate.

SEN03954-00 a 6)

4.

Drive shaft assembly a Install the bearing to the shaft in the correct direction. 1) Install the ring to the shaft first, and then install the bearing to the shaft. 2) Using tool S2, press fit bearing (71) to drive shaft (72).

3)


4) 5)

Install drive shaft assembly (66). Install snap ring (69).


7)

8)

9)

Before setting seal (68), perform the following procedures. Measure depth (d1) to the groove bottom of snap ring (67). Make a mark of the insertion depth of push tool S3 (finishing position) (m4 = d1) on push tool S3. Using tool S3, press fit seal (68). a Threads of shaft: 5/8-11UNC-2B, Thread depth: 36 mm


50-500

19

SEN03954-00 5.


Cylinder block, Piston assembly 1) Assemble the cylinder block and piston assembly according to the following procedure.

CJW11921

50-500

20



SEN03954-00

i)

Install 2 shims (65) and spring (62) to the cylinder block. ii) Compress spring (62) and install snap ring (63). iii) Install spring (61) and shim (60) to cylinder block (56). a When any of cylinder block (56), control plate (52), retainer guide (59), retainer (58), and shim (60) needs to be replaced, replace the whole cylinder block since a dimension of shim (60) must be adjusted. iv) Install retainer guide (59).

CJW12142

6.

v) Install 9 pistons (57) to retainer (58). vi) Install piston and retainer assembly to cylinder block (56). a Oil piston and piston pad.


2)

Remove holding device [6]. a Fit cylinder completely with pistons and retaining device.

3)

Assembly aid: Hold the cylinder block and piston assembly (54) by using an O-ring (96).

Control plate (52) a Control plate clockwise rotation - indexed in the direction of rotation. a Noise grooves are machined - in based on direction of rotation. a Notch (B) is seen on 1 side.

50-500

21


SEN03954-00 a

Indexing screw basic setting - indexing screw (50) (The end is eccentric.) Dimension (m): 20 ± 0.75 mm

7.

1) 2)

Press cylinder block (56) to the bottom. Screw in indexing screw (50). a Groove in mounting position. (The groove is directed up in the following figure.)

Port plate (51) 1) Assemble port plate (51), matching (m1). k Spring preloaded! 2) Insert port plate assembly (51) into housing, guidance with 2 guide bolts [1] that screwed opposite angle.

3) 3) a

50-500

Locking screw (50) - Observe adjusting measure, the angle (m0).

Insert control plate (52) - clockwise rotation. Insert the control plate so that notch (B) will not be seen.

22



8.

Servo piston cover 1) Install servo piston covers (80) and (81) to both sides match mark position (m2), (m3). a Cover (80) will be removed because of filling oil.

SEN03954-00 10. Directional solenoid valve (34) 1) Assemble valve housing assembly (35) according to the following procedure. i) Install plug (42) to housing. 2 Threads of plug: ThreeBond No. 1305 or equivalent ii) Install 4 plugs (41). 3 Plug: 5.6 Nm {0.57 kgm} iii) Install piston (39). iv) Install 2 collars (38) and 2 springs (37).

CJW12132

9.

Charge pump assembly (44) 1) Install wear plate (43) 2) Install coupling (48) and key (49). a Bearing metal (47) is already in flange (45). 3) Install gear (46) to flange (45). 4) Install charge pump assembly (44) with 4 mounting bolts (97).

CJW12131

2)


Install 2 solenoid valves (36) to valve housing assembly (35). a Fit the tube to the solenoid valve housing and install coil (36A) and cap (36B).

50-500

23

SEN03954-00 3)


Install directional solenoid valve assembly (34). 3 Mounting bolt: 10.4 Nm {1 kgm}

CJW11906

11. Speed-related valve (DA valve) 1) Fit the O-ring and install speed-related valve assembly (19).

2)

Fit the O-ring and install high pressure cutoff valve assembly (9). a After installing the pump assembly to the machine, adjust the high pressure cut-off valve assembly. For details, see Testing and adjusting, “Testing and adjusting HST oil pressure”.

12. High pressure cut-off valve assembly 1) Assemble the high pressure cut-off valve assembly according to the following procedure. i) Install adjustment screw (97) and locknut (18) to holder (98). ii) Install piston (17) and spool (16) to barrel (12). iii) Install shuttle spool (15), valve seat (14), and spring seat (13) to barrel (12). iv) Install barrel assembly (12) to the pump case. v) Install spring (11) and spring seat (10) to the pump case. a Set the spring to the dimension measured before disassembly.

50-500

24



13. Low pressure relief valve assembly 1) Assemble the low pressure relief valve assembly according to the following procedure. i) Install adjustment screw (7) to holder (8). ii) Install locknut (6). iii) Install piston (5). iv) Install spring seat (4) and spring (3) to the pump case.

SEN03954-00 14. High pressure relief valve assembly Fit the O-ring and install 2 high pressure relief valve assemblies (1). 3 High pressure relief valve assembly: 200 ± 10 Nm {20.39 ± 1.02 kgm}

CJW11904

15. Filling with oil a Remove servo piston cover (80). (See next item.) Fill up hydraulic aggregates with medium before start-up.

2)

Fit the O-ring and install low pressure relief valve assembly (2). 3 Low pressure relief valve assembly: 70 Nm {7.14 kgm}


50-500

25

SEN03954-00 16. Servo piston cover (80) 1) Install servo piston cover (80) to match mark position (m3). 2) Adjust zero position according to measure, (k). k Adjustments of the correct zero position to be carried out after installation into the machine or on the bench test.

50-500

26


17. Before starting q Observe the operating instructions before starting. q Check the machine for remarkable faults. q Do not operate the machine with defective instruments, warning lights or control elements. q All safety devices must be in a secure position. q Do not carry with you movable objects or secure them to the machine. q Keep oily and inflammable material away from the machine. q Before entering the operator’s cab, check if persons or obstacles are beside or beneath the machine. q Be careful when entering the operator’s cab, use stairs and handles. q Adjust your seat before starting.



SEN03954-00

18. Tightening torque table a If the tightening torque of a mounting bolt, nut, or plug is not shown in this manual, tighten that part according to the following tightening torque table. 1) Bolts The values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 913 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.

Tensile strength class Thread

8.8

10.9

12.9

Nm

kgm

Nm

kgm

Nm

kgm

M3

1.1

0.11

1.6

0.16

1.9

0.19

M4

3.1

0.32

4.5

0.46

5.3

0.54

M5

6.1

0.62

8.9

0.91

10.4

1.06

M6

10.4

1.06

15.5

1.58

18

1.84

M8

25

2.55

37

3.77

43

4.38

M10

51

5.20

75

7.65

87

8.87

M12

87

8.87

130

13.26

150

15.30

M14

140

14.28

205

20.90

240

24.47

M16

215

21.92

310

31.61

370

37.73

M18

300

30.59

430

43.85

510

52.01

M20

430

43.85

620

63.22

720

73.42

M22

580

59.14

830

84.64

970

98.91

M24

740

75.46

1060

108.09

1240

126.44


50-500

27


SEN03954-00 (1) Plugs i) Plugs with internal hexagon and profile seal ring

Tightening torque Thread

50-500


Nm

kgm

Nm

kgm

M8 x 1

5

0.51

G 1/8 A

10

1.02

M10 x 1

10

1.02

G 1/4 A

30

3.06

M12 x 1.5

20

2.04

G 3/8 A

35

3.57

M14 x 1.5

30

3.06

G 1/2 A

60

6.12

M16 x 1.5

35

3.57

G 3/4 A

90

9.18

M18 x 1.5

40

4.08

G1A

140

14.28

M20 x 1.5

50

5.10

G 11/4 A

240

24.47

M22 x 1.5

60

6.12

G 11/2 A

300

30.59

M26 x 1.5

70

7.14

M27 x 2

90

9.18

M30 x 1.5

100

10.20

M33 x 2

140

14.28

M42 x 2

240

24.47

M48 x 2

300

30.59

28



ii)

SEN03954-00

Plugs with internal hexagon, O-ring and UNF-, UN- threads to SAE J 514



Nm

kgm

Nm

kgm

7/16-20UNF

15

1.53

M12 x 1.5

20

2.04

1/2-20UNF

20

2.04

M14 x 1.5

30

3.06

9/16-18UNF

25

2.55

M27 x 1.5

90

9.18

3/4-16UNF

72

7.34

7/8-14UN

127

12.95

11/16-12UN

147

14.99

13/16-12UN

173

17.64

15/16-12UN

198

20.19

15/8-12UN

320

32.63

17/8-12UN

390

39.77


50-500

29


SEN03954-00 (2) SEAL-LOCK - sealing nuts


50-500

30

Nm

kgm

M6

10

1.02

M6 x 0.5

11

1.12

M8

22

2.24

M8 x 1

24

2.45

M10

40

4.08

M10 x 1

44

4.49

M12

69

7.04

M12 x 1.5

72

7.34

M14

110

11.22

M14 x 1.5

120

12.24

M16

170

17.34

M16 x 1.5

180

18.35



SEN03954-00

(3) Oval head screw Oval head screw with inner TORX, thread precoated with “Precote 80”

Tensile strength class 10.9

11.9

Thread Tightening torque Nm

kgm

Nm

kgm

M3

2.1

0.21

---

---

M4

4.7

0.48

---

---

M5

9.1

0.93

9.5

0.97

M6

15.8

1.61

---

---

M8

37.7

3.84

---

---


50-500

31

500 Hydraulic system Removal and installation of HST motor 1 assembly

SEN03954-00

Removal and installation of HST motor 1 assembly

4. 1

5.

Removal k k

k

k

a a

1.

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Slowly loosen the oil filler cap of the hydraulic tank to release the residual pressure in the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. Plug the disconnected hoses to prevent oil leakage. Put tags to the disconnected hoses and pipes and record the installed positions etc. on them.

k


2.

When the mounting bolts are removed, emergency circuit (8) may fall since it is installed to motor 1 with the hose mounting bolts. Take care.


Disconnect front drive shaft (1) from the transfer side. [*1]

6.

7. 3.

Disconnect port T1 hose (4) and port T2 hose (5). Disconnect port A hose (6) and port B hose (7).

Disconnect wiring connectors (T06) (2) and (T11) (3) from HST motor 1.

50-500

32

Support motor 1 assembly (9) with tool [1] placed on the transmission jack and remove 4 motor 1 mounting bolts. [*2] Supporting motor 1 assembly (9) with the hand, lower the transmission jack gradually to remove motor 1 assembly (9). 4

Motor 1 assembly: 60 kg



SEN03954-00

Installation q


[*1]

3

Drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}

[*2]

3

q

Motor 1 assembly mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}




50-500

33


SEN03954-00

Removal and installation of HST motor 2 assembly

k

k

k

a

5.

Disconnect port A hose (6) and port B hose (7).

6.

Support motor 2 assembly (8) with tool [1] placed on the transmission jack and remove 4 motor 2 mounting bolts. [*2]

7.

Supporting motor 2 assembly (8) with the hand, lower the transmission jack gradually to remove motor 2 assembly (8).

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Slowly loosen the oil filler cap of the hydraulic tank to release the residual pressure in the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery.

a

Plug the disconnected hoses to prevent oil leakage. Put tags to the disconnected hoses and pipes and record the installed positions etc. on them.

1.


2.

Disconnect port T1 block and hose (4) and port T2 block and hose (5).

1

Removal k

4.


Disconnect front drive shaft (1) from the transfer side. [*1]

4

3.

Motor 2 assembly: 60 kg

Disconnect wiring connectors (T07) (2) and (T10) (3) from HST motor 2.

50-500

34



SEN03954-00

Installation q


[*1]

3

Drive shaft mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}

[*2]

3

q

Motor 2 assembly mounting bolt: 245 – 309 Nm {25.0 – 31.5 kgm}




50-500

35

500 Hydraulic system Disassembly and assembly of HST motor assembly

SEN03954-00

Disassembly and assembly of HST motor assembly

2. 1

EP servo valve assembly and cover (HST motor 1)

Symbol

Part No.

4 02010-20783 790-201-2740 S 5 793T-417-1120 02010-20783

Part name

Bolt Push tool Push tool Bolt


Special tools

q t q q

CJW12101

1 1 1 1

Disassembly 1.

Seal 1) Protect drive shaft (1) with a tape etc. 2) Remove snap ring (2) and shim (3).

CJW11980

1)

3) 4)

Remove 4 mounting bolts and solenoid valve and housing assembly (5). a Take care of the spring which may jump out.

Tighten screws [1] into the holes of shaft seal (4) blocked with rubber. Pull out shaft seal (4) with pliers.

CJW11982 CJW11981

50-500

36



2) 3) 4)

SEN03954-00

Remove spring seat (7) and spring (8) from port plate (6). Remove spring seat (9) and spring (12). Remove spring seat (11) and spring (10).

6)

Cover 1] Remove cover (25). 2] Remove plug (26) from cover (25).

CJW11987 CJW11983

3. 5)

Disassemble the solenoid and housing assembly (5). 1] Remove caps (14), coil (15) and snap ring (16) of the solenoid in order.

HA servo valve and directional shuttle valve assembly and flushing valve assembly (HST motor 2)

CJW12104 CJW12163

2] 3] a 4] a

Remove spool (18) and bushing (19) from housing (13). Remove pin (20). Do not remove nut (21) and screw (22). Remove plugs (24) from housing (13). Do not remove plug (23).

CJW12103


50-500

37

SEN03954-00 1)

Remove the 4 mounting bolts and solenoid valve and housing assembly (27) from port plate (6). a Take care of the spring which may jump out.


4)

CJW12105

2) 3)

Disassemble 2 solenoids and housing assembly (27). 1] Remove caps (36) and (37), coils (38) and (39), and bushing (40) of the solenoid in order.

CJW12106

Remove spring seat (29) and spring (30) from port plate (6). Remove spring seat (31) and spring (34).

CJW12125

a

Disassemble the housing assembly according to the following procedure. 2] Remove snap ring (43), control bushing (44), and control piston (45) from housing (35). 3] Remove pin (46). a Do not remove nut (47) and screw (48).

CJW12108

50-500

38



4] 5] a

SEN03954-00

Remove control piston (49) and spring (50) from housing (35). Remove plug (51). Do not remove 5 plugs (52).

CJW12107

5)

Remove flushing valve assembly (53) from port plate (6).

CJW12112


50-500

39


SEN03954-00 6)

Disassemble flushing valve assembly (53) according to the following procedure. 1] Remove plug (54). 2] Remove spring (55), plunger (56), orifice (57), and snap ring (58). 3] Remove 2 plugs (59). 4] Remove spring (60), spring seat (61), and spool (62). 5] Remove plug (63). 6] Remove guide (64), orifice (65), and guide (66).

CJW12164

50-500

40



4.

SEN03954-00

Preparation of removal of port plate assembly (6) (Common to HST motors 1 and 2) 1) Break and remove plastic cap (71) and check installed dimension (a) of Minimum Flow Rate Adjustment screw (67).

CJW12111

CJW12165

6)

2) 3) 4)

5)

Loosen locknut (68) and remove Minimum Flow Rate Adjustment screw (67). Push piston (69) to set the angle of rotary group (70) to 0°. Break and remove plastic cap (71) and check installed dimension (b) of Maximum Flow Rate Adjustment screw (96). Remove Maximum Flow Rate Adjustment screw (96). a Plastic cap (71) is used to prevent rusting. Since a spare for it is not supplied, apply paint or take another rustpreventive measure after assembling.


Insert screw [6] to Maximum Flow Rate Adjustment screw and fix rotary group (70). Screw [6]: M12 × 100 mm or longer.

CJW12126

50-500

41


SEN03954-00 7) 8)

a

Make match marks (c) between port plate (6) and housing (82). Remove port plate assembly (6).

CJW12115

5.

Check of port plate q Sliding surface and side guides free of scoring and no wear.

CJW12002

a

Disassemble port plate (6) assembly according to the following procedure. 1) Remove control lens (80). 2) Remove bolt (73) and piston (74). a Do not remove screw (76), rod (72), and piston (69).

Check of control plate Faces smooth and even, free of cracks and scoring.

CJW12039 CJW12113

6.

3) 4) 5)

Screw a bolt of M4 and pull out valve guide (77). Remove poppet (78). Remove valve seat (79).

Removal of shaft and rotary group assembly (81) 1) Remove O-ring (75). 2) Screw [2] in threaded pin into center pin (d). a Fix the cylinder with disc and locknut. q Screw size: M6 × 92 mm 3) Remove screw [6].

CJW12119 CJW12127

50-500

42



4)

SEN03954-00 a

Push the shaft end with a press to remove shaft and rotary group assembly (81) from housing (82). k If the bearings are used again, do not hit on the drive shaft.

Check of housing q Sliding surface and slide guides free of scoring and no wear.

CJW12008 CJW12005

a a

If a press is not available, push the shaft end with tool [3] or [4] to remove rotary group assembly (81).

7.

Since shaft and bearing are used as an assembly, do not remove the bearing.

Disassembly of rotary group assembly (70) 1) Remove screw [2]. 2) Remove cylinder block (83).

CJW12006 CJW12009

3)

Remove shim (84) from cylinder block (83).

CJW12007

CJW12011


50-500

43

SEN03954-00 a


a

Check of cylinder block (83) Bores free of scoring, no evidence of wear.

q

Check of piston and center pin q No scoring and no pittings.

CJW12014 CJW12010

a 4)

5)

Remove retaining ring assembly (85). a Screws are glued. Warm it up to max. 120°C and remove with Torx-tools. Remove 7 pistons (86), spring (87), and center pin (88) from shaft and bearing assembly (89).

Do not disassemble the drive shaft and bearing assembly (89). (If the drive shaft and be ar i ng a ss e mb ly i s de fe c ti ve , replace it whole.)

CJW12116 CJW12128

a

Check of retaining ring (85) No scoring and no evidence of wear.

q

CJW12013

50-500

44



SEN03954-00

Assembly a a a

1.

4)

Clean the all parts and remove burrs, etc. Coat the rotary parts and sliding parts with engine oil (for details, see “Table of fuel, coolant and lubricants”) before installing. If the tightening torque of a mounting bolt, nut, or plug is not shown in this manual, see the tightening torque table.

CJW12022

Assembly of rotary group assembly (70) a If the drive shaft and bearing assembly (89) is defective, replace it whole. (The parts of this assembly cannot be supplied loose.) 1) Install 7 pistons (86), center pin (88), and spring (87) to the drive shaft and bearing assembly (89). 2) Install retaining ring assembly (85) with the screw. a For the tightening torque of the screw, see “Tightening torque table”.

5)

CJW12128

3)

Insert shim (84), center pin (88), and piston (86) in cylinder block (83). a Make sure all parts are fitted in correctly.

Insert the piston to the end of cylinder block (83) and secure it with screw [2].

Set bolt S4 to the shaft and rotary group assembly (81) and protect the drive shaft by type. a Threads of shaft: 7/16-14UNC-2B, Thread depth: 28 mm

CJW12169

2.

Installation of rotary group assembly 1) Heat housing (82) to 80°C.

CJW12024 CJW12021


50-500

45


SEN03954-00 2)

Insert shaft and rotary group assembly (81) into housing (82) to seat position.

3.

Port plate assembly (6) 1) Assemble port plate assembly (6) according to the following procedure. 1] Install valve seat (79). 2] Install poppet (78). 3] Install valve guide (77).

CJW12117

CJW12119

3)

4) 5)

Insert screw [6] (M12 × 100 mm or longer). (Fix the tapered part of cylinder block (83) and set the angle to 0°.) Remove screw [2]. Install O-ring (75) to the housing.

a 4] 5]

Piston (69), rod (72) and screw (76) are already in the port plate (6). Install piston (74) and bolt (73). Thinly apply grease to control plate (80), and then install it to the sliding surface of the port plate assembly (6).

CJW12118

CJW12113

50-500

46



a 2)

SEN03954-00

Take care of assembly design! Install port plate assembly (6) to housing (82), matching marks (c) made when it was removed.

CJW12122

CJW12115

4.

Installation of Minimum Flow Rate Adjustment screw (67) and Maximum Flow Rate Adjustment screw (96). 1) Remove screw [6] and set Maximum Flow Rate Adjustment screw (96). Dimension (b) is the value measured at the time of disassembly. a When bolt is changed q Since the bolt is used to plug the hole simply, do not replace it with long one. 2) Swivel rotary group (70) to “starting position”. 3) Set Minimum Flow Rate Adjustment screw (67) to dimension (a). a Dimension (a) is important for all the type. a Tighten fixing screws (67) and (96) with torque.


50-500

47


SEN03954-00 5.

HA servo valve and directional shuttle valve assembly and flushing valve assembly (53) (HST motor 2) 1) Assemble the flushing valve assembly according to the following procedure. 1] Install guide (66), orifice (65), and guide (64). 3 Guide (66): 3 Nm {0.31 kgm} 3 Guide (64): 8 Nm {0.81 kgm} 2] Install plug (63). 3 Plug: 29 – 38 Nm {2.96 – 3.89 kgm}

3] 4] 5] 6]

Install spool (62), spring seat (61), and spring (60). Install 2 plugs (59). 3 Plug: 40 Nm {4.1 kgm} Install snap ring (58), orifice (57), plunger (56), and spring (55). Install plug (54). 3 Plug: 50 Nm {5.1 kgm}

CJW12164

50-500

48



2)

SEN03954-00

Install flushing valve assembly (53) to port plate (6). 3 Plug: 55 – 60 Nm {5.61 – 6.12 kgm}

6] a

CJW12112

3)

Install 2 solenoids to housing (35). Install bushing (40), coils (39) and (38), and caps (37) and (36) of the solenoid in order.

CJW12106

Assemble housing assembly (27) according to the following procedure. 1] Install plug (51) to housing (35). 2] Install spring (50) and control piston (49) to housing (35). a 5 plugs (52) are already in the housing (35).

CJW12107

4) 5)

3] 4] 5]

Install pin (46). Install control piston (45) and control bushing (44). Install snap ring (43).

Install spring (34) and spring seat (31) to the port plate. Install spring (30) and spring seat (29).

CJW12125

CJW12108


50-500

49

SEN03954-00 6)

Install solenoid valve and housing assembly (27) with the 4 mounting bolts to port plate (6).


2)

Assemble housing assembly (5) according to the following procedure. 1] Install plug (24) to housing (13). 2] Install pin (20). 3] Install bushing (19) and spool (18) to housing (13). a Plugs (23) are already in the housing (13).

CJW12105

CJW12103

6.

EP servo valve assembly and cover (HST motor 1) 1) Cover 1] Install plug (26) to cover (25). 3 Plug: 29 – 38 Nm {3.0 – 3.9 kgm} 2] Install cover (25). 3 Mounting bolt: 39 – 49 Nm {4.0 – 5.0 kgm}

4]

Install snap ring (16), coil (15), and cap (14) in order to housing assembly (13).

CJW12102 CJW11987

50-500

50



3) 4) 5)

SEN03954-00

Install spring (10) and spring seat (11) to port plate (6). Install spring (12) and spring seat (9). Install spring (8) and spring seat (7).

5) 6)

Protect drive shaft (1) with a tape etc. Install snap ring (2).

CJW11980 CJW11983

8. 6)

Install solenoid valve and housing assembly (5) with the 4 mounting bolts.

Filling with oil Fill up hydraulic aggregates with medium before start-up.

CJW12036 CJW11982

7.

Seal (Common to HST motors 1 and 2) 1) Before setting seal (4), measure depth (f) to the groove bottom of snap ring (2). 2) Make a mark of insertion depth (e) of push tool S5, (f) + thickness of shim (3), on push tool S5. 3) Using push tool S5, press fit seal (4). 4) Install shim (3).

CJW12170


9. a

Tightening torque table If the tightening torque of a mounting bolt, nut, or plug is not shown in this manual, see Disassembly and assembly of HST pump assembly, “Tightening torque table”.

10. Before starting a Observe the operating instructions before starting. q Check the machine for remarkable faults. q Do not operate the machine with defective instruments, warning lights or control elements. q All safety devices must be in a secure position. q Do not carry with you movable objects or secure them to the machine. q Keep oily and inflammable material away from the machine. q Before entering the operator’s cab, check if persons or obstacles are beside or beneath the machine. q Be careful when entering the operator’s cab, use stairs and handles. q Adjust your seat before starting. 50-500

51

SEN03954-00

500 Hydraulic system Removal and installation of work equipment control valve assembly

Removal and installation of work equipment control valve assembly

3. 1

Removal k

k k

k

1.

2.

Stop the machine on a level place and, apply the parking brake, and put chocks under the tires. Support the lift arm securely. Stop the engine, and then slowly loosen the oil filler cap of the hydraulic tank to release the residual pressure in the hydraulic tank. Operate the work equipment control lever 2 – 3 times to release the residual pressure in the work equipment circuit. Raise the lift arm, dump the bucket, and support the lift arm with support stand [1] and square bar [2].

Remove the work equipment control valve upper cover (1).

50-500

52

Disconnect the following hoses and tubes. [*1] a Mark all the hoses and tubes with tags to prevent mistakes in the mounting position when installing. a Plug the disconnected hoses to prevent oil leakage. a Since oil will leak through the disconnected hoses and tubes, prepare oil receivers. q (2): Port A1 hose q (3): Port B1 hose q (4): Port A2 tube q (5): Port B2 tube q (6): Bucket DUMP PPC hose q (7): Bucket TILT PPC hose q (8): Lift arm LOWER PPC hose q (9): Lift arm RAISE PPC hose q (10): Port P hose q (11), (12): Port T hoses

Reference: This is the view from the rear lower part of the work equipment control valve.


500 Hydraulic system Removal and installation of work equipment control valve assembly

4.

Remove 3 mounting bolts (13) and move work equipment control valve (14) toward you.

SEN03954-00

Installation q


[*1] a Connect PPC hoses (6) – (9) according to their band colors as shown below. a Connect each PPC hose having an even No. to the rear of the PPC hose having a corresponding odd No. on the work equipment valve: Connect (6) to the rear of (7), (8) to the rear of (9). q Work equipment lever specification: 2-lever q Work equipment lever specification: Monolever (If equipped) 5.

Lift off work equipment control valve assembly (15). 4

Work equipment control valve assembly: 65 kg

q

No.

Connecting point

Band color

(6)

Bucket DUMP

Blue

(7)

Bucket TILT

Red

(8)

Lift arm LOWER

Orange

(9)

Lift arm RAISE

Yellow




50-500

53

500 Hydraulic system Removal and installation of hydraulic tank assembly

SEN03954-00

Removal and installation of hydraulic tank assembly

1

4.

Remove tube (4) from the hydraulic oil filter.

5.

Remove hydraulic oil filter cover mounting bolts (5) and move hydraulic oil filter and cover assembly (6) and its hoses to under the operator's cab.

6.

Disconnect 8 hoses (7), (8), (9), (10), (11), (12), (13), and (14) from the hydraulic tank. [*1]

Removal k k

k

a a

1.

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Operate the work equipment control lever 2 – 3 times to release the residual pressure in the work equipment circuit. Plug the disconnected hoses to prevent oil leakage. Put tags to the disconnected hoses and pipes and record the installed positions etc. on them. Remove hydraulic tank upper cover (1). k Slowly loosen the oil filler cap of the hydraulic tank to release the residual pressure in the hydraulic tank.

2.

Remove cab right undercover (2).

3.

Remove right side fender (3). 4

50-500

Fender: 35kg

54


500 Hydraulic system Removal and installation of hydraulic tank assembly

7.

Sling the hydraulic tank assembly temporarily and remove 1 upper mounting bolt and 2 lower mounting bolts (15). [*2]

SEN03954-00

Installation q


[*1]

2

3

Inserting parts of hoses (6) and (7): Gasket sealant (ThreeBond 1206E or equivalent) Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}

[*2]

3

q

8.

Lift off hydraulic tank (16) and ladder together. 4

Hydraulic tank and ladder assembly: 210 kg (including hydraulic oil)

Hydraulic tank mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}




50-500

55

500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly

SEN03954-00

Disassembly and assembly of hydraulic cylinder assembly

Disassembly 1

1.

Cylinder assembly Set cylinder assembly (1) to tool U1.

2.

Cylinder head and piston rod assembly (Steering cylinder) 1) Using tool U2, remove cylinder head (2) from the cylinder.

790-502-1003

Repair stand

t 1

790-101-1102

Hydraulic pump

t 1

1 790-102-2303 2 or 790-102-3802

Wrench assembly t 1 (for steering)

3 790-302-1340

Socket (for steering) t 1

U

t 1

790-201-1702

Push tool kit

790-101-5021

• Grip

1

01010-50816

• Bolt

1

• Push tool (lift)

1

790-201-1831

• Push tool (bucket)

1

790-201-1741

• Push tool (steering)

1

790-201-1500

Push tool kit

t 1

790-101-5021

• Grip

1

01010-50816

• Bolt

1

790-201-1630

• Plate (lift)

1

790-201-1640

• Plate (bucket)

1

790-201-1550

• Plate (steering)

1

4 790-201-1821

Sketch

Part Name

New/Remodel

Part No.

Q'ty

Symbol

Necessity

Special tools

2)

Pull cylinder head and piston rod assembly (3) out of cylinder (4). a Since oil will flow out when the piston rod assembly is pulled out of the cylinder, prepare an oil receiver.

5

Expander

q 1

796-720-1680

Ring (lift, bucket)

q 1

07281-01589

Clamp (lift, bucket)

q 1

796-720-1740

Ring (steering)

q 1

07281-00809

Clamp (steering)

q 1

790-102-4300

Wrench assembly t 1 (lift, bucket)

790-102-4310

Pin

6 790-720-1000

7

8

50-500

56

t 2



3.

Cylinder head and piston rod assembly (Bucket cylinder and lift cylinder) 1) Remove the mounting bolt of cylinder head assembly (2). q Width across flats of bolt: 24 mm

2)

SEN03954-00 4.

Piston and cylinder head (Steering cylinder) 1) Set cylinder head and piston rod assembly (3) to tool U1. 2) Using tool U3, remove nut (5). q Width across flats of nut (Steering): 46 mm 3) Remove piston assembly (6) and cylinder head assembly (2).

Pull cylinder head and piston rod assembly (3) out of cylinder (4). a Since oil will flow out when the piston rod assembly is pulled out of the cylinder, prepare an oil receiver.


50-500

57

SEN03954-00 5.

Piston and cylinder head (Bucket cylinder and lift cylinder) 1) Set cylinder head and piston rod assembly (3) to tool U1. 2) Remove lock screw (18) of the piston assembly. a Screw size: M12 x 1.75 a If screw (18) is so caulked that it cannot be removed, tighten it and apply a ta p to t he th r ead s o f the p is to n assembly, and then remove it. 3) Using tool U8, remove piston assembly (6). a When not using tool U8, loosen the piston assembly by using 2 holes (A). q Hole (A): φ10 mm 4) Remove cylinder head assembly (2).


6.

Disassembly of piston assembly 1) Remove wear ring (9) and piston ring (10) from piston (8).

a

2)

50-500

58

For only the bucket cylinder and lift cylinder. Remove O-ring and backup ring (11) from position (8).



7.

Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16) and dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20). 6) Remove O-ring (21). (For only the steering cylinder) a Bucket cylinder and lift cylinder

a

SEN03954-00

Assembly a a

1.

Take care not to damage the packings, dust seals, O-rings, etc. Do not insert each backup ring forcibly, but warm it in water at 50 – 60°C and then insert it. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (20). 2) Install buffer ring (19). 3) Install rod packing (18). 4) Using tool U5, install dust seal (17) and secure it with snap ring (16). 5) Install backup ring and O-ring (15). 6) Install O-ring (21). (For only the steering cylinder.)

Steering cylinder


50-500

59

SEN03954-00 2.

Assembly of piston assembly 1) Using tool U6, expand piston ring (10). a Set the tool to the piston ring and turn its handle by 8 – 10 turns to expand the piston ring.


3.

Assembly of cylinder head and piston rod assembly (Steering cylinder assembly) 1) Set cylinder head and piston rod assembly (3) to tool U1. 2) Install cylinder head assembly (2) and piston assembly (6) to the piston rod. 3) Using tool U3, tighten nut (5) to the specified torque. a Degrease and clean the threads of nut (5) and piston rod. 2 Threads of piston rod: Liquid adhesive (LOCTITE No. 262 or equivalent) q

Width across flats of nut: 46 mm Nut (Steering): 785 ± 78.5 Nm {80 ± 8.0 kgm}

3

2) 3) 4)

Remove piston ring (10) from tool U6 and install it to piston (8). Using tool U7, shrink piston ring (10). Install wear ring (9).

4.

a

5)

50-500

For only the bucket cylinder and lift cylinder. Install backup ring and O-ring (11).

60

Assembly of cylinder head and piston rod assembly (Bucket cylinder and lift cylinder) 1) Set piston rod (3) to tool U1. 2) Install cylinder head assembly (2). q When reusing the rod and piston assembly, assemble them according to the following procedure. 3) Using tightening tool U8, tighten piston assembly (6) until the screw holes are aligned. Go to 6). q When replacing either or both of the rod and piston, assemble the new parts according to the following procedure. 4) Using tool U8, install piston assembly (6). 3 When threading lock screw: 294 ± 29.4 Nm {30 ± 3 kgm} a When not using tool U8, loosen the piston assembly by using 2 holes (A). q Hole (A): φ10 mm



SEN03954-00 5.

5)

Make 1 screw hole to install screw (18). a Make 1 hole horizontally with a drill at the V-groove of the threaded parts of piston assembly (6) and rod (3).

Diameter of Depth of tap tap drill hole drill hole 10.3

Cylinder head (Steering cylinder) 1) Set cylinder (4) to tool U1. 2) Sling cylinder head and piston rod assembly (3) and install cylinder (4).

27

Tap to be used

Tapping depth

12 X 1.75

20

3)

4) 6)

Install lock screw (18) and caulk 4 points around it with a punch. a Degrease and clean the fitting part of the lock screw. 2 Threads of lock screw: Liqui d ad he sive (L OCTITE No. 262 or equivalent) 3 Lock screw: 58.9 – 73.6 Nm {6 – 7.5 kgm}


Using tool U2, install cylinder head assembly (2) to the cylinder. 3 Cylinder head: 539 ± 54.0 Nm {55 ± 5.5 kgm} Remove cylinder assembly (1) from tool U1.

50-500

61

SEN03954-00 6.


Cylinder head (Bucket cylinder and lift cylinder) 1) Set cylinder (4) to tool U1. 2) Sling cylinder head and piston rod assembly (3) and install cylinder (4). 3) Install cylinder head assembly (2) to the cylinder. 3 Cylinder head (Bucket): 250 ± 24.5 Nm {25.5 ± 2.5 kgm} 3 Cylinder head (Lift): 162 ± 14.5 Nm {16.5 ± 1.5 kgm}

4)

5)

50-500

a For only the bucket cylinder. Adjust the leveler plate to the following dimensions and tighten the bolt. Dimension (a): 48 ± 1 mm Dimension (b): 119 ± 2 mm

Remove cylinder assembly (1) from tool U1.

62




SEN03954-00

50-500

63

SEN03954-00



50-500

64

SEN03955-00





50

600 Work equipment Removal and installation of work equipment assembly .................................................................................. 2


50-600

1

600 Work equipment Removal and installation of work equipment assembly

SEN03955-00

Removal and installation of work equipment assembly

k

k

1.

4.

Sling bucket cylinder assembly (3) temporarily and pull out rod-side pin (4) to disconnect the cylinder rod and bell crank. [*3] a Install block [1] between the cylinder bottom and frame. a Record the thickness and quantity of the shims.

Stop the machine on a level place and set the lock bar to the frame. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery.

4

Bucket cylinder assembly: 130 kg

Sling the bucket link temporarily and remove bucket link pin (1). [*1] 4

a a

2.

Move the machine to the rear and disconnect the bucket.

1

Removal k

3.

Bucket link assembly: 45 kg

Secure the bucket link to the bell crank with wires, etc. Record the thickness and quantity of the shims.

Remove bucket hinge mounting pin (2). [*2] k Never insert your fingers in the pin holes. a Record the thickness and quantity of the shims. 5.

50-600

2

Set supports [2] under the end of the lift arm and release the residual pressure in the hydraulic piping.



6.

SEN03955-00

Sling lift cylinder assembly (6) temporarily and remove mounting pin (5). [*4] a Record the thickness and quantity of the shims. a When lowering the lift cylinder assembly, put a block on the axle. 4

Lift cylinder assembly (1 pieces): 110 kg

11. Sling bucket link assembly (12) temporarily, pull out mounting pin (13), and remove the bucket link assembly from the bell crank assembly. [*7] 4

7.

Disconnect boom kick-out proximity switch connector CN-F04 (7).

8.

Remove boom kick-out switch (8).

Bucket link assembly: 45 kg

[*5]

12. Sling bell crank assembly (14) temporarily and pull out mounting pin (15). [*8] 13. Lift off bell crank assembly (14). 4

Bell crank assembly: 260 kg

9.

Sling lift arm and bell crank and bucket link assembly (10) temporarily and pull out mounting pin (11). [*6] a Record the thickness and quantity of the shims. a 10. Lift off lift arm and bell crank and bucket link assembly (10). 4

Lift arm and bell crank and bucket link assembly: 1250 kg


50-600

3


SEN03955-00 14. Pull dust seal (17) and bushing (18) out of lift arm (16). [*9]

Installation q k

k

a a

15. Pull dust seal (19) and bushing (20) out of bell crank (14). [*9]

Carry out installation in the reverse order to removal. When starting the engine, check that the directional lever is in neutral and the parking brake is applied. When aligning the pin holes, use a bar. Never insert your fingers in the pin holes. Apply specified lubricant to the seal so that the seal will not be damaged when the pin is inserted. Supply grease to each pin until it comes out through the joint.

[*1] Procedure for installing bucket link pin 1. Sling the bucket link assembly and install cord ring (23), aligning the holes for mounting pin (1). 2.

Insert shims on both sides so that clearances (a) on both sides will be the same. q Clearance (a) (On each side): Max. 1.5 mm q Varieties of shim thickness: 1.5, 3.0 mm

3.

Install mounting pin (1) and lock it with bolt (24). k Never insert your fingers in the pin holes. a Take care that the cord ring will not be caught.

16. Pull dust seal (21) and bushing (22) out of bucket link assembly (12). [*9]

50-600

4



[*2] Procedure for installing bucket hinge pin 1. Operate the control lever to align the holes for bucket mounting pin (2) and install cord ring (25). 2.

Insert a shim in clearance (b). q Clearance (b) (On each side): Max. 1.5 mm q Varieties of shim thickness: 1.5, 3.0 mm

3.

Install mounting pin (2) and lock it with bolt (26). k Never insert your fingers in the pin holes. a Take care that the cord ring will not be caught. a Take care not to damage the pin. a Before installing the pin, apply lubricant to the inside of the bushing. 2 Inside of bushing and seal: Lubricant containing molybdenum disulfide (LM-P or equivalent) a After installing the pin, supply grease. 2 Grease: Hyper White (G2-T) or equivalent

SEN03955-00 [*3] Procedure for installing bucket cylinder pin (on rod side) a It is not necessary to insert a shim in clearance (C). 1. Install mounting pin (4) and lock it with bolt (27). k Never insert your fingers in the pin holes. a Take care not to damage the pin. a Before installing the pin, apply lubricant to the inside of the bushing. 2 Inside of bushing: Lubricant containing molybdenum disulfide (LM-P or equivalent) a After installing the pin, supply grease. 3 Grease: Hyper White (G2-T) or equivalent

2.


Adjust the bucket positioner. For details, see Testing and adjusting, “Testing and adjusting bucket positioner”.

50-600

5

SEN03955-00 [*4] Procedure for installing lift cylinder pin (on rod side) k When starting the engine, check that the directional lever is in neutral and the parking brake is applied. 1. Insert a shim in clearance (d). q Clearance (d) (On each side): Max. 1.5 mm q Varieties of shim thickness: Only 1.5 mm 2.

Install mounting pin (5) and lock it with bolt (28). k Never insert your fingers in the pin holes. a Take care not to damage the pin. a Before installing the pin, apply lubricant to the inside of the bushing. 2 Inside of bushing: Lubricant containing molybdenum disulfide (LM-P or equivalent) a After installing the pin, supply grease. 2 Grease: Hyper White (G2-T) or equivalent


[*6] Procedure for installing lift arm pin (on frame side) 1. Insert a shim in clearance (e). a When installing the right-hand lift arm pin, fit the boss on the right inside of the frame to the lift arm boss to eliminate the clearance and insert shims in the clearance on the opposite side. a When installing the left-hand lift arm pin, insert shims evenly on both sides. q Clearance (e) (On each side): Max. 1.5 mm q Varieties of shim thickness: 1.5, 3.0 mm 2. Install mounting pin (11) and lock it with bolt (29). k Never insert your fingers in the pin holes. a Take care not to damage the pin and seal. a Before installing the pin, apply lubricant to the inside of the bushing. 2 Inside of bushing: Lubricant containing molybdenum disulfide (LM-P or equivalent) a After installing the pin, supply grease. 2 Grease: Hyper White (G2-T) or equivalent

[*5] a Adjust the boom kick-out. For details, see Testing and adjusting, “Testing and adjusting of boom kick-out”.

50-600

6



[*7] Procedure for installing bucket link pin a It is not necessary to insert a shim in clearance (f). q Clearance (f) (On each side): Max. 1.5 mm a Secure the bucket link to the bell crank with chains, etc. 1. Install cord ring (30), aligning the holes for bucket link mounting pin (13). 2.

Install mounting pin (13) and lock it with bolt (31). k Never insert your fingers in the pin holes. a Take care that the cord ring will not be caught. a Take care not to damage the pin and seal. a Before installing the pin, apply lubricant to the inside of the bushing. 2 Inside of bushing: Lubricant containing molybdenum disulfide (LM-P or equivalent) a After installing the pin, supply grease. 2 Grease: Hyper White (G2-T) or equivalent

SEN03955-00 [*8] Procedure for installing bell crank center pin a It is not necessary to insert a shim. 1. Install the mounting pin and lock with the bolt. k Never insert your fingers in the pin holes. a Take care not to damage the pin and seal. a Before installing the pin, apply lubricant to the inside of the bushing and the seal. 2 Inside of bushing and seal: Lubricant containing molybdenum disulfide (LM-P or equivalent) or Hyper White (G2-T) [*9] a Press fit bushings (18), (20), and (22) to lift arm (16), bell crank (14), and bucket link (12) respectively with hydraulic cylinder [3] and then install dust seals. 2 Bushing: Grease (G2-LI) a Apply the grease to the seals to prevent their damages.

a q q

q


Press fit the dust seals with the lips out. Installed dimension (g): 0.25 – 0.80 mm Installed dimension (h): 2 – 3 mm

Greasing Supply grease to each pin. a Supply grease until it comes out of the joint.

50-600

7

SEN03955-00



50-600

8

SEN03956-00





50

700 Cab and its attachments Removal and installation of operator's cab and floor frame assembly............................................................ 2 Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 8 Disassembly and assembly of operator's seat assembly.............................................................................. 16 Removal and installation of air conditioner unit ............................................................................................ 26


50-700

1

SEN03956-00

Removal and installation of operator's cab and floor frame assembly

700 Cab and its attachments Removal and installation of operator's cab and floor frame assembly

1

3.

Open and fix right engine side cover (1). a Check that the cover is locked securely.

4.

Remove right fender (2). 4

Removal k

k

k

q

a

Fender: 35 kg

Stop the machine on a level ground and install the lock bar to the frame to lock the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Precautions for handling refrigerant k Collect refrigerant (R134a) beforehand. a Ask professional traders for collecting and filling the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant (R134a) gets inside ones eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person. k If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant is cooled, and then drain the coolant.

1.

The operator's cab of this machine forms one unit with the floor frame. Recover the refrigerant (R134a). For details, see “Removal and installation of air conditioner unit”. [*1]

2.

Drain the coolant from the radiator. 6

50-700

2

5.

Remove right covers (3), (4) and (5).

6.

Remove hydraulic tank cover (6). k Loosen the hydraulic tank cap gradually to release the pressure in the hydraulic tank.

7.

Disconnect cab ground cable (7) from the lower right of the floor.

8.





9.

SEN03956-00

Disconnect the following wiring harness connectors from the lower right of the floor. q (9): CN-FL2 q (10): CN-FL1 q (11): CN-FL4 q (12): CN-FL3

14. Remove left fender (22). 4

Fender: 35 kg

10. Disconnect 6 PPC hoses (13). 11. Disconnect hose (14) from the brake valve. 12. Disconnect T port hose (15) from the Orbit-roll valve.

15. Remove left covers (23), (24) and (25). 16. Remove air conditioner external air filter case cover (26).

13. Disconnect the following hoses from Orbit-roll valve (16). [*2] q (17): LS port hose (Right) q (18): P port hose (Left lower) q (19): R port hose (Right lower) q (20): L port hose (Right upper) q (21): T port hose (Left upper) (Since hose (21) was disconnected in the previous step from the hydraulic tank, it does not need to disconnect in this step.) a Plug the disconnected hoses to prevent oil leakage. a Put tags to the disconnected hoses and record the installed positions etc. on them.


50-700

3

SEN03956-00


17. Disconnect the following wiring harness connectors from the lower left of the floor. q (27): CN-LR1 q (28): CN-LR10 q (29): CN-LR2 q (30): CN-LR3 q (31): CN-LR12 q (32): CN-LR4 q (33): CN-LT1 q (34): CN-LT12 q (35): CN-LR7 q (36): CN-LR11 q (37): CN-LR6 a Put tags to the disconnected connectors and record the installed positions etc. on them.

19. Disconnect 2 washer hoses (41) from the engine compartment side. 20. Disconnect air conditioner pipes (42) and (43). [*1] 21. Disconnect heater hoses (44) and (45) from the engine side. a Put tags to the disconnected hoses and record the installed positions etc. on them. a Plug the disconnected hoses to prevent oil leakage.

22. Remove air conditioner pipe clamps (46) and (47) from the lower left of the floor.

18. Remove wiring harness clamps (38), (39) and (40).

50-700

4



23. Disconnect the following hoses from the top of brake valve (48). [*3] q (49): A port hose q (50): B port hose q (51): P1 port hose

SEN03956-00

25. Set parking brake lever (53) in the OFF (Release) position. 26. Remove seat belt mounting bolt (54). 27. Remove cover (55).

24. Disconnect the following hoses from brake valve (46). [*3] q (52): T2 port hose q (53): PB port hose q (54): PA port hose a Plug the disconnected hoses to prevent oil leakage. a Put tags to the disconnected hoses and record the installed positions etc. on them.

AJF00729

28. Loosen locknut (56) and remove pin (57). 29. Pull out grommet (58) and brake cable (59) together toward under the floor.

AJF00729


50-700

5

SEN03956-00


30. Remove right and left front mount covers (60).

Installation q

31. Remove right and left rear fender brackets (61).

32. Remove right and left front operator's cab mounting nuts (62). [*4] 33. Remove right and left rear operator's cab mounting nuts (63). [*5]

34. Lift off operator's cab and floor frame assembly (64). a Check that all the wiring and piping are disconnected. 4

Operator's cab and floor frame assembly: 900 kg

AJF00729


[*1] a When installing the hoses of the air conditioner circuit, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner hose, check that O-ring (70) is fitted to it. a Check O-ring (70) for a flaw and deterioration. a When connecting each refrigerant pipe, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8 or ZEXEL ZXL100PG (equivalent to PAG46)) to O-ring (70). 3 Apply engine oil (EO15W-40) to threaded part and seat of mounting bolt. 3 Threaded part of hose (M16 × 1.5): 12 – 15 Nm {1.2 – 1.5 kgm} 3 Threaded part of hose (M22 × 1.5): 20 – 25 Nm {2.0 – 2.5 kgm} 3 Threaded part of hose (M24 × 1.5): 30 – 35 Nm {3.0 – 3.5 kgm}

q

Charging with refrigerant (R134a) Charge the air conditioner circuit with refrigerant (R134a). a Charge capacity: 1,200 ± 50 g

[*2] Bleed air from the steering circuit. For details, see Testing and adjusting, "Bleeding air from steering circuit". [*3] Bleed air from the brake system. For details, see Testing and adjusting, "Bleeding air from brake circuit". [*4]

3

50-700

6

Right and left front operator's cab mounting nuts (62): 824 – 1,030 Nm {84 – 105 kgm}



SEN03956-00

[*5]

3

q


q

Right and left rear operator's cab mounting nuts (63): 824 – 1,030 Nm {84 – 105 kgm}

Hydraulic oil (For details, see "Table of fuel, coolant and lubricants"): Only necessary quantity


Total amount of coolant: 26.5 l (For details, see "Table of fuel, coolant and lubricants")


50-700

7

700 Cab and its attachments Removal and installation of operator's cab glass (Stuck glass)

SEN03956-00

a

Removal and installation of operator's cab glass (Stuck glass)1

Symbol

Part No.

1 793-498-1120 1 2 793-498-1130 X 3 793-498-1110 2

793-498-1210

Part Name

Clear plate Plate Magnet Lifter (Suction cups)


Special tools

If the glass is narrow, you may cut the adhesive by the following method. Insert a fine wire [2] (piano wire, etc.) in the adhesive and grip its both ends with pliers [3], etc. (or hold them by winding them onto something) and cut the adhesive with the wire.

t 2 t 2 t 2

CPW11602

t 2

Removal a a

1.

All sides of each glass of the operator's cab of this machine are stuck. Remove the window glass to be replaced according to the following procedure.

a

Using seal cutter [1], cut the adhesive between broken window glass (1) and operator's cab (2). a

The broken window glass may be removed with knife [4] and a screwdriver. (If the screwdriver is applied directly to the normal window glass, the glass will be broken.) When using knife [4], insert a screwdriver in the cut to widen it and move the knife forward.

CPW11601

CPW11607

2.

50-700

8

Remove the window glass.



Installation 1.

SEN03956-00 3.

Using scraper [5], remove the remaining adhesive. a Do not scratch the paint.

When the adhesive was removed with the scraper, if any paint was flaked off, coat the bare part with paint. a If the glass is installed without repairing the bare part, that part will be rusted. a Do not apply paint to a part which will be coated with primer.

CPW11603 CPW11605

2.

Remove oil, dust, dirt, etc. from the sticking surfaces of cab (2) and window glass (3) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.

4.

Stick both-sided adhesive tape (4) along the inside edge of the glass sticking section. q Size of both-sided adhesive tape: 7 × 4.8 mm a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass.

CPW11604

CPW11606


50-700

9

SEN03956-00 a


Take care the corner (part (b)) of bothsided adhesive tape will not float.

CPW11614 CPW11633

3) a

When sticking the both-sided adhesive tape around a side or a rear window glass, start at center of the top and make a clearance of about 5 mm at end joint (c).

Using tool X2 (suction cups), place window glass (3) on tool X1-1 (5 mm spacer) and match it to the operator's cab.

CPW11615 CWW11608

4)

5.

Position the replacement glass. 1) Stick X1-2 (thin steel sheet) to tool X1-1 (spacer) with adhesive. q Spacer thickness ( t) : 5 mm 2) Match tool X1-3 (magnet) to tools X1-1 and X1-2 and set them to the 2 lower places of the window glass sticking part of operator's cab (2).

5)

6)

Check the clearance between window glass (3) and operator's cab (2) on both sides and adjust it evenly. Stick tape [6] between window glass (3) and operator's cab (2) and draw positioning line (a). Cut the tape between window glass (3) and operator's cab (2) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass.

CPW11613 CPW11616

50-700

10



6.

Apply primer. a The using limit of primer (5) is 4 months after the date of manufacture. Do not use primer (5) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (6), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer and glass primer.

CPW11609

3)

SEN03956-00 a

a a

Parts to be coated with primer: Apply the primer all over dimension (d) on the outside of the both-sided adhesive tape. q Dimension to apply primer (d): 23 mm After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. If the glass primer is applied by mistake, wipe it off with white gasoline. (If wrong primer is applied, the glass will not be stuck.)

CPW11610

CWW11624

Evenly apply paint primer (7) to the parts on the outside of both-sided adhesive tape (4) on operator's cab (2) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPRE a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)


50-700

11

SEN03956-00 4)

Evenly apply glass primer (8) to the black part of window glass (3) to be stuck. 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPRE a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.) a Parts to be coated with primer: Apply the primer to the sticking surface of window glass (3) and all over dimension (d) on both-sided adhesive tape (4) and operator's cab (2). q Dimension to apply primer (d): 23 mm a Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a If the paint primer is applied by mistake, wipe it off with white gasoline. (If wrong primer is applied, the glass will not be stuck.)


7.

Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER “S” 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER “W” a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip. 1) Break aluminum seal (10) of the outlet of adhesive cartridge (9) and install the nozzle.

CPW11612

CWW11625 2)

Cut the tip of the adhesive nozzle (11) so that dimensions ( f ) and (g) will be as follows. q Dimension ( f) : 10 mm q Dimension (g): 12 mm

CPW11617 CPW11611

50-700

12



3)

SEN03956-00 a

Set adhesive cartridge (9) to caulking gun [7]. a An electric caulking gun is more efficient.

a a

CPW11618

Apply adhesive (12) to dimensions (h) and ( j ) of both-sided adhesive tape (4) of operator's cab (2). q Dimension (h): 10 mm q Dimension ( j ) : 12 mm (Approx. twice a s high as adhes iv e tape) Apply adhesive (12) higher than bothsided adhesive tape (4). Apply the adhesive evenly.

CWW11620 4)

Remove release tape (13) of the bothsided adhesive tape on the glass side.

8.

5)

Apply adhesive (12) to the outside of bothsided adhesive tape (4) of the operator's cab. a Before applying the adhesive, check that the primer is applied to the surface to which the adhesive will be applied.

Install window glass (3). a If the glass is positioned wrongly, the adhesive must be removed and cleaned, and then the primer and adhesive must be applied again. Accordingly, position the glass carefully when sticking it. 1) Similarly to step 5, match tools X1-1, X12, and X1-3 and set them to the 2 lower places of the window glass sticking part of operator's cab (2).

CPW11614

CPW11619


50-700

13

SEN03956-00 2)


Using tool X2, raise and place window glass (3) on tool X1-1 (5-mm spacer) and stick it to the operator's cab. a Match the lines of the match tapes stuck in step 5. a Stick the glass within 10 minutes after applying the adhesive. a Before sticking the glass, check that the primer is applied to the surface to which the glass will be stuck.

CPW11623

9.

CPW11622

a

Check clearance ( k ) between the front side of the front glass and each side and adjust it evenly. q Clearance ( k ) : 5 mm

Cure the stuck window glass for a certain time. a Curing time before removing tool X1-1 (5mm spacer) (at temperature of 20°C and humidity of 60%): 10 hours a Curing time before operating machine: 1 day

10. If the front glass and both front glasses are replaced, seal them. 1) Stick masking tapes (14) along the parts to be sealed shown in the figure. a Stick the masking tapes to both inside and outside of the operator's cab.

CPW11628 CWW11626

3)

50-700

After sticking window glass (3), press it evenly. a Press all over the window glass to the degree that the window glass will be stuck to the both-sided adhesive tape. a Do not press the window glass to strongly.

14

CWW11629



2)

SEN03956-00

Fill the joint of the glasses with caulking material (15). a The usable period of the following caulking material is 4 months after the date of manufacture. Do not use the caulking material after its usable period. 2 Caulking material: SUNSTAR PENGUINE SEAL NO. 2505

CPW11631

3)

Remove the caulking material projected from the joint with cardboard [8], etc.

CPW11632

4)

Remove the masking tapes from the window glass.

11. Remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it.


50-700

15

SEN03956-00

700 Cab and its attachments Disassembly and assembly of operator's seat assembly

Disassembly and assembly of operator's seat assembly

1

a

The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manufactured by ISRING HAUSEN is optional.)] is shown below.

A: B: C:

Headrest Back seat Cushion seat

D: E: F:

Left-hand armrest Suspension cover Rails

Disassembly 1.

Headrest 1) Referring to the figure, check the positions of 2 clips (2) of headrest stay (1) on both sides.

50-700

16



2)

a

Apply force (b) to part (a) of each clip (2) in the direction of the arrow to turn the clip and release it from part (d) of headrest stay (1), and then pull out up headrest (3).

SEN03956-00 2.

Back seat 1) Disconnect 3 air hoses (5) from the rear left of back seat (4). a Before disconnecting the air hoses, check their types.

2)

Remove back seat hinge mounting bolt (6) (M8 bolt).

3)

Bring back seat (4) down forward.

Pushing in both clips (2) simultaneously, remove headrest (3).


50-700

17

SEN03956-00 4) 5) 6)

Apply force (E) to the right side of back seat (4) in the direction of the arrow. Applying the force to back seat (4), pull its right side up. Slide back seat (4) sideway and remove it.


3.

Cushion seat 1) Push cushion adjuster lever (7) inward and slide cushion seat (8) to the front end.

2) 3)

50-700

18

Push cushion slide stopper wire (9) down with screwdriver [1], etc. Keeping the state in 2), pull out cushion seat (8) forward and remove it.



4.

Armrest The procedure for disassembling left-hand armrest (10) is shown below.

SEN03956-00 4)

5)

1)

2)

3)

Remove plastic cap (12) from the armrest hinge. a Use a flat-head screwdriver, etc. to remove the cap. Loosen armrest hinge mounting bolt (13).

6)

Turn left-hand armrest (10) up by 180°. a If the armrest is not turned, you cannot apply the tool to upper mounting bolt (15B). Remove plastic cap (14) and upper mounting bolt (15B).

Remove left-hand armrest (10). a There are 2 position adjustment washers (16) installed to each bolt between the armrest and back seat. Take care not to lose them.

Remove plastic cap (14), and then remove lower mounting bolt (15A) (M8 bolt) of lefthand armrest (10).


50-700

19

SEN03956-00 5.

Suspension cover 1) Remove right-hand hinge cover (17). 2) Remove plastic plate (18) from the rear with screwdriver [1], etc. a Take care not to damage the plastic plate by prying it off forcibly with a screwdriver, etc.

3)

50-700


4)

Remove 4 mounting bolts (20), cushion rear fixing plate (21), 2 cushion rails (22), and 4 bushings (23).

5)

Remove 3 metallic suspension cover clips (24).

Remove 4 suspension cover fixing rings (19).

20



6)

7)

6.

Remove 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small) (25): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large) (26): Front lower part; 2 places Remove suspension cover (27). a If you remove the suspension cover without performing the work in steps 5) and 6), the suspension cover may be broken.

SEN03956-00 2) 3)

Slide rails (28) to the rear end. Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the front part of each rail.

4) 5)

Slide rails (28) to the front end. Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the rear part of each rail, and then remove rails (28).

Rails 1) Turn over the seat assembly to set rails (28) on the upside.

a


Take care not to lose height adjustment washers (31) between the rails and suspension.

50-700

21

SEN03956-00

Assembly 1.

Rails 1) Put height adjustment washers (31) between rails (28) and suspension, and then set rails (28) in position.

2)


2.

Suspension cover 1) Set suspension cover (27) in position and install 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large): Front lower part; 2 places

Set rails (28) to the front end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each rail. 3 Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm} 2)

3)

50-700

Install 3 metallic suspension cover clips (24).

Set rails (28) to the rear end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each rail. 3 Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

22



3)

Set 4 bushings (23) and 2 cushion rails (22), and then install cushion rear fixing plate (21) and 4 mounting bolts (20). 3 Cushion rail mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

4)

Install 4 suspension cover fixing rings (19).

5) 6)

Install plastic plate (18) to the rear. Install right-hand hinge cover (17).

SEN03956-00 3.

Armrest The procedure for assembling left-hand armrest (10) is shown below.

1)

Install 2 position adjustment washers (16) for each bolt and set left-hand armrest (10) in position.

2)

Tighten lower mounting bolt (15A) lightly and turn armrest (10) by 180°. Tighten upper mounting bolt (15B) lightly. Tighten lower mounting bolt (15A) and upper mounting bolt (15B) permanently. 3 Upper and lower armrest mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm} Install 2 plastic caps (14).

3) 4)

5)


50-700

23

SEN03956-00 6)

7)

4.

Tighten armrest hinge mounting bolt (13). a Tighten the bolt so that the arm will move smoothly. q Operating effort at armrest end: 49.0 – 78.4 N {5 – 8 kg} Install plastic cap (12).


5.

Back seat 1) Insert the left side of back seat (4), and then lower and set the right side.

Cushion seat 1) Slide in the cushion seat from the front of the fitting position. a If cushion seat (8) is slid to the rear, it is locked by cushion stopper wire (9).

2)

50-700

24

Install back seat hinge mounting bolt (6). 3 Back seat hinge mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}



3)

6.

SEN03956-00

Connect 3 air hoses (5) to the rear left of back seat (4).

Headrest 1) Insert headrest (3) in back seat (4). a Check that 2 clips (2) on both sides are locked securely.


50-700

25

700 Cab and its attachments Removal and installation of air conditioner unit

SEN03956-00

Removal and installation of air conditioner unit

k

k

q

5.

Remove wiper blades (13).

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Precautions for handling refrigerant k Collect refrigerant (R134a) beforehand. a Ask professional traders for collecting and filling the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant (R134a) gets inside ones eyes, it may cause blindness. Therefore, make sure to wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person. k If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant is cooled, and then drain the coolant.

1.


2.

Drain the coolant. 6

3.

Disconnect wiper water hose (12) from the front outside of the cab.

1

Removal k

4.

CPW11631

6.

Disconnect wiper water hose (14) from the inside of the cab.

7.

Disconnect wiper wiring harness connector (15).

8.

Remove wiper motor assembly (16).

CPW11631

[*1]


Remove the monitor panel, referring to the “Removal and installation of monitor panel”.

9.

Remove left duct (17) and right duct (18).

CPW11631

50-700

26



10. Disconnect right lower duct hose (19).

SEN03956-00 16. Remove right cover (30).

11. Remove 8 mounting bolts (20) and plate (21).

CPW11631 CPW11631

12. Remove left cover (22). 13. Disconnect the following wiring harness connectors. q (23): CN-C50 q (24): CN-C49 q (25): CN-AL1

17. Disconnect heater hoses (32) and (33) and air conditioner pipes (34) and (35) at the lower right of air conditioner unit (31). a Plug the disconnected hoses and ports to prevent foreign matter from entering them. [*2] 18. Disconnect wiring harness connector (36).

14. Remove air conditioner internal air filter case (26).

CPW11631

CPW11631

19. Disconnect blower motor wiring harness connector (37) from the lower left of the operator's cab floor and pull out the wiring harness and grommet (38) together above the floor. 15. Disconnect wiring harness connectors (28) and fuse (29).

CPW11631 CPW11631


50-700

27


SEN03956-00 20. Remove air conditioner assembly (31) upward. a Check that all the wiring and piping are disconnected.

3)

Remove air conditioner external air duct (42) from the lower left of the floor.

CPW11631 CPW11631

4)

Remove the 5 mounting bolts and blower motor assembly (43). a Remove the 5 mounting bolts at the arrows (The ones marked with * among them are used to fix the external air filter case, too).

CPW11631

CPW11631

21. Blower motor assembly 1) Remove side cover (39) and front cover (40) at the lower left of the operator's cab. 2) Remove air conditioner external air filter case (41).

CPW11631

50-700

28

CPW11631



CPW11631

SEN03956-00 [*2] a Do not remove the plugs installed when the piping was disconnected to prevent entry of foreign matter until just before connecting the piping. 2 O-ring and threaded part: Compressor oil for R134a (SANDEN: SP10 or equivalent) 3 Hose adapter mounting bolt (44): 8 – 12 Nm {0.8 – 1.2 kgm}

CPW11631

Installation q


[*1] a When installing the hoses of the air conditioner circuit, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner hose, check that O-ring (70) is fitted to it. a Check O-ring (70) for a flaw and deterioration. a When connecting each refrigerant pipe, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8 or ZEXEL ZXL100PG (equivalent to PAG46)) to O-ring (70). 3 Threaded part of hose (M16 × 1.5): 12 – 15 Nm {1.2 – 1.5 kgm} 3 Threaded part of hose (M22 × 1.5): 20 – 25 Nm {2.0 – 2.5 kgm} 3 Threaded part of hose (M24 × 1.5): 30 – 35 Nm {3.0 – 3.5 kgm}

q



CPW11631

q



50-700

29

SEN03956-00



50-700

30

SEN03957-00





50

800 Electrical system Removal and installation of monitor panel ...................................................................................................... 2 Removal and installation of engine controller assembly ................................................................................. 4 Removal and installation of HST controller assembly..................................................................................... 5 Removal and installation of KOMTRAX terminal assembly ............................................................................ 6


50-800

1

800 Electrical system Removal and installation of monitor panel

SEN03957-00

Removal and installation of monitor panel

3.

Remove 8 mounting bolts (1a) and panel cover (1). [*1]

4.

Remove 2 pieces (9) and 1 piece (10) of the monitor panel mounting bolts. [*2]

1

Removal k

k

k

1.

2.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Pull out each switch from panel cover (1) on the left side of the operator's seat and disconnect the following connectors. q (2): CN-L10 q (3): CN-L11 q (4): CN-L09 a The installed connectors and switches depend on the specification.

Pull out each switch from panel cover (1) on the right side of the operator's seat and disconnect the following connectors. q (5): CN-L19 q (6): CN-L07 q (7): CN-L08 q (8): CN-L06 a The installed connectors and switches depend on the specification.

50-800

2


800 Electrical system Removal and installation of monitor panel

5.

Reverse monitor panel assembly (11) halfway and disconnect the following connectors from the rear side. q (12): – q (13): CN-L30 q (14): CN-L28 q (15): CN-L27 q (16): CN-L26 q (17): CN-L25 q (18): CN-L29 q (19): CN-L24 a Take care not to strain the wiring since it is short.

6.

Remove monitor panel assembly (11).

SEN03957-00

Installation q


[*1]

3

Panel cover mounting bolt (1a): 3.44 – 4.40 Nm {0.35 – 0.45 kgm}

[*2]

3

7.

Monitor panel mounting bolts (9) and (10): 2.75 – 3.53 Nm {0.28 – 0.30 kgm}

Remove bracket (20) from monitor panel assembly (11).


50-800

3

800 Electrical system Removal and installation of engine controller assembly

SEN03957-00

Removal and installation of engine controller assembly

4. 1

Removal k

k

k

1.

Disconnect 5 mounting bolts (6) and engine controller assembly (7). [*2] a Take care not to drop the engine controller assembly or give it a shock.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery. Open and fix right engine side cover (1). a Check that the cover is locked securely.

Installation q

a

Carry out installation in the reverse order to removal. Before installing the engine controller assembly, remove foreign matter (water, dirt, etc.) from its wiring harness connector.

[*1]

3

2.

3.

Remove 2 connector mounting bolts (2). [*1] a Width across flats of hexagonal socket of mounting bolt: 4 mm Disconnect connectors CN-EC2 (3), CN-EC1 (4) and CN-EC3 (5).

50-800

4

Wiring harness connector mounting bolt: 3 ± 0.1 Nm {0.31 ± 0.01 kgm}

[*2]

3

Engine controller assembly mounting bolt: 24 ± 4 Nm {2.45 ± 0.4 kgm}


800 Electrical system Removal and installation of HST controller assembly

Removal and installation of HST controller assembly

SEN03957-00 Installation 1

Removal k

k

k

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery.

1.

Slide the operator's seat to the forward end.

2.

Remove cover (1) from the rear of the operator's seat.

3.

Disconnect wiring harness connector CN-HST (2).

4.

Remove HST controller (3). a Take care not to drop the engine controller assembly or give it a shock.


q

a

Carry out installation in the reverse order to removal. Before installing the HST controller assembly, remove foreign matter (water, dirt, etc.) from its wiring harness connector.

50-800

5

800 Electrical system Removal and installation of KOMTRAX terminal assembly

SEN03957-00

Removal and installation of KOMTRAX terminal assembly

4.

Disconnect wiring harness connector CN-L80 (3) on the chassis from KOMTRAX terminal assembly (2). a First, disconnect the wiring harness connector on the chassis then the antenna cable connector because disconnecting the antenna cable connector before disconnecting the wiring harness connector input disconnection of the antenna cable into the KOMTRAX. [*1] a To remove CN-L80 (3), loosen the hexagon socket head screw at its center. [*2]

5.

Disconnect antenna cable connectors (4) and (5) from KOMTRAX terminal assembly (2).

1

Removal k

k

k

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames. Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Disconnect the cable from the negative (–) terminal of the battery.

1.

Open the right door of the operator's cab. a Lock the door securely.

2.

Remove right armrest outside cover (1) of the operator's seat.

3.

Remove KOMTRAX terminal assembly (2).

Installation q

a

Carry out installation in the reverse order to removal. Before installing the KOMTRAX terminal assembly, remove foreign matter (water, dirt, etc.) from its wiring harness connector.

[*1] a First, connect the antenna cable connectors then the wiring harness connector on the chassis. [*2]

3

50-800

6

Hexagon socket head screw at center of wiring harness connector CN-L80 (3): 2.82 Nm {0.288 kgm}


800 Electrical system Removal and installation of KOMTRAX terminal assembly


SEN03957-00

50-800

7

SEN03957-00



50-800

8

SEN03958-01




90 Diagrams and drawings

1

100 Hydraulic diagrams and drawings Automatic greasing circuit diagram................................................................................................................. 2 Hydraulic circuit diagram................................................................................................................................. 5


90-100

1

SEN03958-01

Automatic greasing circuit diagram

100 Hydraulic diagrams and drawings Automatic greasing circuit diagram

1

(If equipped)

90-100

2



SEN03958-01

A: Automatic greasing pump assembly B: Feeder 1 C: Feeder 2 D: Feeder 3 E: Feeder 4 Greasing parts 1. Bucket pin (left) 2. Bucket pin (right) 3. Lift arm pivot pin (left) 4. Lift arm pivot pin (right) 5. Bucket link pin (bucket side) 6. Bucket link pin (bell crank side) 7. Bell crank pin 8. Bucket cylinder head pin 9. Bucket cylinder bottom pin 10. Lift cylinder bottom pin (left) 11. Lift cylinder head pin (left) 12. Lift cylinder bottom pin (right) 13. Lift cylinder head pin (right) 14. Steering cylinder bottom pin (right) 15. Steering cylinder bottom pin (left) 16. Center hinge pin (upper) 17. Center hinge pin (lower) 18. Steering cylinder head pin (right) 19. Steering cylinder head pin (left) 20. Rear axle pivot pin (front side) 21. Rear axle pivot pin (rear side) 22. Rear axle pivot pin (rear side)


90-100

3

SEN03958-01

90-100

4



Hydraulic circuit diagram

Hydraulic circuit diagram WA320-6

1

WA320-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


SEN03958-01 90-100

5

WA320PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


Hydraulic circuit diagram WA320PZ-6

SEN03958-01 90-100

7

100 Hydraulic diagrams and drawings


SEN03958-01

90-100

9

SEN03958-01



90-100

10

SEN03959-01




90 Diagrams and drawings

1

200 Electrical diagrams and drawings Electrical circuit diagram ................................................................................................................................. 3 Connector list and stereogram...................................................................................................................... 29


90-200

1

SEN03959-01

90-200

2

200 Electrical diagrams and drawings


Common electrical circuit diagram (1/9)

Electrical circuit diagram

WA150-6, WA200-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


1

Common electrical circuit diagram (1/9) WA150-6, WA200-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6

SEN03959-01 90-200

3

Common electrical circuit diagram (2/9) WA150-6, WA200-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.



SEN03959-01 90-200

5




SEN03959-01 90-200

7




SEN03959-01 90-200

9

Common electrical circuit diagram (5/9) WA200-6, WA250-6, WA250PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


Common electrical circuit diagram (5/9) WA200-6, WA250-6, WA250PZ-6

SEN03959-01 90-200

11




SEN03959-01 90-200

13

Common electrical circuit diagram (7/9) WA200-6, WA250-6, WA250PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


Common electrical circuit diagram (7/9) WA200-6, WA250-6, WA250PZ-6

SEN03959-01 90-200

15




SEN03959-01 90-200

17




SEN03959-01 90-200

19

Specific electrical circuit diagram (1/4) WA320-6, WA320PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


Specific electrical circuit diagram (1/4) WA320-6, WA320PZ-6

SEN03959-01 90-200

21




SEN03959-01 90-200

23




SEN03959-01 90-200

25

Specific electrical circuit diagram (4/4) WA320PZ-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.


Specific electrical circuit diagram (4/4) WA320PZ-6

SEN03959-01 90-200

27

Connector list and stereogram

Connector list and stereogram WA320-6, WA320PZ-6 (KA SPEC.)

WA320-6, WA320PZ-6 (KA SPEC.)

Connector No.

Model

Number of pins

—

—

2

Water in fuel sensor

Component name

Address of stereogram

Connector No.

Model

Number of pins

Diode

F-1

L70

SWP

8

Speed range select resistor

O-9

1

GND (front frame)

E-1

L71

DT-T

4

Intermediate connector

W-2

DT-T

2

Steering pump pressure switch

H-1

L79

—

5

KOMTRAX engine cut relay

P-6

Connector No.

Model

Number of pins

F07A

DT-T

2

T-1

F10

Terminal

AC-3

F11


Component name

Component name


AL1

DT-T

6


AMBAIR PRESURE

—

3


B01

DT-T

2

Rear work lamp RH

K-9

F12

DT-T

2

Emergency steering pressure switch

H-1

L80

DRC key A

40

KOMTRAX controller

T-8

B02

DT-T

2

Rear work lamp LH

M-8

F14

DT-T

2

Brake oil temperature switch

A-1

L100

Terminal

1

GND (floor)

Y-3

B03

DT-T

2

Back up alarm

M-7

F15

DT-T

3

Lift arm angle sensor (for load meter)

A-4

L101

—

6

FR press select relay

AB-7

B05

DT-T

2

Coolant level sensor

K-9

F16

DT-T

3

Lift arm bottom sensor (for load meter)

A-2

L102

—

5

VIS power hold relay

Z-8

B05

Terminal

1

GND (license lamp)

M-7

F17

DT-T

3

Lift arm rod sensor (for load meter)

E-1

L103

—

5

Motor 2 solenoid relay

Z-8

B06

08027

2

(R) Window sealed washer motor

I-9

FL1

DT-T

12


D-7, V-1

L104

—

5


Z-8

B07

08027

2

(F) Window sealed washer motor

I-9

FL2

DT-T

6


D-8, V-2

L105

—

5

Electrical parking brake relay

AA-7

B08

DT-T

2

Diode

K-9

FL3

DT-T

4


I-1, W-2

L106

—

5

Neutral safety relay

AA-7

B09

DT-T

2

Diode

J-9

FL4

DT-T

6


I-1, V-2

L107

—

5

Engine controller cut 1 relay

Z-7 Z-8

BL1

DT-T

6


X-2

FLC

DT-T

3

Front combination lamp RH

B-6

L108

—

5

Engine controller cut 2 relay

BOOST PRESS & INT

—

4

Boost pressure sensor

AF-4

FLC1

DT-T

3

Front combination lamp LH

H-1

L109

—

5

Back alarm/lamp 1 relay

AB-7

BR1

DT-T

4


L-8

FLH

DT-T

3

Head lamp RH

B-6

L110

—

5

ECSS relay

AB-7

C04

DT

2

Front work lamp (RH) 24V/70W

E-8

FLH

DT-T

3

Head lamp LH

G-1

L111

—

5

HST solenoid safety relay

AB-8

C05

DT

2

Front work lamp (LH) 24V/70W

H-9

FS1

—

15

Fuse box

V-9

L112

—

5

Air clearner clog relay

AB-8

C07

2

Room lamp

H-9

FS2

—

15

Fuse box

V-9

L113

—

5

Boom kick out relay

AB-9

—

3


AG-5

L114

—

5

Bucket leveler relay

AA-9

C09

YAZAKI 7123-2228 YAZAKI -08056 YAZAKI -08056

C10

1

Door switch (LH) (room lamp)

H-9

FUEL RAIL PRESS

1

Door switch (RH) (room lamp)

E-8

HEAD L

DT-T

6


G-1

L115

—

5

Detent active relay

AA-9

Terminal

1

GND to radio body

F-9

HEAD R

DT-T

6


A-5

L116

—

5

Horn relay

AA-9

C11

YAZAKI PA

9

AM/FM radio

F-9

HST

DRC

40

HST controller

Z-6

L117

—

5

Small lamp relay LH

AA-6

C12

M

2

Speaker LH

I-9

INJ. CYL. 1 & 2

—

4

Injector #1 & #2

AE-4

L118

—

5

Small lamp relay RH

AA-5

C13

M

2

Speaker RH

G-9

INJ. CYL. 3 & 4

—

4

Injector #3 & #4

AF-5

L119

—

5

Head lamp relay RH

AA-5

C14

198-Z11-2650

2

Lighter

D-7

INJ. CYL. 5 & 6

—

4

Injector #5 & #6

AG-5

L120

—

5

Head lamp relay LH

AA-5

C15

DT

3


J01

M6409-0075

20

Joint connector

R-6

L121

—

5

Stop lamp relay

C16

DT

2

Warning lamp (beacon)

J02

M6409-0255

20

Joint connector

R-6

L122

—

5

Front work lamp relay

AA-4

C17

SWP

6

Warning lamp (beacon) switch (If equipped)

J03

M6409-0071

20

Joint connector

V-1

L123

—

5

Rear work lamp relay

AB-4

C18

SWP

6

Warning lamp (pat. light) switch (If equipped)

J04

M6409-0075

20

Joint connector

Y-9

L124

—

6

Hazard/turn signal relay

AB-4

C18

Terminal

1

GND (cabin)

E-8

J05

M6409-0072

20

Joint connector

Y-9

L125

—

5

Hazard relay

AB-4

C19

SWP

6

Rear glass heater switch

G-9

J06

M6409-0071

20

Joint connector

Y-9

L126

—

5

Back alarm/lamp 2 relay

AB-6

C20

—

5

Relay for rear glass heater

G-9

J07

M6409-0072

20

Joint connector

R-8

L151

—

5

Front work lamp (yellow) relay (If equipped)

C21

1

Rear glass heater

G-9

J08

M6409-0075

20

Joint connector

Q-4

L152

—

5

Warning lamp (beacon) relay

C22

YAZAKI 7116-2270 YAZAKI 7116-2270

1

Rear glass heater

J-9

J09

M6440-0128

20

Joint connector

Y-9

L153

—

5

Warning lamp (pat.light) relay (If equipped)

C23

DT

4


E-8

J10

M6409-0255

20

Joint connector

Y-9

L154

—

6

Warning lamp (pat.light) switch relay (If equipped)

C47

—

22

Manual A/C control amp

F-9

J11

M6440-0135

20

Joint connector

Z-8

LR1

#8

1


N-3, AB-2

C48

—

14

Manual A/C control amp

F-9

J12

M6409-0075

20

Joint connector

Z-8

LR2

DT-T

12


N-3, AB-2

C49

DT-T

12


F-1

J13

M6409-0128

20

Joint connector

R-6

LR3

DT-T

6


N-3, AB-1

C50

DT-T

12


F-1

J14

M6409-0075

20

Joint connector

Z-8

LR4

#8

1


N-2, AB-1

C140

DRC

40

Tachograph controller

J15

M6440-0128

20

Joint connector

O-4

LR6

#8

1


M-3, X-1

C142

YAZAKI 7119-3170

17

Tachograph

J16

M6409-0128

20

Joint connector

Z-7

LR7

DT-T

12


M-3, X-1

CAM SENSOR

—

3

G sensor

AD-1

J17

M6409-0073

20

Joint connector

Z-7

LR10

DT-T

3


N-3, AB-2

CAN1

DT-T

3

CAN resistor

AG-1

L02

DT-T

4

Starting switch

R-9

LR11

DTP

4


M-3, X-1

CAN2

DT-T

3

CAN resistor

S-1

L03

DT-T

4

Speed range selector switch

R-8

LR12

#8

1


N-3, AB-1

CHK0

X

1

KOMTRAX inspection connector

P-6

L04

SWP

8

Combination lamp switch

T-1

LT1

DT-T

12


M-3, X-2

CHK1

X

1

KOMTRAX inspection connector

P-6

L05

S

10

Wiper switch (front, rear)

S-1

LT2

DT-T

6


M-3, X-2

CL1

SWP

6


C-6, O-2

L06

SWP

6

Hazard switch

R-6

MF1

DTM

12

Multi function lever switch

—

—

Engine pressure switch (low)

C08

Z-5

L07

SWP

6

Front work lamp switch

Q-5

OIL PRESURE SWITCH

Diode

L08

SWP

6

Rear work lamp switch

R-6

PD1

DT-T

6

Throttle pedal switch

O-2

2

Diode

L09

SWP

6

ECSS switch

T-1

PD2

DT-T

2

Throttle pedal switch

O-2

—

2

Engine coolant temperature sensor

AD-4

L10

SWP

6

Monitor 1 switch

U-1

R00

Terminal

1

GND

M-8

—

2

IMA fuel pump actuator

AH-4

L11

SWP

6

Monitor 2 switch

T-1

R01

Terminal

1

Battery relay

A-8

CRANK SENSOR

—

3

Ne sensor

AD-1

L13

DT-T

2

Horn switch

T-1

R02

Terminal

1

Slow blow fuse

A-9

D01

SWP

8

Diode

O-8

L15

DT-T

4

FNR switch

S-2

R03

Terminal

1

Slow blow fuse

B-9

D02

SWP

8

Diode

O-8

L16

SWP

6

Loadmeter A/B (If equipped)

U-1

R04

Terminal

1

Battery relay

A-9

D03

SWP

8

Diode

O-8

L17

SWP

6

Loadmeter total (If equipped)

V-1

R05

Terminal

1

Slow blow fuse

B-9

D07

DT-T

2

Diode

O-7

L24

AMP 070

20

Monitor panel

R-2

R05A

Terminal

1

Slow blow fuse

B-9

D08

DT-T

2

Diode

O-7

L25

AMP 070

18

Monitor panel

R-2

R06

Terminal

1

Slow blow fuse

B-9

D09

DT-T

2

Diode

O-7

L26

AMP 070

12

Monitor panel

R-2

R11

Terminal

1

Slow blow fuse

B-9

D10

DT-T

2

Diode

O-7

L27

AMP 070

18

Monitor panel

Q-3

R15

Terminal

1

Battery relay

B-7

D21

DT-T

2

Diode

K-2

L28

AMP 070

12

Monitor panel

Q-4

R16

Terminal

1

Battery relay

A-7

D22

DT-T

2

Diode

J-1

L29

AMP 070

12

Monitor panel

T-7

R20

Terminal

1

GND (rear frame)

J-1

E01

DT-T

2

Starting motor safety relay

AF-5

L30

AMP 070

14

Monitor panel

S-7

R21

DT-T

2

Fuel level sensor

M-5

E02

SUMITOMO 6189-0442

3

Alternator

M-6

L34

DT-T

2

Stop lamp switch

W-2

R22

DT-T

6

Rear combination lamp LH

M-6

E03

Terminal

1

Alternator terminal B

M-7

L35

DT

2

PPC valve with electrical detent

Q-9

R23

DT-T

6

Rear combination lamp RH

K-9

E05

Terminal

1

Heater relay terminal B

C-7

L36

DT

2


R-6

R24

DT-T

2

License lamp (If equipped)

L-9

E06

Terminal

1

Heater relay

C-9

L37

DT

2


R-6

R26

Terminal

1

GND (rear frame)

G-1

E06A

DT-T

2

Diode

K-2

L38

DT-T

2

UN switch +24 V (If equipped)

Z-4

R29

DT-T

2

Oil fan EPC solenoid

L-9

E07A

Terminal

1

Heater relay terminal A

AF-5

L39

DT-T

2

Key on +24 V (If equipped)

Z-4

R59

DT-T

2

Fan reverse solenoid

M-8

E07B

—

1

Electrical intake air heater

AD-9

L45

DT-T

6

Auto lubrication

AB-2

R90

Terminal

1

Heater relay terminal E

L-4

E10

DT-T

2

Freon compressor magnet clutch

AH-1

L46

M

2

Buzzer

W-9

SV

DT-T

12

Service connector

Y-8

E14

Terminal

1

GND (engine controller)

AG-1

L47

DT

2

Parking brake indicator switch

Y-3

T01

DT-T

4

HST pump solenoid

AC-4

E15

Terminal

1

GND (engine controller)

AH-1

L48

08027

6

Wiper timer

X-2

T01A

—

2

Diode

AD-4

E19

Terminal

1


AG-6

L49

08027

4

Flasher

AA-3

T01B

—

2

Diode

AD-4

E20

Terminal

1


AG-6

L50

DT-T

12


Z-6

T05

DT-T

2

Clutch control EPC solenoid

N-2, AN-7

E21

Terminal

1

Starting motor terminal C

AC-7

L52

M

4

Rear wiper motor

X-9

T06

DT-T

2

HST motor 1 EPC solenoid

L-1, AK-2

E26

DT-T

2

Engine oil level sensor

AF-5

L53

DT

2

Parking brake remind switch

Z-5

T07

DT-T

4

HST motor 2 solenoid & motor 2 overrun solenoid

L-2, AJ-7

E30

Terminal

1

Starting motor terminal B

AE-4

L54

DT-T

3

Variable shift control switch

T-8

T09

DT-T

4

Speed sensor

L-2, AL-8

E33

DT-T

2

Dust indicator

J-9

L55

DT

2

Air suspension seat

Z-5

T10

DT-T

2

HST oil temperature sensor

L-2, AK-8

E41

DT-T

2


AF-1

L57

M

6

Front wiper motor

Q-3

T11

DT-T

3

HST oil pressure sensor

M-1, AL-3

E42

DT-T

2


AH-2

L58

M

2

12V option converter output

Z-4

T12

DT-T

2

Brake accumurator pressure switch

I-1

EC1

DRC

60

Engine controller module

AE-1

L59

DT-T

4

Bucket lever LDM cancel switch (If equipped)

Q-6

T13

—

1

HST filter clogging sensor

M-1

EC2

DRC

50


AD-2

L60

DT-T

6


Z-4

T14

Terminal

1

GND

M-1

EC3

DTP

4


AF-1

L61

DT-T

4

Boom lever TCS cancel switch

Q-6

T15

DT-T

2

Parking brake solenoid

ER1

DT-T

12


D-8, AE-5

L62

DT-T

4


Q-6

T15A

DT-T

2

Diode

ER2

DT-T

12


D-8, AE-5

L63

SWP

6

FNR active switch

Q-9

T18

DT-T

2

Parking brake pressure switch (for monitor indicator)

ER3

DT-T

2


D-8, AE-5

L64

SWP

6

Traction switch

Q-9

T31

DT-T

2

Diode

F01

08160-70001

2

Horn (high)

C-1

L65

SWP

6

Work lamp (yellow) (If equipped)

R-6

T32

DT-T

2

Diode

F02

08160-70001

2

Horn (low)

D-1

L66

X

1


O-3

TEL

DT-T

12


F03

DT-T

3

Bucket positioner proximity switch

A-3

L67

DT-T

12


W-9

TOOL PORT

—

3

CAN resistor

F04

DT-T

3

Lift arm positioner proximity switch

A-4

L68

DT-T

2

Resistor

O-7

Z01

DT-T

2

Diode

F07

DT-T

2

ECSS solenoid valve

F-1

L69

SWP

6

Auto reversible fan switch

Q-9

Z02

DT-T

2

Diode

CL2

SWP

8


CL31

DT-T

2

CL32

DT-T

COOLANT TEMP CP3 PUMP REGULATOR


C-7, O-3

AH-2

L-2, AL-8 N-1 N-2, AN-7

P-6 AD-2

SEN03959-01 90-200

29

200 Electrical diagrams and drawings


SEN03959-01

90-200

31

SEN03959-01



90-200

32

WA 320-6 Shop Manual

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