AAA-S85N2E01-945, Kawasaki WHEEL LOADER SHOP MANUAL Powered by NISSAN PE6T34 Engine. ‘SERIAL NUMBERS 85N2-0101 and up, Troubleshooting 01 Kawasaki Heavy Industries, Ltd.Safety Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below. @This manuals intended for properly trained and equipped service technicians. @Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. @Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. @Piace the machine on a level and solid ground, and place chocks against the wheels to prevent movement. @Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE" tag to the steering wheel. @2e sure to release the internal pressure before you remove a pipe, such as the hydraulic oll, air, or engine coolant pipe. @When the boom or bucket is raised or when a unitis ited by a crane, be sure to place a stand or adequate cribbing Under the unit to prevent unexpected dropping @To remove a heavy unit (20kg (40 lbs) or more), be sure to use a crane or other lifting tool. @Just after stopping operation, be careful not to directly touch a hot component. You may get burned. ‘@Always store the tools in good condition, and use them property.Safety Symbols ‘An accident may occur if you disregard the safety rules. In this manual, several expressions are used according to the danger levels of inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against the possible problems before starting service work. If the specified conditions are not satisfied or the specified procedure is not | observed, there is a strong possibilty that an accident resulting in Injury or death will occur. ‘The message shows the possible accidents and preventive measures. Hf the specified c are not satisfied or the specified procedure is not ‘observed, there is a strong possibility that an Incident resulting in minor injury or major damage of the product will occur. ‘The message shows the possible incidents and preventive measures. We cannot predict all the possible accidents or incidents that may occur during service work. Therefore, an accident that is not written in this manual may occur. To protect yourself from all the accidents, be careful in doing service workSymbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol | _ttem Deseription Shows the condition or procedure that will Reference’ p at wil be useful or efficient in doing service work. Shows the weight ofa part or unit. The weight oy eign | MOU be considered in selecting wire ope or Tightenin “rave ‘Shows the tightening torque of a section that cable for slinging work or determining the working posture. should be carefully tightened during assembly work, ‘Shows the type of coating or adhesive and the RS) Coating | coating section. aay Oller | Shows the oil or water supply port and the refill Supply | amount | Shows the oil or water drain port and the drain \wnkeey | Drainage | amount. IMPORTANT If the specified conditions are not satisfied or the specified procedure is not ‘observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. ‘The message shows the preventive measures.QOTroubleshooting 01 Cautions Regarding Troubleshooting -:+--+--s-ssese 01-003 How to Use Quick Troubleshooting Table-:-+--+--- 01-004 Safety Precautions --- se sevesreseeseneseeees 4-005; Quick Troubleshooting Table Power Group 1. Engine hard to start or will not start ++ Excessive black smoke from exhaust Exhaust smoke is white / blue Engine runs rough or misfiring Engine has low power: Excessive oil consumption Excessive fuel consumption --~ Engine produces an abnormal noise Engine is overheating Torque Converter and Transmission Group 1. Machine does not move in any shift lever position ~ “01-014 2. Machine does not move at a certain shift lever position +--+ 01-015 (or: Machine moves only in a certain shift lever position) 3. Machine moves at the neutral position »+---++-- -- 01-016 (Example: Machine moves forward at the neutral position) Large shock at starting or changing speed / direction ~ 01.017 Large time lag at starting or changing speed / direction=:------- 01-018 Low power: ssoesneeaneenene 01-019 (Defective torque converter or transmission) Torque converter oil is overheating +--+ 01-020 Machine moves reverse when starting to climb up on a slope using inching brake -----+--- ; 01-021 9. Automatic speed change is not possibles-+-s--srsseseeseeses 01.022 (Serial No. 182 and above) 10. PUS (QUAD) switch does not work. 01-023 01-001Group 1. Boom and/or bucket do not move 2. Boom andlor bucket have low power, or move too slowly 3. Excessive cylinder dritt 4 Boorn andjor bucket are spongy’ (Holding bucket against the ground is not possible) Bucket positioner (kick-out) does not work:~"~ Steering is not possible or hard to steer -~ Machine sways, or a shock during steering. ‘Abnormal noise in hydraulic system 9. Others - Brake Group 1. Brake does not work well (in the worst case, the brake does not work at all) Brake is dragging when released: Brake oil level lowers too much Stepping on the brake pedal sounds the buzzer Air pressure does not rise, or too stow in rising ~~ veer (Pressure indicated on the pressure gauge is too small) 6. Parking brake does not work ==: (or: Releasing the brake is not possible) Electrical Group 1. Engine will not stop even ifthe starter switch is turned to “OFF” (or: Starting the engine is not possible) ~~ 2. Instrument panel does not indicate properly 3, Breaker of the transmission controller is turned off-~ Operator Station Group 01-024 01-025 01-026 01-027 01-028 01-029 01-030 01-031 + 01-032 01-033 01-034 01-035 + 01-036 01-037 01-038 01-039 01-040 01-041 (Note: North American machines may use a different A/C unit) Air conditioner cooling is poor ~~ Air flow from the air conditioner is too small-~ Condenser motor of the air conditioner will not operate Compressor of the air conditioner does not operate Compressor of the air conditioner has an abnormal noise: ‘Switching the mode between heater and eee ene cooler is not possible +--+ 01-002 01-042 01-043 01-044 01-045 01-046 01-047Cautions Regarding Troubleshooting © Important points ‘The important points for troubleshooting is to carefully read the operation manual and shop manual to get enough information on the operation, circuits, structure, and function of each component. Hf you have enough knowledge of them, you can easily determine the cause of the problem ‘There are various causes for each problem, therefore experience will be needed to determine Which is the actual cause of the problem It is necessary to know the normal operation of each component. In addition, itis also important to know the abnormal condition when problem ‘occurs, This chapter shows various examples of past problems, and describes possible causes and remedies for each problem @ Before starting troubleshooting To prevent incorrect diagnosis, talk with the persons concerned, particularly with the operator, to get enough information on the problem. If possible, check the machine by repeating the symptom. If the problem cannot be repeated, do not provide any repair service. For instance, assume that the operator complains that the boom power is low, and the rim-pull is also low. In this case, there are two possible causes; low hydraulic power and low rim-pull. The remedies against both causes are much different from each other. It you hastily determine the wrong cause without checking the actual condition of the problem, it will take too much time to solve the problem. As a result, you will not be trusted by the user. 01-003, The following questions will be helpful in determining of the cause, Answer the questions to prevent an incorrect diagnosis. 1. Did the problem occur suddenly? 2, When did the operator notice the problem? 3.1s there any past problem that may be the cause of this problem? 4,When the problem occurred, what kind of work was the operator doing? 5. Has the machine had the same kind of problem before? 6.Has the machine been repaired or inspected recentiy? 7. Does the machine have any other problem? @ Troubleshooting © Check before determination of cause A problem may be caused by unsatisfactory daily maintenance, such as low or improper oil or a clogged filer. Be sure to check the machine for oil level, appearance, unpleasant odor, ete. to prevent time loss due to other unnecessary tests, ® Inspection procedure As a rule, check the easy-to-be-repaired system first (excluding the cases where the cause can be easily determined based on the past experiences). This machine is controlled by electrical, hydraulic, and mechanical systems. The most easy-to- be-repaired system is the electrical system. Check the electrical system first. If no problem is detected in the electrical system, check the hydraulic system, and then the mechanical system,How to Use Quick Troubleshooting Table To immediately determine the cause of the problem without disassembling parts, use the quick troubleshooting table. From the problem explained by the user and the check points written in the table, you can immediately determine the cause of the problem. @ How to use quick troubleshooting table (1) According to the problem explained by the user, ‘open the quick troubleshooting table to the page where the corresponding problem is described Check the machine according to the “Symptomsicheck point’ field in the table. Start from the easy-to-be-checked point. Operate the machine, and write the check marks "yin the corresponding circles “ © * if the problem occurs, 2) 8) 01-004 (4) Generally, the possible cause that has many check marks will be the actual cause. If two or more possible causes have several check marks, check each possible cause to prevent an incorrect diagnosis, In this case, start from the easy-to-be checked item.Safety Precautions ‘A WARNING) Unexpected operation of the machine may cause jent resulting in injury or death. Therefore, to provide repair service during engine running, be sure to observe the following items: © Park the machine on a level ground. © Apply the parking brake. Brace the tires with chocks to prevent accidental movement. Determine the signals between the service technicians. Prohibit any person from walking into dangerous areas. + Near articulation area of the machine + Under the mact + Around the engine + In front of or behind the machine Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident: Lock the boom and bucket control levers in the cab. ‘Remove the starter key. Hang a “DO NOT OPERATE!” tag on the steering wheel. © Securely brace the boom / attachment in the raised position. ‘A CAUTION Be careful, injury may occur if high pressure oil sprays out. To prevent such an accident, before removing the plug from the pressure measurement Port, be sure to: * Release the residual pressure from the pipe. © Open the cap of the hydraulic oil tank. Do not enter the articulation area of the machine if the engine is operating. An accident resulting in injury or death may occur. To enter the articulation area, be sure to stop the engine, and remove the starter key. In addition, | hang a “DO NOT START THE ENGINE!” tag on the steering wheel. Unexpected operation of the machine may cause an accident resulting in injury or death. To crawl under the machine, be sure to stop the engine, and brace the tires with the chocks to Prevent them from rotation. Give signals to the person in the cab during the work. Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. ‘An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. 01-005Engine hard to start or will not start Bez iV QUICK TROUBLESHOOTING TABLE Power Group 4, Engine hard to start or will not start Before testing: ‘Transmission shift lover must be in “NEUTRAL” position. Machine may start & move suddenly | during testing causing serious Injury or death. ‘Symptoms//check point Never attempt to start the machine from the ground. # Securely chock the wheels to prevent movement. Possible cause (Cranking speed too low (100 rpm or lass) When the starter switch Is set to ON, the magnetic switch ‘Starter motor operating but not cranking the engine emits a sound A large amount of smoke from exhaust (Crankshaft rotation restricted Engine has low power ‘A small amiount of smoke from exhaust Excessive fuel consumption oll consumption ‘Almost no emoke from exhaust O/O[O|O[O|O/O|O/O O] Starter motor deas not operate Detective engine stopper moter, relay or diode 7 L —] Fusibie link is blown /removed _ { [ Diode pack (Cummins) blown /removed § | Battery rays detecive | ST Neutral relay is detective [ [Rete . =| Batery chargeiow ——~Tolo Balin charge ‘E | Starting circuit connections loose or corroded i Inspections 3) Disconnected electrics wing : | | Inspectiondrepair Detective starter motor 5 | Inspostonaropair Defective starter switch or starter elay | | nspectontrepair | Detective air heater - loo ° inspecion&repair No fuel in fuel tank ‘of fo} ‘Add oo, Bod Tue nw Defective feed pump 3 Replacement Ful line improperly connected lo o [1 [re pining _| § | Detective injection pump | jo, jefe | JO) [Replacement | Detective nozzle ° lo] 0/0) | Replacement Clogged tet iter eament ~ Oo Of | l0|0) |eteering | Air inthe fue system - oO, 6 (|_| Airbleeding Injection pump timing inco oO. | |Readsiment | Broken or damaged fuel pipe Oo} Repair Clogged gauze titer (notin Curnrine) i) Cesring «| Damages ring gear o. Disassemby repair 2 | Damaged or seized engine 1. Disassembiyrpar | Viscosity of engine oil too high for temperature, oO Oil replacement 2 [Vane cserances incorrect oO} Readisiment @| Low engine compression O° [| inspectiontrepair ‘| Valve timing incorrect To Readjvement 5) Clogged air cleaner element 1 1 [eteaning 01-006Excessive black smoke from exhaust asz iV QUICK TROUBLESHOOTING TABLE Power Group 2. Excessive black smoke from exhaust 1 | ] || | | mon | | | iid 1 | z | & e mn 4 aa \ | a ais || S Sele || z gigs 8 2) | | | EER | gaa ) |§) |e)9/3| 2 8)5 a) gigid] |slElel8 aes b 8) 5 8\8)5 S5a882652 23 ggigseeee ses eleleisisiglgigieiaie Sig /2 SS) S/R E/88)F BUSBEBBBEHE ane Gane se SS288688 beaeay | Too much sludge deposited on air heater __jooos TOL || [tearing | 1 Clogged air heater eleme _ [ojofolo] Ol [Cleaning 4 | Detective rbocharger(sezur.cte) ~ iol i) Feplacoment 2 | itieakage rom turbocharger on compressor side [| [O| _| [ Seal epacorst Too much fuel injectec iO} Readjustment Uneveny worn plunge ‘ol epaconent §| Detective delvery valve elo! Replacement & Defective nozzle —IJe'6) Roplaconent | | inappropriate tue | Fuol replacement, = nection timing to eary jo) eadusinens | Defective boost compensator - 0 Replacement ‘Wom piston ring or cylinder liner lool Replacement E3|-Too much olin oil pan - oe eductonin ol amu 3. Exhaust smoke is white / blue | [ineston ting Too rate Gl | | Excemel cos engine jO|o Cl eripping down trom valve stem ; = - Piston ring or cylinder liner worn —_jolo Replacement “Too much olin ol pan O Valve clearances incorest 6 “Turbocharger oil seals leaking compressor sideEngine runs rough or misfiring sez V QUICK TROUBLESHOOTING TABLE Power Group 4, Engine runs rough or misfiring | TT] PEPE E Ld} | A | {| lle | | | 8 | | i} | |e \ | \| = | | A a] | | ae | £ 3 | a aid als Bp ag é | 2 5 gee fees 298 eesaeeeqgerl e/a/kisise a gis ele gigizigis|e 82/35 8/5 Eleigigies/6 5 Bee epeggez ad 5/5/88) 2)/5/8/ 8/3/2812 3/22 2/82/22 8/25 5 2/5/53 5/5 5 2/515 =e Bebo 8 SESS a8 oa Incorrectly adjusted link and rod (o10 OlO] [OT] [Readjustment Fuel leakage from the injection pipe olololo| O[O) | [Repair _| Unequally adjusted injection amount [OF Tolar Jot) Jreasisiment §| Maitunctioning governor [ [O[O/O|O) | Readiustment | Unequally adjusted nozzie injection pressure Ol Jo) Oo) To) | | Ressiusiment | | Imoroperty atomized fuel at nozzle Ol Jol Jofol ol || |Resdiusiment | 3 tmoroperty adjusted ile spring ~ 0} JO}O[o) | resemen Impropety adjusted dumper spring jojo} | Tesciusiment Maifunctioning delivery valve | jo) | jo 0/0] | [Replacement ‘Air in the fuel system ‘Of6) Jol TF Jolol | |air being Imperfectly fitted valve insert O|O|O/O | [O] Repair Improperly adjusted valve clearance jofol_|o| (O| Reagiusiment '3| Improperly adjusted vaive timing ‘ol lol [6 (© | Readusiment 5 F Unequally adjusted compression pressure lo|_lolojolo Readjustment Extremely cold engine ojo) T fo ‘@| Worn engine mountrubber O|O) || [Replacement —_ -E| Improperly adlusted iding speed Ch Ol [OlOP [7 | Reedustment ‘S| Corroded control wire O° LOO} JOT [Replacement 01-008Engine has low power e5z iV QUICK TROUBLESHOOTING TABLE Power Group 5. Engine has low power Ty] | ] | | | Check before starting work | | (1) Perform the stall est. If the engine speed is less than 200 rpm from the standard valve, the 1] engine has low power. t bey dl 8 i Sle ‘ ale | | S| |p 2[8) |g 5 8 Ble| |8lg #2] 2) | jel | lalele| (8/2 Syfeei eege 28 2/gieiaisielg slz|z\s|£|8\2| SHE Cea eee e ae 5 3/8/8\2)e/s/5|Sls/2|g) gle 22 2/3/8)5 5 2/85 5|8)8| Posse coum fale é)6 6/8 se 18 818 8 are Poor quality fuel of} fol fol I OO] [O [ener rase oper adustes wjecion amout/@: Too anal Di Too wwe [S(O _|O| |S) SI Readjustment Clogged fuel titer element | joo seme, | Water orairintuel system | lo Fuel cepacerent | Fuel pressure too low(overtiow valve) io oO} lol O| | [Valve adjustment} 2 imoropery atomized tual et nozzie ser o\6) TOO] oa sistent | Improperly adjusted injection timing - ooo! jo! | | lojolo [Tining adustmane © tMatfunctioning deivery valve oO I ojo) | = Matfunctioning feed pum o_o} Replacement [ Maifunctioning injection pump ° jo epacoment Detective boost compensator [ Replacement =| Greaged ar cleaner element O[O|o) L Samat £/ inadequate or high temperature intake air "lolol [fo S| Mattuncioning turbocharger fo | [Replacement | Too much carbon deposited on airheater lo [Ly ee | =| Clogged or damaged exhaust pipe or mutfier oO} |o [Repair [Piston or eyinder ner worn mm Replacement ‘2| Worn, sticking, or broken piston ring ol jo lo Replacement El sezednsion mm Rescomert ‘5 ] Wom or seized vaive ster [Jol fo Replacoment | imperfectly fitted vaive insert oO oO} jo [Replacement § | Improperly adjusted control linkage | lol 1 {Tol [Readjustment & | Enaine stopper cable not uly rturing to “RUN ort lo eadusment 01-009Excessive oll consumption Bz IV QUICK TROUBLESHOOTING TABLE Power Group 6. Excessive oil consumption 5 ] 1] Pe Check before starting work 3 | | (1) Careful fi he fuel tank Zell |g || fe Filtve car cann ext tothe mare ee) ie || | Cheok after the day's operation gs) | 2 1) dd. (1) Carefully measure and record the exactamount |x |Z 5) | 2 | | | | |g of fuel required to refi the fuel tank SES) | | el) | 3] ) Careuty measure and recardtheewactamaunt |S ]g-2/ 4 Big lS oto requred tore crankeacerotnern’ [EVE S| 2 SER BE mark flee (2 Fefs jig ithe oilconsumpton exceedsos%orihene [E/E 5) [2 $ 8/29 8/g/5 consumption, there is aprobiem, gs| |g (2 88/2 2 ae Example: 52 seats 3 als The loader uses 252.0 of fuelin 8 hours. It also geee2 sage ge consumes 1.1 € ofolin Bhour,istisercessver | 18 58/8 8/5 S/o k's |g Cause 252 x,005-126@ Maxonconmmpion. | [2218/8 Eig) gie|5) 2 1.1 0 is within the normal range. eee esse & 65/5/85 (8214/2 5 Possible cause. Gaede goa sa Remedy ‘Worn piston or cylinder liner * lol folojol | jojo \eonesnen nt ‘Aligned piston ring end gap o oo) Deassonoi then insufficient piston ring tension lO | Piston sng replacement Improper break-in of piston ring lo ll Pertorm breakin 2 Piston rings installed upsige down oF I Dzossonby &restenbh 2 | Broxen or sezed piston ng —— SIS [OLFPmon ena repacemen | Wom piston ring * ol 0/0] | fPisn ia repacomon Sculted eyinderfner™ jo} “lo Liner eplacement ‘Worn vaive ster or guide - fol E do \Vaive stem replacement Wor valve stem seal Io of [o-ring replacement “| Wom or broken seal rng 0) ol [Sealing eplacoment [£3{ Carbon clogged in ol returmhole jol_| Cm Disassembiyacleaning *{ Improper installation of seal ring } Cm Disassembly & reassembh Oi leakage [ 0 [0 [Revair | Excess of engine ol 5) TIO} [oterainage | imeroperqualty or vscosly of engine ot [ + Repaceot ‘Clogged air cleaner element oto) Element eaning As isted below, there are several causes that promote quck abrasion of the engine, Carefully check the engine, and | determine the cause. | © Extremely cold engine | @ Low quality or improper viscosity of engine oil | @ Overload | @ Dust drawn into engine due to defective ir cleaner element © Dust drawn into engine due to missing or damaged bolt, hose, or broken gasket in suction system 01-010Excessive fuel consumption ezv QUICK TROUBLESHOOTING TABLE Power Group Excessive fuel consumption TTT] ] Ii] hha dd | ;i dd Noma! fuel consugtion guidlines: 1] | Light applications: 16.28 /hour | \ | Average applications: 23.9 ¢/hour | | Heavy severe applications: 22.4 ¢/hour z]} | | \ | al | | | Note: The above figures are under thetolowng = fx} | \ | conditions, 2] | | St lle | ig [asian] Easiest [Opratin mat] | B | ee Fel ae 5) | 2/8)./3) 8 seeebeae Be Sslelgio § pete e cise Geese alge & geeeesisgs Be)g)5/2is)2 8/215) 2) 8|ai2/2) 9/3) 3 8/2 Bes 58) Pesala cose pieces 888 beeeeas improper adjusted nozzle njecion pressure | 0] | 0] || |__| Resdusimene § | Improperly atomized fuel at nozzle ol} ©] | [Readjustment 42] Imoropery or unequaly adjusted injecon amount || TO|_|_[Readivnmen = meroper seating of delve valve seat o Of) [elaconent |B | improperly adjusted injection timing | [o eagjusiment Detective boost compensator o Replacoment ‘Worn o seized piston or piston ring __|o [0] | [Repaiéreplacement 2] Worn cylinder liner _ io Repairarepiacement £2) imoroper seating between valve seat andinset’ 0 Repair Impropety adjusted vave clearance lo TO) 1 [Reasiosmont Extremely clogged air cleaner et ojo) Lf [eveanioa Clogged or damaged exhaust [CLT [nerecontrepar _,| Extremely cold engine lo! LO) | eaten 2h <. rrr inspection 3| Draaged brake | | srcadhustment Clutch slipping - i I I Disassembly&repair Seizure in dive ine | Cee Dissssembiyaropir Insufficient tre inflation pressure i I I Readsnent “g| * Note Check and if necessary replace the air cleaner retiton indicator Refer 62-045, E é 01-011Engine produces an abnormal noise a5ZV QUICK TROUBLESHOOTING TABLE Power Group 8. Engine produces an abnormal noise | | | | fl Check before starting work Oe | | a Fiel | | 8 5 | : Cy. 8 | 8 | ei ls 2] a). 9) | Bs 8g jeg] | aSegeges) | Ble §)$/2)9/8 2] pibeeees eleleig giz s/) 3 Sle /5 e//3/8/B)5) | | Sele gels se | geedeggea, ose couse BEE IE Remedy improper tiring-advance angle o|_[o|_[o eadiusinert Uneualyaajustd injacon amount lolol_{o! adhsiment § | injection timing too early - | 6 Reaciusinent [injection ting 00 lato io [ool Readusiment 2) Unequaly adjusted nozzie injection pressure lof_|_lolo reactor} 2 | impropery atomized fuel at nozzle (atter-dripping, ets) |O| _|O|0/O. L Nozze replacement Malfunction of delivery valve o|_lololo | Vaiverepiacement Poor fuel quality (low cetane value) | || Fuel replacement ‘Worn or seized internal parts —_jofolol |__| Disascembivarepair Insufficient intake air quantity olo Inspectiontrepair Improper valve clearance o seizure of valve lo} Inspeciondrepar | Lewin ex terpereure ory i - J ero colt oot 0 Ersajstnent insufficient compression pressure or compression air |, Pp Replacoment of temperature oO. Ce Excessive oll coming up into eyinder lof ol | Jol fol | | | |Regasimenta Excessive ether injecton (Cummins only) Pt tol LO) | [Reduce use of ether 01-012Engine is overheating az IV QUICK TROUBLESHOOTING TABLE Power Group Engine is overheating | Check before starting work (1) Check the coolant level | (2) Check te torque converter ol for overheat. Hit jet and outlets too sme 8 f 2 is a is 3) |g Is overheated, check te machine by refering to | =| | age page 01-020. a} |Z] Baslhs 3] [5| BigiElgia 3] 8 BBB S] ee dle/2iz ‘A WARNING ae tl i aig 5 aie 5/58 Serious burns can occur due to hot 8| (8) [e/g )2|2)3|z)2 coolant under pressure. §| 12 ae §)s)5|s|8 Never remove the radiator cap when the °) |2) |G/g/E/slsieie ‘engine or coolant is hot B gee s/s B)ais §|8/3/3/8) 5515 38/2 ele|s|5/2/ 8/2) 8/3 gise gie/f|22 8/8 2/5 B82 SiS /ElE Slelelgis Si2)8 Sielelg se ei2|/® zigie 2/98 2/3/82 818/= ale bulgigig 2 2/2i8 Possible cause oojmalels eels) <)0T Re med y ‘a] Improperly adjusted fan belt tension /broken belt jol_To| |] [Readhustmentieplace_| § | Wom or seized bearing a lof | fof | ‘Bearing replacement | Air drawn into pump from suction side lo ‘Tightening hove band | Detective water — oe Seal replacement | Damaged impelier To} ‘Pump replacement 7 [Matneonofthemosta—_ To | Replacement ‘Water leakage from coolant line lO | 4 | Coolant overtow due to Biow-by gas of TT fo! ‘Accumulation of water scale inside cylinder Block 3 o| internally cloggeé-rust/ corrosion Gy Ofo|ol {o} 5| Internally clogged-water scale oO O|O|O 3] Waterleakage 3 @ | i [ rearing T Disassembly | noreney atomized uel at nozzle | Deonbl 3 | Improperly adjusted injection timing _ Co | Readjusment 5 | Clogged or da ” “| Repair 3 | Gas leakage irom cyinder head nozzle tube FJOL [| Rewiacerent Gas leakage from head gasket [16/10 | casket epicement | Continuous operation under heavy load. or improper operation Tnstracion for operator 5 Incorrect insleation of gauge Replacement 01-013,Machine does not move in any shift lever position 85Z IV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 1. Machine does not move in any shift lever | - ] position 8 | Boe Check before starting work E lig | (1) Cheek thatthe parking brake is released PTB a | | (2) Check the torque converter ol level sof 8. (8) Check the fuse of the controller system, zlai8 Boe | (Fuse #7) ggleis| ie} (2 | | (4) Chooktnat necreutprotcerottecontotaris fx |¥/8/=, SB | |g on. (Ret 62-027) zsig2) jg ie | 2 (©) Check that the creult protector nearthebatery |S)8/B/slgi [gi 8 | |S relay is on, (et 62-014) slgzeis sels | 3 (te creut protectoris of, noeecticaloreuts | B/8/2 8/8 c/5 5 3 | F wilopeatecceptergnesanson. ronan | 5/8 8/5 ele 5 | a radio circuits.) seeegaee igs 5 8/515 RSs aa aS zig flee a8 3s g)s/=/elE|2 9) 2/8) Sbeigee ill 8/8 \2/2/5/2/2) 22 /8/8 age ae egies ge 52h e2 865 5 Possible cause SPiP le Siaie we lee) Pome ay ‘Air drawn into suction line of the torque converter pump] O|O|O) I [O}O) [Tightening hose band Defective torque converter pump ol lo) Te Pump replacement ‘Damaged torque converter ~ “| [oo ) Poiassembivarepai | Sticking clutch pressure regulator vaive ° I DisassombWyarepair ‘Malfunctioning immer solenoid valve ol L Disassembiyrepair ‘Malfunctioning inching switch olor | [Switch replacement Detective controler O)__| |_| [Contoterenacement I ime} Repairing cable 01.014Machine does not move at a certain shift lever position. a5z iv QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group | 2. Machine does not move at a certain shift lever position (OR:: Machine moves only ina certain shift lever position) g E £ Resistance ofthe solenoid valve cols too high more than 28-26 2) ‘Machine may move unexpectedly during testing causing injury or death. ‘Block the machine securely. ‘Always stay clear of the articulation ‘area and wheels when the engine Is ‘Ae cerain shit ever poston th eonoer IN LED india sumed on and will oot go ow i i 5 i 5 ‘Symptoms /check point iMochine does nol mov ala corn shit over potion, bit moves at al the ater portions iooks and smells as if it was scorched (black) ‘ores ww a canon on alo cer oer Fess noe Clutch ol prossure ls always high despite shit lever position end output LED E ‘onrter Nan OUT LED near dt corecond wn ac hr or fon ash BON é 5 8 & a i 3 2 Z Ss BR gz Fl 3\Z| Sialgis rneing. (Pale eie siz tjeeiag - a BS gota i 2€ ABE i fs 5/28 |2 a 2/3) 8) e/g] 5/3/38 |2 i [slg alajile (Ela Ezlg 2 eel a 5 8/gi2| 2/8) 8/8)& ielelelsi2i2/g/elz\2/3/z : ABREORAE 213 ale 3 2 asese galt Possible cause P)8 |e) Sa} 8 |< /e)8/6 Remedy ‘Clutch slipping lo) Jol | TT] TTT Dissrombly Seized eutoh folo| Disstonbiy Cte ol oaks internally ol | lol | Dass vof euch solena valve detect mo | Solo aie Cotte solenol valve i detctve | lo Soon val id valve disconnected Repaking cate | CCuch solenoid vatve steking in OFF postion | ac Soleo wave ‘Clutch solenoia valve sticking in ON postion cle | Selon ae SmON (es i rT Shit iover Soiior scr stkna nON Gauss ofoston| ||| CULT eee, Shitover swich teking inOFF (egardess of postion}O) | |) |O/O lo Shier id an | ‘Solenoid vaive | Damaged clutch solenoid valve diode | Seen cat - _ T Te trol Detective contoter rl jo} [eect * In some cases the solenoid valve spool eannot be pressed due to seizure of contamiraton. 2] + Retero “operation ertor preventive function” page 62.020 01-015Machine moves at the neutral position 85zV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group | 3. Machine moves at the neutral position ge & | | | (Example: Machine moves forward at the He | le i || neutral position) ie | 3 | eee Check before stating work 2.) ls | (1) Check that the ground is level He 3 a] |g ee |g 2 [2 | x|E 8 |3s 2/88 Be || Sleg js | slg eee els sai8 28/8 | sss eee gee olkieg | agains | e)28 elgisi 52) | | | Possible cause 3 58|8/5/5 83 LI | Remedy Seized chon forward side* ofo| | ° | [igor ialunetioning forward solenoid valve T [Soienoivave | (sticking at ON position)” op Oo replacomont Detective contolermauncioned air outputing "FF |_|] : ontoler replacement Defective shift lever(maifunctioned after outputting "F')"|O. lolol Tot TT Shift lever replacement ‘The same possible cause but involving the reverse clutch or circuit could occur withthe opposite symptoms. ® Remarks 01-016Large shock at staring or changine speeds /directon aezV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 4, Large shock at starting or changing speeds /direction Possible cause ‘Symptoms/hesk paint Pressing the trimmer solenoid valve with your finger wil cause the pressure to drop* ‘Large shock at a certain shift lever position only Controller output LED “D” indicator does not light properly “Temperature of the torque converter ols too high Foreign material is on the line filter Resistance of the trimmer coll is O or infinite Remedy Malfunctioning control valve or regulator valve Disassomblyarepair Maifunctioning cont plug Maifunctioning trimmer solenoid valve | (defective cal ee.) Defective immer circuit of controller Damaged or worn clutch disk ‘Trimmer solenoid vaive is sticking (closed) ‘Trimmer solenoid vaive wiring is disconnected, improperly connected, or detective TO) O [O]O] Large shock at all the shiftlever positions oO. [O)O O/O} Cuten olt pressure rises too quickly a al the shift lever positions lo Disassombiyaropair Solenoid valve replacement [Controer replacement Reconnect or repaie = Remarks In some cases, due to seizeing or contamination, the solenoid valve spool may not move by pressing. 01-017Large shock at staring or changine speed/directon _85Z IV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 5. Large time lag at starting or changing | } | ‘speed /direction | Symptoms/check point Clutch ol pressure risas to0 slowly at all the shift lever postions Clutch ol pressure is too low or rises 100 slowly at a certain shit lever {Clutch ol pressure is too low at all the shift lever positions 5 a 2 8 3 a8 gs a BR 3 8 5 2 |_| & 25 2le28 gece 8 (2/283 3 a 2 sige Elgigis8 2 (3/82 asGigis¢ |2/3/5/8 wa 535 2 sag 2 eg 2g2 88 2 lgieise Essie Ese gi8iae Seisjcle 28 2/8 /Els! sega st2558 Possible cause ° BFPO) faomecy ‘Malfuncioning contol valve or regulator valve le) [_[_ [Deassomivarepar _| Haluntonng contol vav, tre us, PuaGe | o 7) sospai Broken or non-esiient control valve spring olor jo Sring replacement Maltunctioning trimmer soleneid vaive spool (eticking oper ojo} Disassombiy@repair Detective trimmer circuit of controller O|oo| Z "|_| controler replacomont Internally leaked clutch oi 20 pero ond Maifunctioning inching pressure switch I } Switch replacement Restricted suction line-pinched, internally defectve [O10 DSTO [Reniace hose 01-018Low power ZV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group TT TT] 6. Low power (Defective torque converter or transmission) is set to the neutral position Check before starting work (1) Check the parking brake and foot brake for dragging (2) Check the torque converter oil level. (@) Check that no load is applied to the hydrauiic tine (4) Step on the accelerator pedal, and check thatthe link of the engine governor operates at full stroke. (6) Check that the stop lever ofthe engine governor Is fully open. Machine moves even ifthe shift lev. ‘Symptoms /check paint Silver powder (Aluminum) is on the line fiter and strainer O_O O | Output poweris too small at al the shift lever postions ‘Large time lag at a certain shift lever position only Pump produces an abnormal shrieking)noise ‘Output power is too small at a certain shift lever position only “Torque converter oll is discolored or emits nasty smal “Torque converter oll Is milky and cloudy in color Clutch oil prassure is too low at a certain shift iever position Pump is extremely heated Iron andlor fiber material Possible cause Remedy ° 3 ‘Ai drawn ino suction ine of oraue converter lo) | temenia eso ose Broken toque converter bine and pump | ol [| “Tergue converter eral pressuTe to ow im [autora ces Seized cutch jojo! fol) | | | | foliage Clutch slipping - a 5 ‘ol | at ssasomiy ard Internatly leaking clutch ol ol lol | | | lol a enon and “Festrcted suction ine pinched, itamaly defective JOT [lO LOL |enace rose 01-019Torque converter oi is overheating 8ezV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group T TT 7. Torque converter oil is overheating al | | lal : meen ale (ogg BiG Check before starting work | (3 ig | \z z (1) Check the torque converter oil level 3) 5 a 5 Oil level too high. | < NE 8 if (2) Check the engine coolant for overneat. tis | = Siege) | ig | idle ‘overheated, check the engine by referring to gs] 3/5/8/8 i iE age 01-013. ai ga sle8 g/l 5|= algiel jgig|8 BlEls Sie] Fe gigs ile ali 8 gl] Sgisigia) |s/scig/ale eel 2 8 algl] g|s 8 side 5 8)S/sl<| (2/2 2/2515 a Eg S| aie ls] ae ei8|/i18 E/g/S\els/2/2/8/8/8/3 9/2 /5 al2ig Sil 5 33/22 83/3 SelElsl8 sicielele gle /2 Bgeesaatg cee. 5 ele e/8/el8|2/sla/fleis tle 8/3 /8/5/8/E 8 S/Else/ 5 bE Sls 8/e/$ Ss alais/5 25/2 Bega ss s5 8 alzsa 5 Possible cause corse toa So/e) Remedy ‘A raw nest ne of true conver lo | 3) Eats Intemally torque converter leakage | | Damaged torque converter | ° 7 hese Toraue converter pup discharge anountioo sma | (0) ae Seized clutch ololo | endear Clutch slipping | Jololo| aie ‘Scale deposited in water line of torque converter cooler | ) ‘Cooler cleaning Restricted suction ine-pinched, internally detective fe) Co) (of) L Replace hose Wrong oil viscosity is used lo} jo} | peer ot Servic or parking brake dragging | | Ieee (Operator is using too high a gear for load CECT - “rain operator Incorec indication of gauge (no alarm) { Ores "Aaa switch detective (Gaugein green zone) |||) || || Repace swich Contamination in il cooler (ol side) I a} [[ Repiace cooler | Low tire pressure _ [ Adivsto epee | Oi cooler bypass valve defective (intern oO loan or Engine RPM too low Engine power 10 low I I 01-020Machine moves reverse when climbing 85ZV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 1] TT] Rly | | | 8. Machine moves reverse when starting to climb up on a slope using inching brake ‘Symptoms/check point ‘After pedal release, too much time is required to turn off the controller LED *" indicator Possible cause Remedy Large time lag in clutch engagement | tinelagoroie Delay in resetting inching pressur onl ‘Switch replacement | 01-021Automatic speed change is not possible 8ezv QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 9, Automatic speed change is not possible (Serial. No. 152 and above) Check before starting work (1) Manually change the speed from tst speed to ‘3d speed. If manual speed change is impossible, refer to page 01-015 “Machine does ot move at a certain shift lever positon.” ‘Actual speed increase or reduction does not correspond with the set speed ‘Symptoms/check point ‘Speed is fixed to 3rd speed, and is not increased to 4th speed Indicator does not light ‘Speed is fixed to 2nd speed, and automatic speed change is not possible ‘Speed is properly increased on a downward slope Controller LED "SS" does not flicker or ight when IAIC Is moving (One or more planetaries are excessively hot/parking brake is hot or a 2 3 22st 5 gigi28 Possible cause 5} £ = Remedy Baiaive sitiover"A poston or dterive wingT™ 5 1 [it ver pice conor || emia Damaged ond earea ov esmnosedwren” TO | feerngtres ‘Speed sensor signal eit eer oF MODET “177 Tensor rpaconaat adjusted speed sensor O}O} °° oF readjustment Defective controller 0} Oo _| Controller replacement Low speed(engine up power too iow) alo Fert page 01400 Parking or service brakes dragging jololo om Repair brake creat 01-022PUS (QUAD) switch does not work a5z iV QUICK TROUBLESHOOTING TABLE Torque Converter and Transmission Group 10. PUS (QUAD) switch does not work TT ] le | 1/4 | roan | | go | || | | | | | Li | | | | | | L i Check before starting work (1) Check thatthe PUS (QUAD) switeh ls actuated at the 2nd forwardreverse speed postion. Atother postons, shitting down isnot possible, (2) Check the tuses. Symptoms/check point Controler input LED "S" indicator doas nat light when the PUS (QUAD) CControler input LED "S" indicator lights when the PUS (QUAD) switch is | 5 i || } B/E. | | 5| 28 glee Possible cause sjoer tt | Remedy oT 7 [Sten repicoment Tet t T [par wre Lo Cl [[leentoter replacement 01-023Boom and/or bucket do not move, aszV QUICK TROUBLESHOOTING TABLE Hydraulic Group 1. Boom andjor bucket do not move ej] lili 2 13 igi lel BS. Ee 2 ag Check betore starting work iQ : gl] gle (1) Check the of level aie 8 | ges (2) Check thatthe loading control lock levers fuily | a zg 2E8 oon z] | 2 lel 3) | gizis es] ob 3 4 age ¥ gfe | 88 g e ls] 2g 8 £ 5 3| | |@lg) 5] |e 2} 8) | |Zisg S| |g2 2] 2 | >| [EB 2 | 3 yee ae] gee. gage 2g 0888 Biss eS 2/3 oF Rls gi3\& Sess eaalas eye peeei ies a3 He SRae gd geass Be Se\S sg S322 = 2 #3) 33/2 3/5 3|/E/3/2 3|3/8 al2| eee e(2 2/slg 2 2 3/8 2\f) 83/8 s/8 5/3/23 5 8/2 HE be 8S gsig 358 3/8 Passe cause ali 82 8 213 2/82/08 2 ea r a Broken pump dive shat lo) ‘o| Jol replement —————— [| oessono q Internally damaged steering pump iO ‘Brepair 7 £) raty daraged an pave | oltsagensy Interaly damaged plot pump | jo} | || loleesey + + Dees ‘Ol leakage from main relief valve oof fol | Ty achat Dscosent ‘Ol leakage from overioad rele valve o Jol [_ |_| eats Multiple control valve plunger sticking ey Of Ol reieinent Detective pilot reli valve lo} | | Iemadhaet (aly earaged yinder | 6 Desert ~ Exchange of he overoad elie valve means tal the valves should be changed between the rod and botom sides 5 é 01-024Boom and/or bucket have low power or slow. asz iV QUICK TROUBLESHOOTING TABLE Hydraulic Group 2. Boom andjor bucket have low power, or | 5 vig move too slowly iyi iia é Check before starting work | \3 3 (1) Check the ol eve oe : (2) Check that the loading contol lock lever is fully 1) 8 open. z 3) 8 E (8) Step on the accelerator pedal ana checkthatine |Z] | [BB | |S E lever of the engine governor operates at full x Bs] 2 Z| seks, MeasuradustHign de 9 Specs. | Ele] (8/8) | | 8 g (4) Chock that the stop lever ofthe engine governor |S |B |8)8) | 3) 2 2 is aly open, £/8|_|8/8|_ 6) § 3 (©) Checkthatthe machine doesnotmoveitine [8/3 35g 222 (8 fs shitiover ofthe ranemissionisattreneural | §/8/2/g/8/8/2/82/8) |.) 83/8 bein, Orasonatezedcturesraucapover |"'lg)g §/8/818 24/9 glee |s availabe o hycraulics clegigjzie celg|g/fi85 15 ‘isp tonya 8)8/8/3/8 8) 85/3) 2/2| 25 3 | ele Sela eie2 s/flg\es a8 Sl£|58/s/8)5|e2\¢ Bee se ee sage giegi2)3 g/2£/8/2/3)82 € Belg 222/32 /s 8/8/22 8 Posabe ause a6 8\6 6 6)a5 S2la|38 ea Internally damaged steering pump ol | | tl | Disassembly . Tal Disassemt Internally damaged main pump O10 ° tone (Ol leakage from main relief valve re | eee iO Internally damaged cylinder oO} |O Oil leakage ftom reducing valve of piotrelietvave | ‘o| 0 Diss Oils cold, wrong oil viscosity (too thick) jo} lo) | Suction sie air leak-clamp, hose, Oxings jo} 0 o} | o | |Stersrers Sucion ine pinched or hteraly defective ol fol | | o| stag sor 01-025Excessive oylinder drift az IV QUICK TROUBLESHOOTING TABLE Hydraulic Group 3. Excessive cylinder drift 2 iE | 3 ] | |22 8) } 18 8 [es 128 | The maximum dit at is measured according to lig i289 2) instuetions on page 09-013. Sig /s8 = | e |E |28 3 | a £2 gs, 8 Trapped oll under pressure can spry| | <| 8 |g £33 8 out causing injury. 3) 3 3 S883 ‘Always release tank and tapped) |5| | 2 |8 3288 8 cylinder pressure before removing} |S] | 2 |3 282 2 any ines, plugs or components. e)/ 8 |2 Sse 8 - — 1% BB, 285 2 e| | 8 23 566 = é B ef $48 Ss & |ael ess|22 eg e 28) 523 cb) 8 6 |82) S02 so £22 2 220 32 2 Beale Ee: Ff 928/83 $)2)88/ 83) 205/55 Lif: 28 382/63 Possible cause Gass se Fas Gt TRemedy Tntral boom eynder piston sel ol leakage o 6 [O_|Seaiesiacement | Internal bucket cylin piston seal ol eal O ||) fseatreracement [Ol eakage tom mail a) to Disseombivtrepair Oitieakage trom multiple contol valve overoad canase ter me ‘ol [Deassontharopar Ol eskage tom reducing valve ofpiotreietvave | || | | O Daassonbiy Brea * These tests must be carefully done or injury could result = Remarks 01-026‘The boom or bucket is spongy 8ezv QUICK TROUBLESHOOTING TABLE Hydraulic Group 4, Boom and/or bucket are spongy (Holding bucket against the ground is not possible-front wheels off the ground) or the lifted front wheels soon ig back even though the lever is at the 8 = 5 3 | é 3 | 5 2 | 2lZ [2 |2 2 | z e |i) 2 | & \2 2 | 2 Be 5 | Bag 38 | a D8 2 ge EE 8 €l2 8 geass |g 8 Sle £ Be 83_ 2 § gf gels2s jz 2 ess 23iseisel2 (2 eee able a2e|e | S28 £2 35285 & SEIS 88/83 egle le age §2 53 38 Se § Possible cause Glas £868 68/85 8 asa eay GYRE an oetoateervareeTROaRTAT |S TSO Gl) || foment < | make-up val | 0 0 (6 [___[_[Bisassombiyarepar| Make-up valve does not open on Bucket od ice r TP Potessenoyarepa Ol leakage from make-up valve for boom rod ade | S| |Dassemoiyarepai Make-up vale opening impossible on boom rod sie || EPO fiassembirpai * Regarding check point above, switching the overload relief valves means that the valves should be changed between the rod and bottom sidas of the bucket circu. % Remarks 01-027Bucket positionerikick-out) doesn't work e5Z IV QUICK TROUBLESHOOTING TABLE Hydraulic Group 5. Bucket positioner (kick-out) does not work Check before starting work (1) Cheak the fuses. (Refer to 62-015) (2) Check thatthe distance between the proximity ‘switch and detection bar is propery adjusted (6mm # 2) (@) Check all the connectors of the electrical power line tobe sure they ae properly connected. ‘Symptoms//check point LED lamp ofthe proximity switch does not Magnet coil resistance value Is indicated as infinity or O Possible cause Remedy Detective proximity ewtch ol o | Forni oc Broken magnet coil inside pilot valve [| Magnet replacement \sonnoctd elcclpowe ne | fener 01-028‘Steering is not possible or hard to steer Bz IV QUICK TROUBLESHOOTING TABLE Hydraulic Group 6. Steering is not possible or hard to steer T ] ] Pelt dap | 2 Ft ig) | Check belore starting work 3] | | le} | | (1) Check te ol level in tne stering gear box. gs | | 2 (2) Check that the drop arm stopper is properly | gs} | |g me adjusted zl] | | lel) (88) | 81 | 18 @) Creckiecondionotinesesingintene, §— |) 2g) Eg lal BE (8) Cheek operating contons. Fl rake % Be) ge) | la] ge application & heavy loading can prevent steering | # 2s |e | 3/8 ‘even when steering system is normal. S IBI5\ 5 2 3) |Ei2 (5) Measure steering wheel force to see it itis 5 (2/5/8|2 2) 28 Greater than normal. (Peter to 43-009) el, siaisle 5s) 28 ala | zislg[alg 2 2a|_ (315 sisi2ie|s/8/8)8 80/2/2818 £2 /2/8/s|\s|3/a\2/3|8|8/2/2 88/5 /8ie/2/8/S)e|8lslsie 2 fe e/8)8/2/8|8/s/g/ei2 2/218 2/3/2| 8) 2)3/2/2|/8)2/8/8/8)% Sbsaea se ciea 22) 2/2)2)2)2\8/8/8|3\2)8\¢ sags a geese fe 6 AH esis | 5/8|2 5)8|8 Foxe ee 5886 a5 2235 038 soca Tera darage of stag gearbox olol fo) | lol | Deseo Tier damage of eering pump rt Dacca erforate performance) 90) | joo | | jo) | feeear \ ‘Disassembly _Maltunctoning steering valve or ow contra plunger ° OP Jerepaie fective main relief valve | | | Disassombly | Detective man rt va —_ 9} jo] | jo terete Detective oveond rela vave ‘olol oO} [Besse Defective steering oyinder | i inched or rteraly defecve | [Of ete arena Col ol viscosity oo thick for weather I become weak steering tothe right) % Remarks * Regarding check point above, exchange of the overload relief valve means that the valves should be changed between the left and right sides. The problem will itch sides also (weak steering to the let wil, after exchange, 01-029,Machine sways, or a shock during steering a5z IV QUICK TROUBLESHOOTING TABLE Hydraulic Group 7. Machine sways, or a shock during steering i] TT] 1] | || eo \| || ETTTE LTT] || ' | gs | || || es \ | | Be yd ele | | is) || | gif gis) | sla | (8/5) | BE | (Szlelz sie | 3/2/28 Sle | [2/3/82 a|zZ | i288 gif ete Elo ge Ps Sle fgides| Lagu segs zi2:) 22 (2/2 5/5 3) 223 R28 #3 [eagle H sieges oss slsiea 23/8/2/2)5/3) Possible cause BB |2/5/5/0)0) Remedy Loose steering cyinder pin* ojo] | | | Pin replacment - Use of | Tre having aierent ameter o| | |__| eda iametor tres iaige diference i airpressure olives =|“ OO | Steering stopper bolt or bots misausted o} | Roading the machine ato hgh a speed CECT Teds speod | [Steering inkage loose or worn 6 06 I Inspect & rep nge Air trapped in eyinders o lo lo eee * Have an operator quickly move the steering wheel right and left a faw degrees. If the cylinder pin moves back & forth replace the pin & bushings. Ifthe cylinders jump up & down add shims. = Remarks 01-030Abnormal noise in hydraulic system esZV QUICK TROUBLESHOOTING TABLE 8. Abnormal noise in hydraulic system | increasing the engine speed emits a whining sound-Hydraulics slow Nolse may vary with engine speed or circut being used ‘Symptoms /eheck point Pump emits a shrieking sound Possible cause Remedy Hose band tghtoning Fran no up aon no off Terns inal atone : Seer | High-pressure hose contact with chassis. ea ‘check ‘Suction hose pinched or internally defective _ ‘Suction line or strainer restricted Inspector replace hose Drain & inspect tank 01-031Others sez iV QUICK TROUBLESHOOTING TABLE Hydraulic Group 9. Others, When the bucket lever is set to “Roll-back’ position, the bucket will be dump \When the boom lever is switched from “DOWN' to “NEUTRAL”, the boom continu to lower* z = g ‘Symptoms/check point rrixed with the torque converter oll ‘When boom lever is set to "FLOAT the boom goes only into power down. foaming (Engine may stall) jghtly down frst and then tit back ‘When the boom lever Is st to “UP* position, the boom wil and then rise Hydraulic eyinder packings leak repeatedly Passib muse Remedy Detective (incompietely closed) load check valve in T ‘multiple control valve boom line ° Lo Disassombiyéropair Datecvencorpletly cbsedjibad check valve a + Seas cee ey coon ° | | (oaged oe of slow reurn chock valvoin Beaming] | | Toiessonbiana ret ve opal valve or Eskrctonn me cet ae ah 5 TTocemoneyaroar ‘Ar eran eo pu ecto | | agen ose |* . PL ra pum } amp dase Damaged hydraulic oil pump _ a Lt lO} and repair Pit eet vave detective or misajusted Do Pages Excessive hydraulic oll temp, due to cooler problems or | | | 7 |_| Testeooling improper evarenen mporemso TT Erase tron Water in hydraulic oll [ O| Drain & replace cit * Very cold or thick ol will also cause this symptom. If the problem stops when the oll warms up or the proper viscosity ll is used the orifice is normal, = Remarks 01-032QUICK TROUBLESHOOTING TABLE a8z IV Brake does not work well Brake Group TERE 9 clezeagge 2\2|8)8|< See ele alga eee (spuey inok wo ° sds ao4m Buses sy) Aveppns paydde 5] eye1g ain uaLya sum oUILDeW ‘nea yenipe opewowne | | fy) uaaMieg ainsseid yo oy u souBreyip abe) 8} ou | Jour yoxonno pue alo no payend & pot 0849s afons s2}SeU sy “9X 1801 O40 To) WOH, ‘sreyp Ayeai8 ape u01 Jo ounssoud yo oyexq au 'possaid = jeped oHEAG OMT LOU, peseid vay sour6/ Supe no ona sod yr pu WU HR ‘ape 4201 aly jo 7eu) 0 endo soe ‘51 9pre1u0y,@1n Jo eunssaud jo axe1q ou ‘passed s!jepad aye1q ou USM, 0M JOU SBOP jeped 629 ys] 10 BU 94) JOURS ~enjen au peuioeds eur uew 88 51 fenjea se0m pourrgo ou, “siedieo Busn Hip oe19 eu Jo seem ota eunseaW, yuled yoaus 7eworauAg Defective brake valve Defective air master Defective automatic adjuster valve Improperly aligned cil passages inside wheel hub = 3 3 : 8 5 =% : 3 fee gs a) si OE EGE 3), Pad SEEE S 85 Seee g See 825s E gfe Uns 5 bse 7686 s < 6ee8 01-033