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KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL(SN:A71001 & UP) – PDF DOWNLOAD
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- KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A71001 and UP
- PUBLICATION NUMBER:CEBM004602
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KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL(SN:A71001 & UP)
KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL(SN:A71001 & UP) – PDF DOWNLOAD:
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KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL(SN:A71001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts
TABLE OF CONTENTS:
KOMATSU AVANCE PLUS WA250-3MC WHEEL LOADER SERVICE REPAIR MANUAL(SN:A71001 & UP)
MAIN MENU........................................................................................................................................ 0 COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 2 00 FORWARD....................................................................................................................................... 13 01 GENERAL....................................................................................................................................... 29 DIMENSIONAL DRAWING.......................................................................................................................... 30 GENERAL SPECIFICATIONS....................................................................................................................... 31 WEIGHT TABLE................................................................................................................................. 34 FUEL, COOLANT AND LUBRICANTS................................................................................................................. 35 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS......................................................................................... 35 ENGINE OIL SPECIFICATIONS................................................................................................................ 36 NORMAL OPERATION..................................................................................................................... 36 ARCTIC OPERATION..................................................................................................................... 36 DIESEL FUEL SPECIFICATIONS............................................................................................................... 37 COOLANT SPECIFICATIONS................................................................................................................... 37 GENERAL.............................................................................................................................. 37 WATER................................................................................................................................ 37 ANTIFREEZE........................................................................................................................... 38 INHIBITORS/CONDITIONERS.............................................................................................................. 38 10 STRUCTURE AND FUNCTION........................................................................................................................ 43 POWER TRAIN.................................................................................................................................. 47 PATH OF POWER TRANSMISSION................................................................................................................... 48 TORQUE CONVERTER, TRANSMISSION PIPING........................................................................................................ 51 HYDRAULIC SYSTEM DIAGRAM................................................................................................................. 52 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 53 TORQUE CONVERTER............................................................................................................................. 54 TORQUE CONVERTER OIL FILTER.............................................................................................................. 56 TRANSMISSION................................................................................................................................. 57 CLUTCH................................................................................................................................... 60 FORWARD, REVERSE CLUTCH.............................................................................................................. 60 1ST, 3RD CLUTCH...................................................................................................................... 61 2ND, 4TH CLUTCH...................................................................................................................... 61 FORWARD 1ST.......................................................................................................................... 63 FORWARD 2ND.......................................................................................................................... 64 FORWARD 3RD.......................................................................................................................... 65 FORWARD 4TH.......................................................................................................................... 66 REVERSE 1ST.......................................................................................................................... 67 TRANSMISSION CONTROL VALVE................................................................................................................... 68 UPPER VALVE.............................................................................................................................. 69 LOWER VALVE.............................................................................................................................. 70 TRANSMISSION SOLENOID VALVE.............................................................................................................. 71 TORQUE CONVERTER OUTLET PORT VALVE....................................................................................................... 72 PILOT REDUCING VALVE..................................................................................................................... 73 TRANSMISSION SOLENOID VALVE.............................................................................................................. 74 PRIORITY VALVE........................................................................................................................... 75 MAIN REGULATOR VALVE..................................................................................................................... 76 QUICK RETURN VALVE....................................................................................................................... 77 MODULATION FILL VALVE.................................................................................................................... 81 DIRECTIONAL SELECTOR SPOOL............................................................................................................... 83 EMERGENCY MANUAL SPOOL................................................................................................................... 84 OPERATION OF FORWARD 1ST................................................................................................................. 86 ACCUMULATOR VALVE........................................................................................................................ 88 DRIVE SHAFT.................................................................................................................................. 90 AXLE......................................................................................................................................... 91 FRONT AXLE............................................................................................................................... 91 REAR AXLE................................................................................................................................ 92 AXLE MOUNT............................................................................................................................... 94 DIFFERENTIAL................................................................................................................................. 96 FRONT DIFFERENTIAL....................................................................................................................... 96 REAR DIFFERENTIAL........................................................................................................................ 97 TORQUE-PROPORTIONING DIFFERENTIAL........................................................................................................ 99 FINAL DRIVE..................................................................................................................................100 CENTER HINGE PIN.............................................................................................................................101 STEERING PIPING..............................................................................................................................102 STEERING COLUMN..............................................................................................................................103 PRIORITY VALVE...............................................................................................................................104 STEERING VALVE (ORBITAL).....................................................................................................................107 CONNECTION BETWEEN HAND PUMP AND SLEEVE..................................................................................................114 2-WAY RESTRICTOR VALVE.......................................................................................................................116 BRAKE........................................................................................................................................117 BRAKE PIPING.............................................................................................................................117 POWER MASTER CYLINDER....................................................................................................................118 BRAKE OFF............................................................................................................................119 OIL PRESSURE STARTING TO RISE........................................................................................................119 PRESSURE RISING......................................................................................................................120 RELIEF VALVE.........................................................................................................................120 ONE BRAKE LINE ACTUATED..............................................................................................................121 BRAKE....................................................................................................................................122 PARKING BRAKE................................................................................................................................124 PARKING BRAKE CONTROL....................................................................................................................124 PARKING BRAKE............................................................................................................................125 HYDRAULIC SYSTEM.............................................................................................................................126 STEERING AND HYDRAULIC PUMP..............................................................................................................126 HYDRAULIC PIPING.........................................................................................................................127 HYDRAULIC SYSTEM DIAGRAM.................................................................................................................128 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................130 WORK EQUIPMENT LEVER LINKAGE.................................................................................................................132 HYDRAULIC TANK...............................................................................................................................133 OIL FILTER BYPASS VALVE..................................................................................................................134 BREATHER.................................................................................................................................135 PPC VALVE....................................................................................................................................137 OPERATION OF PPC VALVE...................................................................................................................138 PPC RELIEF VALVE.........................................................................................................................141 ACCUMULATOR FOR PPC VALVE................................................................................................................142 MAIN CONTROL VALVE...........................................................................................................................144 2-SPOOL VALVE............................................................................................................................144 3-SPOOL VALVE............................................................................................................................146 RELIEF VALVE.............................................................................................................................148 SAFETY VALVE (WITH SUCTION)..............................................................................................................149 SUCTION VALVE............................................................................................................................150 MAIN CONTROL VALVE OPERATION.............................................................................................................151 BOOM AND BUCKET SPOOLS AT NEUTRAL POSITION...........................................................................................151 BOOM SPOOL AT RAISE POSITION.........................................................................................................152 BOOM SPOOL AT LOWER POSITION.........................................................................................................153 BOOM SPOOL AT FLOAT POSITION.........................................................................................................154 BUCKET SPOOL AT TILT BACK POSITION...................................................................................................155 BUCKET SPOOL AT DUMP POSITION........................................................................................................156 WORK EQUIPMENT...............................................................................................................................158 WORK EQUIPMENT LINKAGE...................................................................................................................158 BUCKET...................................................................................................................................160 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................161 BUCKET POSITIONER....................................................................................................................162 BOOM KICK-OUT........................................................................................................................162 PROXIMITY SWITCHES...................................................................................................................164 ROPS CAB.....................................................................................................................................166 AIR CONDITIONER PIPING.......................................................................................................................167 MACHINE MONITOR SYSTEM.......................................................................................................................168 MAIN MONITOR.............................................................................................................................169 MAIN MONITOR DISPLAY FUNCTION........................................................................................................170 PREHEATING OUTPUT FUNCTION...........................................................................................................172 TROUBLE DATA DISPLAY MODE............................................................................................................173 MAINTENANCE MONITOR......................................................................................................................174 MAINTENANCE MONITOR DISPLAY FUNCTION.................................................................................................174 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.......................................................................................................178 SHIFT CONTROL SYSTEM FUNCTION............................................................................................................179 INPUT SIGNALS........................................................................................................................179 OUTPUT SIGNALS.......................................................................................................................180 SHIFT CHARACTERISTICS....................................................................................................................181 SAFETY FUNCTION......................................................................................................................185 TROUBLESHOOTING......................................................................................................................185 MODEL (ENGINE) SELECT SIGNAL.............................................................................................................185 TRANSMISSION CONTROLLER..................................................................................................................186 CONNECTOR SIGNALS....................................................................................................................186 LED DISPLAY..........................................................................................................................187 ECSS.........................................................................................................................................188 ECSS HYDRAULIC AND ELECTRICAL DIAGRAM....................................................................................................189 SENSORS AND SWITCHES.........................................................................................................................190 BRAKE OIL LEVEL SENSOR...................................................................................................................190 RADIATOR WATER LEVEL.....................................................................................................................191 ENGINE OIL LEVEL SENSOR..................................................................................................................191 FUEL LEVEL SENSOR........................................................................................................................192 ENGINE WATER TEMPERATURE SENSOR..........................................................................................................193 TORQUE CONVERTER OIL TEMPERATURE SENSOR..................................................................................................193 ENGINE SPEED SENSOR......................................................................................................................194 ENGINE OIL PRESSURE SENSOR...............................................................................................................194 ENGINE.......................................................................................................................................195 ENGINE STARTING CIRCUIT..................................................................................................................195 ENGINE STOP CIRCUIT......................................................................................................................196 AUTOMATIC PREHEATING CIRCUIT.............................................................................................................197 RIBBON HEATER............................................................................................................................199 Q.H.S. WATER TEMPERATURE SENSOR..........................................................................................................199 HEATER RELAY.............................................................................................................................199 ELECTRICAL TRANSMISSION CONTROL..............................................................................................................200 COMBINATION SWITCH.......................................................................................................................201 TRANSMISSION CUT-OFF FUNCTION............................................................................................................202 PARKING BRAKE NEUTRALIZER RELAY FUNCTION.................................................................................................204 KICK-DOWN SWITCH, HOLD SWITCH............................................................................................................205 KICK-DOWN SWITCH.....................................................................................................................205 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM...................................................................................................206 KICK-DOWN SWITCH OPERATED............................................................................................................207 CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I).....................................................................................208 CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE II)...................................................................................209 CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE III)..................................................................................210 ELECTRICAL WIRING DIAGRAM....................................................................................................................211 ELECTRICAL WIRING DIAGRAM (1/6)..........................................................................................................211 ELECTRICAL WIRING DIAGRAM (2/6)..........................................................................................................213 ELECTRICAL WIRING DIAGRAM (3/6)..........................................................................................................215 ELECTRICAL WIRING DIAGRAM (4/6)..........................................................................................................217 ELECTRICAL WIRING DIAGRAM (5/6)..........................................................................................................219 ELECTRICAL WIRING DIAGRAM (6/6)..........................................................................................................221 20 TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................................................223 STANDARD VALUE TABLE.........................................................................................................................227 ENGINE TABLE - IN CHASSIS................................................................................................................227 CHASSIS TABLE............................................................................................................................228 SERVICE TOOLS TABLE..........................................................................................................................236 ENGINE.......................................................................................................................................238 ADJUSTING ENGINE STOP MOTOR CABLE........................................................................................................238 ADJUSTING ENGINE STOP SOLENOID...........................................................................................................238 MEASURING AND ADJUSTING VALVE CLEARANCE..................................................................................................238 MEASURING BLOW-BY PRESSURE...............................................................................................................238 MEASURING COMPRESSION PRESSURE...........................................................................................................238 MEASURING COOLANT TEMPERATURE............................................................................................................238 MEASURING ENGINE LUBRICATING OIL PRESSURE................................................................................................238 MEASURING ENGINE SPEEDS..................................................................................................................238 MEASURING EXHAUST COLOR..................................................................................................................238 MEASURING EXHAUST GAS TEMPERATURE........................................................................................................238 MEASURING FUEL FILTER INLET RESTRICTION..................................................................................................238 TEST AND ADJUSTING FAN BELT TENSION......................................................................................................238 TEST AND ADJUSTING FUEL INJECTION TIMING.................................................................................................238 ACCELERATOR PEDAL............................................................................................................................239 OPERATING FORCE..........................................................................................................................239 OPERATING ANGLE..........................................................................................................................240 SHIFT LEVER..................................................................................................................................241 OPERATING FORCE..........................................................................................................................241 TRAVEL...................................................................................................................................241 STALL SPEEDS.................................................................................................................................242 TORQUE CONVERTER STALL SPEED.............................................................................................................242 HYDRAULIC STALL SPEED....................................................................................................................243 FULL STALL SPEED.........................................................................................................................243 TORQUE CONVERTER.............................................................................................................................244 TRANSMISSION OIL PRESSURE....................................................................................................................244 EMERGENCY MANUAL SPOOL.......................................................................................................................246 OPERATION................................................................................................................................246 STEERING WHEEL...............................................................................................................................248 PLAY.....................................................................................................................................248 OPERATING FORCE..........................................................................................................................248 OPERATING TIME...........................................................................................................................249 STEERING OIL PRESSURE........................................................................................................................250 METHOD OF MEASURING MAIN RELIEF PRESSURE.................................................................................................250 METHOD OF ADJUSTING MAIN RELIEF PRESSURE.................................................................................................251 BRAKE........................................................................................................................................252 BRAKE PEDAL..............................................................................................................................252 OPERATING EFFORT.....................................................................................................................252 TRAVEL...............................................................................................................................252 BRAKE PEDAL LINKAGE......................................................................................................................253 TESTING..............................................................................................................................253 ADJUSTING............................................................................................................................253 BRAKE PERFORMANCE........................................................................................................................255 BRAKE OIL PRESSURE.......................................................................................................................256 BRAKE DISC WEAR..........................................................................................................................257 BLEEDING AIR.............................................................................................................................258 PARKING BRAKE................................................................................................................................259 PARKING BRAKE PERFORMANCE................................................................................................................259 PARKING BRAKE LINKAGE....................................................................................................................260 PARKING BRAKE PISTON STROKE..............................................................................................................261 PARKING BRAKE DISC WEAR..................................................................................................................262 WORK EQUIPMENT...............................................................................................................................263 WORK EQUIPMENT CONTROL LEVER.............................................................................................................263 PPC VALVE................................................................................................................................264 MEASURING PRESSURE...................................................................................................................264 WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................266 WORK EQUIPMENT MEASUREMENT...............................................................................................................268 WORK EQUIPMENT - HYDRAULIC DRIFT.........................................................................................................269 BUCKET POSITIONER............................................................................................................................270 BOOM KICK-OUT................................................................................................................................271 MAIN MONITOR.................................................................................................................................273 FUEL LEVEL SENSOR............................................................................................................................275 CHECKING FOR ABNORMALITY.................................................................................................................275 TROUBLESHOOTING GENERAL......................................................................................................................277 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................279 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................281 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................................282 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.........................................................................................282 HANDLING CONTROL BOX.................................................................................................................287 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.................................................................................288 CHECKS BEFORE TROUBLESHOOTING............................................................................................................290 JUDGEMENT OF POWER TRAIN.................................................................................................................291 PRECAUTIONS WHEN TROUBLESHOOTING.........................................................................................................292 SAFETY...............................................................................................................................292 METHODS FOR TROUBLESHOOTING..........................................................................................................292 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING......................................294 PREVENTING RECURRENCE OF TROUBLE.........................................................................................................295 HYDRAULIC EQUIPMENT..................................................................................................................295 OIL CHECKS.......................................................................................................................295 CLEANING FRAGMENTS OF DAMAGED PARTS..............................................................................................295 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................296 CATEGORY OF TROUBLESHOOTING CODE NUMBER..............................................................................................296 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE..................................................................296 METHOD OF USING MATRIX TROUBLESHOOTING TABLES............................................................................................298 METHOD OF USING ENGINE RELATED CHARTS....................................................................................................300 TROUBLESHOOTING ELECTRICAL CONNECTORS........................................................................................................305 CONNECTOR TYPES..........................................................................................................................307 CONNECTOR PIN ARRANGEMENT................................................................................................................308 DIAGRAM (1/2)........................................................................................................................308 DIAGRAM (2/2)........................................................................................................................309 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................................................................310 ELECTRICAL CIRCUIT DIAGRAMS..............................................................................................................318 ENGINE START, STOP SYSTEM............................................................................................................318 PREHEATING SYSTEM....................................................................................................................319 TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...........................................................................................321 MACHINE MONITOR SYSTEM (1 of 2)......................................................................................................323 MACHINE MONITOR SYSTEM (2 of 2)......................................................................................................325 TROUBLESHOOTING SYSTEMS OF:..................................................................................................................327 TROUBLESHOOTING OF TRANSMISSION CONGTROLLER SYSTEM (A-MODE)..............................................................................327 OUTLINE..............................................................................................................................328 FUNCTION.........................................................................................................................328 TROUBLESHOOTING..................................................................................................................328 FAILURE CODE TABLE...............................................................................................................328 TABLE OF TROUBLESHOOTING MODES AND CAUSES........................................................................................329 ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................330 A-1 TROUBLESHOOTING CODE [12]........................................................................................................332 F SOLENOID SIGNAL SYSTEM.........................................................................................................332 A-2 TROUBLESHOOTING CODE [13]........................................................................................................333 R SOLENOID SIGNAL SYSTEM.........................................................................................................333 A-3 TROUBLESHOOTING CODE [14]........................................................................................................334 ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM........................................................................................334 A-4 TROUBLESHOOTING CODE [16]........................................................................................................335 ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM......................................................................................335 A-5 TROUBLESHOOTING CODE [20]........................................................................................................336 ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...................................................................................336 A-6 TROUBLESHOOTING CODE [21]........................................................................................................337 ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.........................................................................................337 A-7 TROUBLESHOOTING CODE [22]........................................................................................................338 ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM........................................................................................338 A-8 TROUBLESHOOTING CODE [23]........................................................................................................339 ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM........................................................................................339 A-9 HOLD SWITCH SIGNAL SYSTEM........................................................................................................340 A-10 KICK-DOWN SWITCH SYSTEM.........................................................................................................341 A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM..............................................................................................342 A-12 NEUTRALIZER RELAY SIGNAL SYSTEM.................................................................................................343 A-13 BUZZER SIGNAL SYSTEM............................................................................................................344 A-14 NETWORK SIGNAL SYSTEM...........................................................................................................345 A-15 CONTROLLER POWER SOURCE SYSTEM..................................................................................................346 TROUBLESHOOTING ELECTRICALLY CONTROLLED SUSPENSION SYSTEM D MODE - (ECSS)..............................................................347 ECSS-ELECTRICAL/HYDRAULIC SCHEMATIC..................................................................................................348 ECSS-WORKING CHART...................................................................................................................348 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL............................................................................................349 INSPECTION/ADJUSTMENT............................................................................................................349 TROUBLESHOOTING OF ELECTRICAL (E-MODE)...................................................................................................351 E-1 ENGINE DOES NOT START............................................................................................................352 (A) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.........................................................352 (B) CHECK FUEL SHUT-OFF SOLENOID.................................................................................................354 E-2 ENGINE DOES NOT STOP.............................................................................................................355 E-4 TRANSMISSION IS NOT SET TO NEUTRAL...............................................................................................356 WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)...................................................................356 E-10 PREHEATING IS NOT CARRIED OUT...................................................................................................358 E-11 PREHEATING REMAINS ACTUATED.....................................................................................................360 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...................................................................................363 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,...............................365 A. ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS...............................................................365 B. SOME LAMPS DO NOT LIGHT UP ...................................................................................................366 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT BO NOT GO OUT..................................366 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS..............................367 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH.............................................................368 A. ENGINE OIL LEVEL DISPLAY FLASHES..............................................................................................368 B. ENGINE WATER LEVEL DISPLAY FLASHES............................................................................................369 C. BRAKE OIL LEVEL DISPLAY FLASHES...............................................................................................370 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH..........................................................371 A. ENGINE OIL PRESSURE DISPLAY FLASHES...........................................................................................371 B. BATTERY CHARGE LEVEL DISPLAY FLASHES..........................................................................................372 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.......................................................................373 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...............................................................374 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP...........................................375 A. CHECK LAMP....................................................................................................................375 B. CAUTION LAMP..................................................................................................................375 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP.......................376 A. CHECK LAMP....................................................................................................................376 B. CAUTION LAMP..................................................................................................................376 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR............................377 K-11 NIGHT LIGHTING IS ON EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS ON......................................................378 K-12 SERVICE METER DOES NOT WORK.....................................................................................................379 K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED....................................................................................380 K-14 ABNORMALITY IN GAUGE ITEMS......................................................................................................381 A. ABNORMALITY IN FUEL GAUGE.....................................................................................................381 B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.................................................................................382 C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.........................................................................383 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)..........................................................................................385 TROUBLE DATA DISPLAY.................................................................................................................387 TABLE OF ACTION CODES AND FAILURES CODES.............................................................................................388 ACTION CODE TABLE................................................................................................................388 FAILURE CODE CHART...............................................................................................................388 M-1 MAIN MONITOR DOES NOT WORK.......................................................................................................389 M-2 WHEN STARTING SWITCH IS TURNED ON ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT..............................................390 M-3 SPEEDOMETER DISPLAYS DOES WORK PROPERLY..........................................................................................391 M-4 ABNORMALITY IN SHIFT INDICATOR...................................................................................................392 A. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F................................................................................392 B. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R................................................................................392 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F..............................392 D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R..............................393 E. DOES NOT DISPLAY 1ST, 4TH.....................................................................................................393 F. DOES NOT DISPLAY 3RD, 4TH.....................................................................................................393 G. DOES NOT DISPLAY 2ND, 3RD.....................................................................................................394 H. DOES NOT DISPLAY 1ST, 2ND.....................................................................................................394 M-5 HIGH BEAM DOES NOT LIGHT UP......................................................................................................395 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP............................................................................................396 A. L.H. TURN SIGNAL DOES NOT LIGHT UP...........................................................................................396 B. R.H. TURN SIGNAL DOES NOT LIGHT UP...........................................................................................396 M-7 ABNORMALITY IN PARKING DISPLAY...................................................................................................397 A. PARKING LAMP DOES NOT LIGHT UP................................................................................................397 B. PARKING LAMP STAYS ON.........................................................................................................397 M-8 ABNORMALITY IN PREHEATING SYSTEM.................................................................................................398 A. DOES NOT CARRY OUT PREHEATING.................................................................................................398 B. ONLY MONITOR DISPALY DOES NOT LIGHT UP........................................................................................399 C. ALWAYAS CARRIES OUT PREHEATING FOR 1 MINUTE...................................................................................399 D. PREHEATING STAYS ON...........................................................................................................399 E. PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE................................................................................400 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.................................................................................................402 M-10 ABNORMALITY IN FRONT WORKING LAMP...............................................................................................403 A. NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP .....................................................................403 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP.................................................................403 C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP.........................................................................403 M-11 ABNORMALITY IN REAR WORKING LAMP................................................................................................404 A. NEITHER MONITOR DISPLAY, NOR REAR WORKING LAMP LIGHT UP ......................................................................404 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP.................................................................404 C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP.........................................................................404 M-12 ABNORMALITY IN TRNASMISSION CUT-OFF.............................................................................................406 A. WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT NOT SWITCHED AND DISPALY IS NOT GIVEN.................................406 B. MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON.......................................................................406 C. MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED...............................................................407 M-13 ABNORMALITY IN PARKING DRAGGING WARNING.........................................................................................408 A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N AND CAUTION LAMP FLASHES....408 B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT ....408 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, ...............................410 A. ACTUATED CONTINUOUSLY.........................................................................................................410 B. NOT ACTUATED..................................................................................................................410 M-15 ABNORMALITY IN BUZZER...........................................................................................................411 A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)...................................................411 B. BUZZER ALWAYS SOUNDS..........................................................................................................411 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...........................................................................412 M-17 ABNORMALITY IN FALIURE DISPLAY MODE.............................................................................................413 A. DOES NOT ENTER FAILURE DISPLAY MODE...........................................................................................413 B. TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE..................................................413 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)................................................................................................414 S1 STARTING PERFORMANCE IS POOR......................................................................................................416 S2 ENGINE DOES NOT START.............................................................................................................417 (1) ENGINE DOES NOT TURN.........................................................................................................417 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT....................................................................................418 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START..............................................................................419 S-3 ENGINE DOES NOT PICK UP SMOOTHLY.................................................................................................420 S-4 ENGINE STOPS DURING OPERATIONS...................................................................................................421 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................422 S-6 ENGINE LACKS OUTPUT (NO POWER)...................................................................................................423 S-7 EXHAUST GAS IS BLACK.............................................................................................................424 S-8 OIL CONSUMPTION IS EXCESSIVE.....................................................................................................425 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................426 S-10 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................427 S-11 OIL IN COOLING WATER............................................................................................................428 S-12 OIL PRESSURE LAMP LIGHTS UP.....................................................................................................429 S-13 OIL LEVEL RISES.................................................................................................................430 S-14 WATER TEMPERATURE BECOMES TOO HIGH..............................................................................................431 S-15 ABNORMAL NOISE IS MADE..........................................................................................................432 S-16 VIBRATION IS EXCESSIVE..........................................................................................................433 TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)...............................................................................434 POWER TRAIN..........................................................................................................................436 T-1 MACHINE DOES NOT START.......................................................................................................436 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.........................................................437 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.......................................................................439 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....................................................................440 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....................................................................................441 STEERING SYSTEM......................................................................................................................442 T-6 STEEERING WHEEL DOES NOT TURN................................................................................................442 T-7 STEERING IS HEAVY............................................................................................................443 T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK............................................................................444 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING........................................................................444 BRAKE SYSTEM.........................................................................................................................445 T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR................................................................................445 T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS..........................................................................................446 WORK EQUIPMENT.......................................................................................................................447 T-12 BOOM DOES NOT RISE..........................................................................................................447 T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER...........................................................................448 T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT....................................................................449 T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)..................................................................449 T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM...........................................................................................449 T-17 BOOM SHAKES DURING OPERATION................................................................................................450 T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....................................................450 T-19 BUCKET DOES NOT TILT BACK...................................................................................................451 T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER............................................................................452 T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.....................................................................453 T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER................................................................................453 T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.........................................................................................453 T-24 BUCKET SHAKES DURING LOADING PERATION.......................................................................................454 T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...................................................454 T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY...............................................................455 TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER...................................................................................456 SERVICE TOOLS........................................................................................................................458 GAUGE MANIFOLD...................................................................................................................458 STRUCTURE AND HANDLING OF GAUGE MANIFOLD.....................................................................................459 CHARGING HOSES...............................................................................................................461 GAS LEAK DETECTOR................................................................................................................462 HALIDE TORCH LEAK DETECTOR...................................................................................................462 ELECTRIC LEAK TESTER.........................................................................................................464 VALVE FOR SERVICE CANS...........................................................................................................466 MAINTENANCE PROCEDURE................................................................................................................467 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...................................................................................467 PROHIBITED WORK..............................................................................................................467 OTHER PRECAUTIONS............................................................................................................467 BLEEDING AIR FROM REFRIGERATION CIRCUIT..........................................................................................469 PURPOSE......................................................................................................................469 CONNECTING GAUGE MANIFOLD....................................................................................................469 EVACUATION...................................................................................................................470 AIR-TIGHTNESS CHECK..........................................................................................................470 GAS-LEAK CHECK...............................................................................................................471 EVACUATION (REPEATING).......................................................................................................471 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT..............................................................................472 CHARGING FROM THE HIGH-PRESSURE SIDE.........................................................................................472 CHARGING FROM THE LOW PRESSURE SIDE..........................................................................................473 WHEN THE AMBIENT TEMPERATURE IS LOW..........................................................................................474 WHEN THE AMBIENT TEMPERATURE IS HIGH.........................................................................................474 REPLACING SERVICE CANS...........................................................................................................475 CHECKING THE AMOUNT OF REFRIGERANT...............................................................................................475 REMOVAL OF GAUGE MANIFOLD........................................................................................................477 DISCHARGING THE REFRIGERANT......................................................................................................477 DAILY CHECKS.....................................................................................................................478 CHECK REFRIGERANT LEVEL......................................................................................................478 CLEANING THE CONDENSER.......................................................................................................478 CHECKING THE V-BELT..............................................................................................................478 CHECKING OIL LEVEL...............................................................................................................479 PROCEDURE FOR CHECKING.......................................................................................................479 PROCEDURE FOR CHECKING OIL LEVEL.............................................................................................479 ADDING AND REMOVING OIL......................................................................................................480 ADDING OIL BY EVACUATION.....................................................................................................480 TROUBLESHOOTING......................................................................................................................481 VISUAL AND ACOUSTICAL CHECKS.....................................................................................................481 DEFECTIVE COOLING................................................................................................................482 TROUBLESHOOTING TABLE............................................................................................................ 0 DEFECTIVE HEATING................................................................................................................486 TROUBLESHOOTING USING GAUGE MANIFOLD.............................................................................................487 PREPARATIONS BEFORE MEASURING................................................................................................487 INSUFFICIENT REFRIGERANT.....................................................................................................487 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER...................................................................488 AIR INSIDE REFRIGERATION SYSTEM..............................................................................................489 MOISTURE IN REFRIGERATING SYSTEM.............................................................................................490 REFRIGERANT DOES NOT CIRCULATE...............................................................................................491 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE............................................492 DEFECTIVE COMPRESSION BY COMPRESSOR..........................................................................................493 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................494 METHOD OF USING MANUAL.......................................................................................................................498 PRECAUTIONS DURING OPERATION.................................................................................................................499 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...............................................................................................499 PRECAUTIONS WHEN CARRYING OUT INTSTALLATION WORK.........................................................................................500 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...............................................................................................501 OTHER PRECAUTIONS........................................................................................................................501 SPECIAL TOOL LIST............................................................................................................................502 ENGINE.......................................................................................................................................505 ALTERNATOR...............................................................................................................................505 CYLINDER HEAD............................................................................................................................505 ENGINE OIL COOLER........................................................................................................................505 FUEL INJECTION PUMP......................................................................................................................505 NOZZLE HOLDER............................................................................................................................505 STARTING MOTOR...........................................................................................................................505 THERMOSTAT...............................................................................................................................505 TURBOCHARGER.............................................................................................................................505 WATER PUMP...............................................................................................................................505 COVERS, LADDER AND ENGINE HOOD...............................................................................................................506 REMOVAL..................................................................................................................................506 INSTALLATION.............................................................................................................................509 RADIATOR, HYDRAULIC COOLER...................................................................................................................510 REMOVAL..................................................................................................................................510 INSTALLATION.............................................................................................................................511 MUFFER AND AIR CLEANER.......................................................................................................................512 REMOVAL..................................................................................................................................512 INSTALLATION.............................................................................................................................512 ENGINE.......................................................................................................................................513 REMOVAL..................................................................................................................................513 INSTALLATION.............................................................................................................................516 TORQUE COVERTER CHARGING PUMP................................................................................................................517 REMOVAL..................................................................................................................................517 INSTALLATION.............................................................................................................................517 TORQUE COVERTER TRANSMISSION.................................................................................................................518 REMOVAL..................................................................................................................................518 INSTALLATION.............................................................................................................................527 TORQUE COVERTER..............................................................................................................................529 DISASSEMBLY..............................................................................................................................529 ASSEMBLY.................................................................................................................................531 TRANSMISSION.................................................................................................................................533 DISASSEMBLY..............................................................................................................................533 ASSEMBLY.................................................................................................................................542 CLUTCH PACK..................................................................................................................................555 DISASSEMBLY..............................................................................................................................555 DISASSEMBLY OF FR CLUTCH PACK........................................................................................................555 DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK...............................................................................................557 DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK...............................................................................................559 ASSEMBLY.................................................................................................................................561 ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK.............................................................................................561 ASSEMBLY OF 1ST AND 3RD CLUTCH PACK..................................................................................................565 ASSEMBLY OF 2ND AND 4TH CLUTCH PACK..................................................................................................569 PARKING BRAKE................................................................................................................................573 DISASSEMBLY..............................................................................................................................573 ASSEMBLY.................................................................................................................................575 TRANSMISSION CONTROL VALVE...................................................................................................................578 REMOVAL..................................................................................................................................578 INSTALLATION.............................................................................................................................580 DISASSEMBLY..............................................................................................................................581 ASSEMBLY.................................................................................................................................583 TRANSMISSION SOLENIOD VALVE..................................................................................................................586 DISASSEMBLY..............................................................................................................................586 ASSEMBLY.................................................................................................................................587 ACCUMULATOR VALVE............................................................................................................................588 DISASSEMBLY..............................................................................................................................588 ASSEMBLY.................................................................................................................................589 DRIVE SHAFT..................................................................................................................................590 DISASSEMBLY..............................................................................................................................590 ASSEMBLY.................................................................................................................................592 FRONT AXLE...................................................................................................................................594 REMOVAL..................................................................................................................................594 INSTALLATION.............................................................................................................................596 REAR AXLE....................................................................................................................................597 REMOVAL..................................................................................................................................597 INSTALLATION.............................................................................................................................601 DIFFERENTIAL.................................................................................................................................604 DISASSEMBLY..............................................................................................................................604 ASSEMBLY.................................................................................................................................608 AXLE HOUSING.................................................................................................................................617 DISASSEMBLY..............................................................................................................................590 ASSEMBLY.................................................................................................................................622 CENTER HINGE PIN.............................................................................................................................628 REMOVAL..................................................................................................................................628 INSTALLATION.............................................................................................................................635 STEERING VALVE...............................................................................................................................639 REMOVAL..................................................................................................................................639 INSTALLATION.............................................................................................................................641 DISASSEMBLY..............................................................................................................................642 DISASSEMBLY OF ROTOR.................................................................................................................642 ASSEMBLY.................................................................................................................................645 ASSEMBLY OF CONTROL SIDE.............................................................................................................645 ASSEMBLY OF ROTOR....................................................................................................................647 PRIORITY VALVE...............................................................................................................................650 REMOVAL..................................................................................................................................650 INSTALLATION.............................................................................................................................651 STEERING CYLINDER............................................................................................................................652 REMOVAL..................................................................................................................................652 INSTALLATION.............................................................................................................................653 POWER MASTER CYLINDER........................................................................................................................654 REMOVAL..................................................................................................................................654 INSTALLATION.............................................................................................................................655 DISASSEMBLY..............................................................................................................................656 ASSEMBLY.................................................................................................................................659 PARKING BRAKE DISC...........................................................................................................................664 REMOVAL..................................................................................................................................664 INSTALLATION.............................................................................................................................665 HYDRAULIC TANK...............................................................................................................................666 REMOVAL..................................................................................................................................666 INSTALLATION.............................................................................................................................667 HYDRAULIC FILTER.............................................................................................................................668 REMOVAL..................................................................................................................................668 INSTALLATION.............................................................................................................................668 WORK EQUIPMENT...............................................................................................................................669 REMOVAL..................................................................................................................................669 INSTALLATION.............................................................................................................................670 MAIN CONTROL VALVE...........................................................................................................................671 REMOVAL..................................................................................................................................671 INSTALLATION.............................................................................................................................672 DISASSEMBLY..............................................................................................................................674 ASSEMBLY.................................................................................................................................676 HYDRAULIC LINES..............................................................................................................................677 PPC VALVE TO MAIN CONTROL VALVE..........................................................................................................677 PPC VALVE....................................................................................................................................679 REMOVAL..................................................................................................................................679 INSTALLATION.............................................................................................................................680 CYLINDER.....................................................................................................................................681 BUCKET CYLINDER..........................................................................................................................681 REMOVAL..............................................................................................................................681 INSTALLATION.........................................................................................................................682 BOOM CYLINDER................................................................................................................................683 REMOVAL..................................................................................................................................683 INSTALLATION.............................................................................................................................684 HYDRAULIC CYLINDER...........................................................................................................................685 DISASSEMBLY..............................................................................................................................685 ASSEMBLY.................................................................................................................................687 WORK EQUIPMENT...............................................................................................................................690 REMOVAL..................................................................................................................................690 INSTALLATION.............................................................................................................................693 ECSS SYSTEM..................................................................................................................................695 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL................................................................................................695 ECSS SOLENOID VALVE......................................................................................................................696 REMOVAL..............................................................................................................................696 INSTALLATION.........................................................................................................................696 ECSS CONTROL VALVE.......................................................................................................................697 REMOVAL..............................................................................................................................697 INSTALLATION.........................................................................................................................697 COUNTERWEIGHT................................................................................................................................698 REMOVAL..................................................................................................................................698 INSTALLATION.............................................................................................................................698 FUEL TANK....................................................................................................................................699 REMOVAL..................................................................................................................................699 INSTALLATION.............................................................................................................................700 CAB (ROPS)...................................................................................................................................701 REMOVAL..................................................................................................................................701 INSTALLATION.............................................................................................................................702 MONITOR......................................................................................................................................703 MAIN MONITOR.............................................................................................................................703 REMOVAL..............................................................................................................................703 INSTALLATION.........................................................................................................................704 MAINTENANCE MONITOR......................................................................................................................705 REMOVAL..............................................................................................................................705 INSTALLATION.........................................................................................................................705 AIR CONDITIONER..............................................................................................................................706 AIR CONDITIONER UNIT.....................................................................................................................706 REMOVAL..............................................................................................................................706 INSTALLATION.........................................................................................................................711 CONDENSER................................................................................................................................712 REMOVAL..............................................................................................................................712 INSTALLATION.........................................................................................................................713 DRY RECIEVER.............................................................................................................................714 REMOVAL..................................................................................................................................714 INSTALLATION.........................................................................................................................715 COMPRESSOR...............................................................................................................................716 REMOVAL..............................................................................................................................716 INSTALLATION.........................................................................................................................717 40 MAINTENANCE STANDARD..........................................................................................................................767 TRANSMISSION, ENGINE MOUNT...................................................................................................................768 TORQUE CONVERTER CHARGING PUMP...............................................................................................................770 SAL (2) 32 + SAL (2) 25..................................................................................................................770 TORQUE CONVERTER.............................................................................................................................772 TRANSMISSION.................................................................................................................................775 FORWARD, REVERSE CLUTCH..................................................................................................................782 1ST, 3RD CLUTCH..........................................................................................................................784 2nd, 4th CLUTCH..........................................................................................................................786 TRANSMISSION CONTROL VALVE...................................................................................................................788 UPPER VALVE..............................................................................................................................788 LOWER VALVE..............................................................................................................................792 SOLENOID VALVE...........................................................................................................................794 ACCUMULATOR VALVE........................................................................................................................796 DRIVE SHAFTS.................................................................................................................................798 DIFFERENTIAL.................................................................................................................................800 FINAL DRIVE..................................................................................................................................806 AXLE MOUNT...................................................................................................................................808 CENTER HINGE PIN.............................................................................................................................810 STEERING COLUMN..............................................................................................................................812 PRIORITY VALVE...............................................................................................................................814 MASTER CYLINDER..............................................................................................................................816 BRAKE........................................................................................................................................818 PARKING BRAKE................................................................................................................................820 HYDRAULIC PUMP...............................................................................................................................821 MAIN CONTROL VALVE...........................................................................................................................822 2-SPOOL VALVE............................................................................................................................822 3-SPOOL VALVE............................................................................................................................826 PPC VALVE....................................................................................................................................830 HYDRAULIC CYLINDER...........................................................................................................................832 STEERING CYLINDER MOUNT......................................................................................................................834 WORK EQUIPMENT LINKAGE.......................................................................................................................836 BUCKET.......................................................................................................................................840 BUCKET POSITIONER AND KICK-OUT...............................................................................................................842 90 OTHERS........................................................................................................................................843 ELECTRICAL WIRING DIAGRAM (1/6)..............................................................................................................845 ELECTRICAL WIRING DIAGRAM (2/6)..............................................................................................................847 ELECTRICAL WIRING DIAGRAM (3/6)..............................................................................................................849 ELECTRICAL WIRING DIAGRAM (4/6)..............................................................................................................851 ELECTRICAL WIRING DIAGRAM (5/6)..............................................................................................................853 ELECTRICAL WIRING DIAGRAM (6/6)..............................................................................................................855 TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...................................................................................................857 MACHINE MONITOR SYSTEM (1 OF 2)..............................................................................................................859 MACHINE MONITOR SYSTEM (2 OF 2)..............................................................................................................861
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