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KOMATSU AVANCE PLUS WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL (SN:A78001 AND UP) – PDF DOWNLOAD
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- KOMATSU AVANCE PLUS WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A78001 AND UP
- PUBLICATION NUMBER:CEBM004702
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KOMATSU AVANCE PLUS WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL (SN:A78001 AND UP)
KOMATSU AVANCE PLUS WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL (SN:A78001 AND UP) – PDF DOWNLOAD:
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KOMATSU AVANCE PLUS WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL (SN:A78001 AND 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 WA250PT-3MC PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL (SN:A78001 AND UP)
MAIN MENU................................................................................................................................ 0 COVER.................................................................................................................................... 1 CONTENTS................................................................................................................................. 2 00 FORWARD............................................................................................................................... 13 SAFETY............................................................................................................................... 13 SAFETY NOTICE.................................................................................................................... 13 IMPORTANT SAFETY NOTICE...................................................................................................... 13 GENERAL PRECAUTIONS.......................................................................................................... 13 PREPARATIONS FOR WORK........................................................................................................ 13 PRECAUTIONS DURING WORK...................................................................................................... 13 GENERAL.............................................................................................................................. 15 HOW TO READ THE SHOP MANUAL.......................................................................................................... 16 VOLUMES.......................................................................................................................... 16 DISTRIBUTION AND UPDATING........................................................................................................ 16 FILING METHOD.................................................................................................................... 16 REVISED EDITION MARK............................................................................................................. 16 REVISIONS........................................................................................................................ 16 SYMBOLS.......................................................................................................................... 16 HOISTING INSTRUCTIONS................................................................................................................ 17 HOISTING......................................................................................................................... 17 WIRE ROPES....................................................................................................................... 17 COATING MATERIALS.................................................................................................................... 18 STANDARD TIGHTENING TORQUE........................................................................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS..................................................................................... 20 TIGHTENING TORQUE OF HOSE NUTS................................................................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......................................................................................... 21 TIGHTENING TORQUE FOR FLARED NUTS................................................................................................ 21 ELECTRIC WIRE CODE................................................................................................................... 22 CLASSIFICATION BY THICKNESS...................................................................................................... 22 CLASSIFICATION BY COLOR AND CODE................................................................................................. 22 CONVERSION TABLES.................................................................................................................... 23 METHOD OF USING THE CONVERSION TABLE............................................................................................. 23 01 GENERAL............................................................................................................................... 29 SPECIFICATION DRAWING................................................................................................................ 30 WA250PT-3 (WITH BUCKET ATTACHMENT)............................................................................................... 30 WA250PT-3 (WITH FORK ATTACHMENT)................................................................................................. 32 SPECIFICATIONS....................................................................................................................... 34 WA250PT-3 (MATERIAL HANDLING ARM)................................................................................................ 36 WEIGHT TABLE......................................................................................................................... 38 FUEL, COOLANT AND LUBRICANTS......................................................................................................... 39 ENGINE OIL SPECIFICATIONS........................................................................................................ 40 NORMAL OPERATION............................................................................................................. 40 ARCTIC OPERATION............................................................................................................. 40 DRIVE TRAIN, BRAKE AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....................................................................... 41 FINAL DRIVE OIL SPECIFICATIONS............................................................................................... 41 DRIVE AXLE OIL SPECIFICATIONS................................................................................................ 41 DIESEL FUEL SPECIFICATIONS....................................................................................................... 41 COOLANT SPECIFICATIONS........................................................................................................... 42 SUPPLEMENTAL COOLANT ADDITIVES............................................................................................... 44 COOLING SYSTEM TEST KIT...................................................................................................... 48 10 STRUCTURE AND FUNCTION................................................................................................................ 49 POWER TRAIN.......................................................................................................................... 53 PATH OF POWER TRANSMISSION....................................................................................................... 54 TORQUE CONVERTER AND TRANSMISSION PIPING......................................................................................... 56 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM............................................................................................ 57 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM........................................................................................... 58 TORQUE CONVERTER..................................................................................................................... 59 TORQUE CONVERTER OIL FILTER...................................................................................................... 61 TRANSMISSION......................................................................................................................... 63 CLUTCH........................................................................................................................... 66 FORWARD, REVERSE CLUTCH...................................................................................................... 66 1ST, 3RD CLUTCH.............................................................................................................. 67 2ND, 4TH CLUTCH.............................................................................................................. 67 OPERATION OF CLUTCH.......................................................................................................... 68 FORWARD 1ST.................................................................................................................. 69 FORWARD 2ND.................................................................................................................. 70 FORWARD 3RD.................................................................................................................. 71 FORWARD 4TH.................................................................................................................. 72 REVERSE 1ST.................................................................................................................. 73 TRANSMISSION CONTROL VALVE....................................................................................................... 75 UPPER VALVE.................................................................................................................. 76 LOWER VALVE.................................................................................................................. 77 TRANSMISSION SOLENOID VALVE.................................................................................................. 78 TORQUE CONVERTER OUTLET PORT VALVE........................................................................................... 79 PILOT REDUCING VALVE......................................................................................................... 80 TRANSMISSION SOLENOID VALVE.................................................................................................. 81 PRIORITY VALVE............................................................................................................... 82 MAIN REGULATOR VALVE......................................................................................................... 83 QUICK RETURN VALVE........................................................................................................... 84 MODULATION FILL VALVE........................................................................................................ 88 DIRECTIONAL SELECTOR SPOOL................................................................................................... 90 EMERGENCY MANUAL SPOOL....................................................................................................... 91 DRIVE SHAFT.......................................................................................................................... 96 AXLE................................................................................................................................. 97 FRONT AXLE....................................................................................................................... 97 FRONT DIFFERENTIAL............................................................................................................... 98 REAR AXLE........................................................................................................................ 99 REAR DIFFERENTIAL................................................................................................................100 TORQUE PROPORTIONING DIFFERENTIAL................................................................................................102 FINAL DRIVE..........................................................................................................................103 AXLE MOUNT...........................................................................................................................104 FRONT AXLE.......................................................................................................................105 REAR AXLE........................................................................................................................105 CENTER HINGE PIN.....................................................................................................................106 STEERING PIPING......................................................................................................................107 STEERING COLUMN......................................................................................................................108 PRIORITY VALVE.......................................................................................................................109 STEERING VALVE (ORBITAL).............................................................................................................112 CONNECTION BETWEEN HAND PUMP AND SLEEVE..........................................................................................118 2-WAY RESTRICTOR VALVE...............................................................................................................120 BRAKE PIPING.........................................................................................................................121 POWER MASTER CYLINDER................................................................................................................122 BRAKE OFF........................................................................................................................123 OIL PRESSURE STARTING TO RISE....................................................................................................123 PRESSURE RISING..................................................................................................................124 RELIEF VALVE.....................................................................................................................124 ONE BRAKE LINE ACTUATED..........................................................................................................125 BRAKE................................................................................................................................126 OPERATION........................................................................................................................127 PARKING BRAKE CONTROL............................................................................................................128 PARKING BRAKE....................................................................................................................129 HYDRAULIC PIPING.....................................................................................................................130 STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM................................................................................132 WORK EQUIPMENT LEVER LINKAGE.........................................................................................................134 HYDRAULIC TANK.......................................................................................................................135 OIL FILTER BYPASS VALVE..........................................................................................................136 BREATHER.........................................................................................................................137 PPC VALVE............................................................................................................................138 OPERATION OF PPC VALVE...........................................................................................................140 FUNCTION OF PPC VALVE............................................................................................................141 PPC RELIEF VALVE.....................................................................................................................143 ACCUMULATOR (FOR PPC VALVE)..........................................................................................................144 MAIN CONTROL VALVE...................................................................................................................145 3-SPOOL VALVE....................................................................................................................145 RELIEF VALVE.....................................................................................................................147 SAFETY VALVE (WITH SUCTION)......................................................................................................148 SUCTION VALVE................................................................................................................149 BOOM AND BUCKET SPOOL AT "NEUTRAL" POSITION......................................................................................150 BOOM SPOOL AT "RAISE" POSITION...................................................................................................151 BOOM SPOOL AT "LOWER" POSITION...................................................................................................152 BOOM SPOOL AT "FLOAT" POSITION...................................................................................................153 BUCKET SPOOL AT "TILT BACK" POSITION.............................................................................................154 BUCKET SPOOL AT "DUMP" POSITION - SLOW SPEED DUMP................................................................................155 BUCKET SPOOL AT "DUMP" POSITION - FAST SPEED DUMP................................................................................156 COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED......................................................................................157 COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL......................................................................................158 WORK EQUIPMENT LINKAGE...............................................................................................................159 BUCKET...............................................................................................................................161 BUCKET POSITIONER AND BOOM KICK-OUT..................................................................................................162 BUCKET OR FORK POSITIONER........................................................................................................163 BOOM KICK-OUT....................................................................................................................163 PROXIMITY SWITCH.................................................................................................................165 OPERATION OF THE PROXIMITY SWITCH............................................................................................167 ROPS CAB.............................................................................................................................168 AIR CONDITIONER......................................................................................................................169 AIR CONDITIONER PIPING...........................................................................................................169 MACHINE MONITOR SYSTEM...............................................................................................................170 MAIN MONITOR.........................................................................................................................171 MAIN MONITOR DISPLAY FUNCTION....................................................................................................172 PREHEATING OUTPUT FUNCTION.......................................................................................................174 MAINTENANCE MONITOR DISPLAY FUNCTION.................................................................................................176 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM...............................................................................................179 SYSTEM...........................................................................................................................179 SHIFT CONTROL SYSTEM FUNCTION....................................................................................................180 INPUT SIGNALS................................................................................................................180 OUTPUT SIGNALS...............................................................................................................180 SHIFT CHARACTERISTICS........................................................................................................181 SAFETY FUNCTION..................................................................................................................184 TROUBLESHOOTING..................................................................................................................185 MODEL (ENGINE) SELECT SIGNAL.....................................................................................................185 TRANSMISSION CONTROLLER..........................................................................................................186 LED DISPLAY..................................................................................................................187 SENSORS AND SWITCHES.............................................................................................................188 BRAKE OIL LEVEL SENSOR.......................................................................................................188 RADIATOR WATER LEVEL.............................................................................................................189 ENGINE OIL LEVEL SENSOR..........................................................................................................189 FUEL LEVEL SENSOR................................................................................................................190 ENGINE COOLANT TEMPERATURE SENSOR................................................................................................191 ENGINE SPEED SENSOR..............................................................................................................192 ENGINE OIL PRESSURE SENSOR.......................................................................................................192 ELECTRICAL WIRING DIAGRAM (1/7)......................................................................................................193 ELECTRICAL WIRING DIAGRAM (2/7)......................................................................................................195 ELECTRICAL WIRING DIAGRAM (3/7)......................................................................................................197 ELECTRICAL WIRING DIAGRAM (4/7)......................................................................................................199 ELECTRICAL WIRING DIAGRAM (5/7)......................................................................................................201 ELECTRICAL WIRING DIAGRAM (6/7)......................................................................................................203 ELECTRICAL WIRING DIAGRAM (7/7)......................................................................................................205 ENGINE STARTING CIRCUIT..............................................................................................................207 ENGINE STOP CIRCUIT..................................................................................................................208 AUTOMATIC PREHEATING CIRCUIT.........................................................................................................209 RIBBON HEATER....................................................................................................................211 Q.H.S. WATER TEMPERATURE SENSOR..................................................................................................211 HEATER RELAY.....................................................................................................................211 ELECTRICAL TRANSMISSION CONTROL......................................................................................................212 COMBINATION SWITCH...................................................................................................................213 TRANSMISSION CUT-OFF FUNCTION........................................................................................................214 PARKING BRAKE NEUTRALIZER RELAY FUNCTION.............................................................................................216 KICK DOWN, HOLD SWITCH...............................................................................................................217 KICK-DOWN SWITCH.................................................................................................................217 HOLD SWITCH......................................................................................................................217 KICK DOWN ELECTRIC CIRCUIT DIAGRAM...................................................................................................218 DUMP SPEED SWITCH....................................................................................................................223 QUICK COUPLER SWITCH.................................................................................................................224 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................................................................................225 STANDARD VALUE TABLE.................................................................................................................229 ENGINE TABLE - IN CHASSIS........................................................................................................229 CHASSIS TABLE....................................................................................................................230 ELECTRICAL PARTS TABLE...........................................................................................................235 SERVICE TOOLS TABLE..................................................................................................................238 ENGINE...............................................................................................................................240 ADJUSTING ENGINE STOP MOTOR CABLE................................................................................................240 ADJUSTING ENGINE STOP SOLENOID...................................................................................................240 MEASURING AND ADJUSTING VALVE CLEARANCE..........................................................................................240 MEASURING BLOW-BY PRESSURE.......................................................................................................240 MEASURING COMPRESSION PRESSURE...................................................................................................240 MEASURING COOLANT TEMPERATURE....................................................................................................240 MEASURING ENGINE LUBRICATING OIL PRESSURE........................................................................................240 MEASURING ENGINE SPEEDS..........................................................................................................240 MEASURING EXHAUST COLOR..........................................................................................................240 MEASURING EXHAUST GAS TEMPERATURE................................................................................................240 MEASURING FUEL FILTER INLET RESTRICTION..........................................................................................240 TEST AND ADJUSTING FAN BELT TENSION..............................................................................................240 TEST AND ADJUSTING FUEL INJECTION TIMING.........................................................................................240 ACCELERATOR PEDAL....................................................................................................................241 OPERATING FORCE..................................................................................................................241 OPERATING ANGLE..................................................................................................................242 SHIFT LEVER..........................................................................................................................243 OPERATING FORCE..................................................................................................................243 TRAVEL...........................................................................................................................243 STALL SPEEDS.........................................................................................................................244 TORQUE CONVERTER STALL SPEED.....................................................................................................244 HYDRAULIC STALL SPEED............................................................................................................245 FULL STALL SPEED.................................................................................................................245 TORQUE CONVERTER.....................................................................................................................246 TRANSMISSION OIL PRESSURE............................................................................................................246 EMERGENCY MANUAL SPOOL...............................................................................................................248 OPERATION........................................................................................................................248 STEERING WHEEL.......................................................................................................................250 PLAY.............................................................................................................................250 OPERATING FORCE..................................................................................................................250 OPERATING TIME...................................................................................................................251 STEERING OIL PRESSURE................................................................................................................252 METHOD OF MEASURING MAIN RELIEF PRESSURE.........................................................................................252 METHOD OF ADJUSTING MAIN RELIEF PRESSURE.........................................................................................253 BRAKE................................................................................................................................254 BRAKE PEDAL......................................................................................................................254 OPERATING EFFORT.............................................................................................................254 TRAVEL.......................................................................................................................254 BRAKE PEDAL LINKAGE..............................................................................................................255 TESTING......................................................................................................................255 ADJUSTING....................................................................................................................255 BRAKE PERFORMANCE................................................................................................................257 BRAKE OIL PRESSURE...............................................................................................................258 BRAKE DISC WEAR..................................................................................................................259 BLEEDING AIR.....................................................................................................................260 PARKING BRAKE........................................................................................................................261 PARKING BRAKE PERFORMANCE........................................................................................................261 PARKING BRAKE LINKAGE............................................................................................................262 PARKING BRAKE PISTON STROKE......................................................................................................263 PARKING BRAKE DISC WEAR..........................................................................................................264 WORK EQUIPMENT.......................................................................................................................265 WORK EQUIPMENT CONTROL LEVER.....................................................................................................265 PPC VALVE........................................................................................................................266 MEASURING PRESSURE...........................................................................................................266 HYDRAULIC PRESSURE...............................................................................................................268 MEASUREMENT......................................................................................................................271 HYDRAULIC DRIFT..................................................................................................................272 BOOM KICK-OUT....................................................................................................................273 BUCKET / FORK POSITIONER.........................................................................................................274 MAIN MONITOR.........................................................................................................................276 FUEL LEVEL SENSOR....................................................................................................................278 CHECKING FOR ABNORMALITY.........................................................................................................278 TROUBLESHOOTING GENERAL..............................................................................................................279 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................................................281 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................283 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................284 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.................................................................................284 HANDLING CONTROL BOX.........................................................................................................289 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.........................................................................290 CHECKS BEFORE TROUBLESHOOTING....................................................................................................292 JUDGEMENT OF POWER TRAIN.........................................................................................................293 PRECAUTIONS WHEN TROUBLESHOOTING.................................................................................................294 SAFETY.......................................................................................................................294 METHODS FOR TROUBLESHOOTING..................................................................................................294 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING..............................296 PREVENTING RECURRENCE OF TROUBLE.................................................................................................297 HYDRAULIC EQUIPMENT..........................................................................................................297 OIL CHECKS...............................................................................................................297 CLEANING FRAGMENTS OF DAMAGED PARTS......................................................................................297 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................298 CATEGORY OF TROUBLESHOOTING CODE NUMBER......................................................................................298 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE..........................................................298 METHOD OF USING MATRIX TROUBLESHOOTING TABLES....................................................................................300 METHOD OF USING ENGINE RELATED CHARTS............................................................................................302 TROUBLESHOOTING ELECTRICAL CONNECTORS................................................................................................307 CONNECTOR TYPES..................................................................................................................308 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................311 ELECTRICAL CIRCUIT DIAGRAMS......................................................................................................319 ENGINE START, STOP SYSTEM....................................................................................................319 PREHEATING SYSTEM............................................................................................................320 TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...................................................................................321 MACHINE MONITOR SYSTEM (1/2).................................................................................................323 MACHINE MONITOR SYSTEM (2/2)................................................................................................. 0 WORK EQUIPMENT DUMP SPEED AND QUICK COUPLER SYSTEM........................................................................... 0 TROUBLESHOOTING SYSTEMS OF A MODE - TRANSMISSION CONTROLLER SYSTEM...................................................................329 OUTLINE..........................................................................................................................330 FUNCTION.....................................................................................................................330 TROUBLESHOOTING..............................................................................................................330 FAILURE CODE TABLE...........................................................................................................330 TABLE OF TROUBLESHOOTING MODES AND CAUSES....................................................................................331 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM.....................................................................332 A-1 TROUBLESHOOTING CODE [12]....................................................................................................334 F SOLENOID SIGNAL SYSTEM.....................................................................................................334 A-2 TROUBLESHOOTING CODE [13]....................................................................................................335 R SOLENOID SIGNAL SYSTEM.....................................................................................................335 A-3 TROUBLESHOOTING CODE [14]....................................................................................................336 ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM....................................................................................336 A-4 TROUBLESHOOTING CODE [16]....................................................................................................337 ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM..................................................................................337 A-5 TROUBLESHOOTING CODE [20]....................................................................................................338 ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...............................................................................338 A-6 TROUBLESHOOTING CODE [21]....................................................................................................339 ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.....................................................................................339 A-7 TROUBLESHOOTING CODE [22]....................................................................................................340 ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM....................................................................................340 A-8 TROUBLESHOOTING CODE [23]....................................................................................................341 ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM....................................................................................341 A-9 HOLD SWITCH SIGNAL SYSTEM....................................................................................................342 A-10 KICK-DOWN SWITCH SYSTEM.....................................................................................................343 A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM..........................................................................................344 A-12 NEUTRALIZER RELAY SIGNAL SYSTEM.............................................................................................345 A-13 BUZZER SIGNAL SYSTEM........................................................................................................346 A-14 NETWORK SIGNAL SYSTEM.......................................................................................................347 A-15 CONTROLLER POWER SOURCE SYSTEM..............................................................................................348 TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D MODE - (ECSS)..........................................................349 ECSS - ELECTRICAL/HYDRAULIC SCHEMATIC............................................................................................350 ECSS - WORKING CHART.............................................................................................................350 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL .......................................................................................351 INSPECTION/ADJUSTMENT........................................................................................................351 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................................................................353 E-1 ENGINE DOES NOT START........................................................................................................354 A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCYH IS TURNED TO START.....................................................354 B. CHECK FUEL SHUT-OFF SOLENOID..............................................................................................356 E-2 ENGINE DOES NOT STOP.........................................................................................................357 E-4 TRANSMISSION IS NOT SET UP TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISION CUT-OFF IS NORMAL)..........................358 E-10 PREHEATING IS NOT CARRIED OUT...............................................................................................360 E-11 PREHEATING REMAINS ACTUATED.................................................................................................362 E-12 ABNORMALITY IN QUICK COUPLER SYSTEM.........................................................................................364 E-13 ABNORMALITY IN TILT CYLINDER OPERATION......................................................................................365 A. ONLY SLOW DUMP SPEED IS AVAILABLE.........................................................................................365 B. DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE ...............................................................366 C. TILT BACK IS NOT AVAILABLE................................................................................................367 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...............................................................................369 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO....371 A. ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS............................................................371 B. SOME LAMPS DO NOT LIGHT UP................................................................................................372 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT DO NOT GO OUT..............................372 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECS), ALL LAMPS ON MAINTENANCE MONITOR D....373 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH.........................................................374 A. ENGINE OIL LEVEL DISPLAY FLASHES..........................................................................................374 B. ENGINE WATER LEVEL DISPLAY FLASHES........................................................................................375 C. BRAKE OIL LEVEL DISPLAY FLASHES...........................................................................................376 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH .....................................................377 A. ENGINE OIL PRESSURE DISPLAY FLASHES.......................................................................................377 B. BATTERY CHARGE LEVEL DISPLAY FLASHES......................................................................................378 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND...................................................................379 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...........................................................380 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP.......................................381 A. CHECK LAMP................................................................................................................381 B. CAUTION LAMP..............................................................................................................381 K-9 THERE IS NOT ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP........................382 A. CHECK LAMP................................................................................................................382 B. CAUTION LAMP..............................................................................................................382 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENACE MONITOR DOES NOT LIGHT UP)......383 K-11 NIGHT LIGHING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAY LIT UP............................................384 K-12 SERVICE METER DOES NOT WORK.................................................................................................385 K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED................................................................................386 K-14 ABNORMALITY IN GAUGE ITEMS..................................................................................................387 A. ABNORMALITY IN FUEL GAUGE.................................................................................................387 B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.............................................................................388 C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....................................................................389 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)......................................................................................391 TROUBLE DATA DISPLAY.............................................................................................................393 TABLE OF ACTION CODES AND FAILURE CODES..........................................................................................394 ACTION CODE TABLE............................................................................................................394 FAILURE CODE CHART...........................................................................................................394 M-1 MAIN MONITOR DOES NOT WORK...................................................................................................395 M-2 WHEN STARING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT.......................................396 M-3 SPEEDOMETER DISPLAYS DOES NOT WORK PROPERLY..................................................................................397 M-4 ABNORMALITY IN SHIFT INDICATOR...............................................................................................398 A. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F............................................................................398 B. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R............................................................................398 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER I............................398 D. DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R...........................399 E. DOES NOT DISPLAY 1ST, 4TH.................................................................................................399 F. DOES NOT DISPLAY 3RD, 4TH.................................................................................................399 G. DOES NOT DISPLAY 2ND, 3RD.................................................................................................400 H. DOES NOT DISPLAY 1ST, 2ND.................................................................................................400 M-5 HIGH BEAM DOES NOT LIGHT UP..................................................................................................401 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................402 A. L.H. TURN SIGNAL DOES NOT LIGHT UP........................................................................................402 B. R.H. TURN SIGNAL DOES NOT LIGHT UP........................................................................................402 M-7 ABNORMALITY IN PARKING DISPLAY...............................................................................................403 A. PARKING LAMP DOES NOT LIGHT UP............................................................................................403 B. PARKING LAMP STAYS ON.....................................................................................................403 M-8 ABNORMALITY IN PREHEATING SYSTEM.............................................................................................404 A. DOES NOT CARRY OUT PREHEATING.............................................................................................404 1. MONITOR DISPLAY ALSO DOES NOT LIGHT UP................................................................................404 2. ONLY MONITOR DISPLAY LIGHTS UP........................................................................................404 B. ONLY MONITOR DISPLAY DOES NOT LIGHT UP....................................................................................405 C. ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE................................................................................405 D. PREHEATING STAYS ON.......................................................................................................405 E. PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE............................................................................406 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.............................................................................................408 M-10 ABNORMALITY IN FRONT WORKING LAMP...........................................................................................409 A. NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP..................................................................409 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP.............................................................409 C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP.....................................................................409 M-11 ABNORMALITY IN REAR WORKING LAMP............................................................................................410 A. NEITHER MONITOR DISPLAY, NOR rear WORKING LAMP LIGHT UP...................................................................410 B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP.............................................................410 C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP.....................................................................410 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.........................................................................................412 A. WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN.................................412 B. MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON...................................................................412 C. MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED...........................................................413 M-13 ABNORMALITY IN PARKING DRAGGING WARNING.....................................................................................414 A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS A............................414 B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W............................414 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU................................415 A. ACTUATED CONTINUOUSLY.....................................................................................................415 B. NOT ACTUATED..............................................................................................................415 M-15 ABNORMALITY IN BUZZER.......................................................................................................416 A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)...............................................416 B. BUZZER ALWAYS SOUNDS......................................................................................................416 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY.......................................................................417 M-17 ABNORMALITY IN FAILURE DISPLAY MODE.........................................................................................418 A. DOES NOT ENTER FAILURE DISPLAY MODE.......................................................................................418 B. TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE..............................................418 TROUBLESHOOTING SYSTEMS OF (S MODE)..................................................................................................419 S1 STARTING PERFORMANCE IS POOR..................................................................................................421 S2 ENGINE DOES NOT START.........................................................................................................422 (1) ENGINE DOES NOT TURN.....................................................................................................422 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT................................................................................423 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START..........................................................................424 S-3 ENGINE DOES NOT PICK UP SMOOTHLY.............................................................................................425 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................426 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................427 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................428 S-7 EXHAUST GAS IS BLACK.........................................................................................................429 S-8 OIL CONSUMPTION IS EXCESSIVE.................................................................................................430 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................431 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................432 S-11 OIL IN COOLING WATER........................................................................................................433 S-12 OIL PRESSURE LAMP LIGHTS UP.................................................................................................434 S-13 OIL LEVEL RISES.............................................................................................................435 S-14 WATER TEMPERATURE BECOMES TOO HIGH..........................................................................................436 S-15 ABNORMAL NOISE IS MADE......................................................................................................437 S-16 VIBRATION IS EXCESSIVE......................................................................................................460 TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEM (T-MODE)............................................................................438 POWER TRAIN......................................................................................................................440 T-1 MACHINE DOES NOT START...................................................................................................440 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.....................................................441 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR...................................................................443 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR................................................................444 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.................................................................................445 STEERING SYSTEM..................................................................................................................446 T-6 STEERING WHEEL DOES NOT TURN.............................................................................................446 T-7 STEERING IS HEAVY........................................................................................................447 T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK........................................................................448 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING....................................................................448 BRAKE SYSTEM.....................................................................................................................449 T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR............................................................................449 T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS......................................................................................450 WORK EQUIPMENT...................................................................................................................451 T-12 BOOM DOES NOT RISE......................................................................................................451 T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.......................................................................452 T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT................................................................453 T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)..............................................................453 T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM.......................................................................................453 T-17 BOOM SHAKES DURING OPERATION............................................................................................454 T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE................................................454 T-19 BUCKET DOES NOT TILT BACK...............................................................................................455 T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER........................................................................456 T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.................................................................457 T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER............................................................................457 T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.....................................................................................457 T-24 BUCKET SHAKES DURING LOADING OPERATION..................................................................................458 T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...............................................458 T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY...........................................................459 TROUBLESHOOTING SYSTEMS OF AIR CONDITIONER...........................................................................................461 SERVICE TOOLS....................................................................................................................463 GAUGE MANIFOLD...............................................................................................................463 STRUCTURE AND HANDLING OF GAUGE MANIFOLD.................................................................................464 CHARGING HOSES...........................................................................................................466 GAS LEAK DETECTOR............................................................................................................467 HALIDE TORCH LEAK DETECTOR...............................................................................................467 ELECTRIC LEAK TESTER.....................................................................................................469 VALVE FOR SERVICE CANS.......................................................................................................471 MAINTENANCE PROCEDURE............................................................................................................472 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...............................................................................472 PROHIBITED WORK..........................................................................................................472 OTHER PRECAUTIONS........................................................................................................472 BLEEDING AIR FROM REFRIGERATION CIRCUIT......................................................................................474 PURPOSE..................................................................................................................474 CONNECTING GAUGE MANIFOLD................................................................................................474 EVACUATION...............................................................................................................475 AIR-TIGHTNESS CHECK......................................................................................................475 GAS-LEAK CHECK...........................................................................................................476 EVACUATION (REPEATING)...................................................................................................476 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT..........................................................................477 CHARGING FROM THE HIGH-PRESSURE SIDE.....................................................................................477 CHARGING FROM THE LOW PRESSURE SIDE......................................................................................478 WHEN THE AMBIENT TEMPERATURE IS LOW......................................................................................479 WHEN THE AMBIENT TEMPERATURE IS HIGH.....................................................................................479 REPLACING SERVICE CANS.......................................................................................................480 CHECKING THE AMOUNT OF REFRIGERANT...........................................................................................480 REMOVAL OF GAUGE MANIFOLD....................................................................................................482 DISCHARGING THE REFRIGERANT..................................................................................................482 DAILY CHECKS.................................................................................................................483 CHECK REFRIGERANT LEVEL..................................................................................................483 CLEANING THE CONDENSER...................................................................................................483 CHECKING THE V-BELT..........................................................................................................483 CHECKING OIL LEVEL...........................................................................................................484 PROCEDURE FOR CHECKING...................................................................................................484 PROCEDURE FOR CHECKING OIL LEVEL.........................................................................................484 ADDING AND REMOVING OIL..................................................................................................485 ADDING OIL BY EVACUATION.................................................................................................485 TROUBLESHOOTING..................................................................................................................486 VISUAL AND ACOUSTICAL CHECKS.................................................................................................486 DEFECTIVE COOLING............................................................................................................487 TROUBLESHOOTING TABLE........................................................................................................489 DEFECTIVE HEATING............................................................................................................491 TROUBLESHOOTING USING GAUGE MANIFOLD.........................................................................................492 PREPARATIONS BEFORE MEASURING............................................................................................492 INSUFFICIENT REFRIGERANT.................................................................................................492 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER...............................................................493 AIR INSIDE REFRIGERATION SYSTEM..........................................................................................494 MOISTURE IN REFRIGERATING SYSTEM.........................................................................................495 REFRIGERANT DOES NOT CIRCULATE...........................................................................................496 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE........................................497 DEFECTIVE COMPRESSION BY COMPRESSOR......................................................................................498 30 DISASSEMBLY AND ASSEMBLY..............................................................................................................499 METHOD OF USING MANUAL...............................................................................................................503 PRECAUTIONS DURING OPERATION.........................................................................................................504 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.......................................................................................504 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK..................................................................................505 PRECAUTIONS WHEN COMPLETING THE OPERATIONS....................................................................................... 0 OTHER PRECAUTIONS................................................................................................................506 SPECIAL TOOL LIST....................................................................................................................507 ENGINE...............................................................................................................................510 ALTERNATOR ASSEMBLY..............................................................................................................510 CYLINDER HEAD ASSEMBLY...........................................................................................................510 ENGINE OIL COOLER ASSEMBLY.......................................................................................................510 FUEL INJECTION PUMP ASSEMBLY.....................................................................................................510 NOZZLE HOLDER ASSEMBLY...........................................................................................................510 STARTING MOTOR ASSEMBLY..........................................................................................................510 THERMOSTAT ASSEMBLY..............................................................................................................510 TURBOCHARGER ASSEMBLY............................................................................................................510 WATER PUMP ASSEMBLY..............................................................................................................510 COVERS, LADDER AND ENGINE HOOD.......................................................................................................511 REMOVAL..........................................................................................................................511 INSTALLATION.....................................................................................................................514 RADIATOR, HYDRAULIC COOLER ASSEMBLY..................................................................................................515 REMOVAL..........................................................................................................................515 INSTALLATION..................................................................................................................... 0 MUFFER AND AIR CLEANER...............................................................................................................517 REMOVAL.......................................................................................................................... 0 INSTALLATION.....................................................................................................................517 ENGINE ASSEMBLY...................................................................................................................... 0 REMOVAL..........................................................................................................................518 INSTALLATION.....................................................................................................................521 TORQUE CONVERTER CHARGING PUMP.......................................................................................................522 REMOVAL..........................................................................................................................522 INSTALLATION.....................................................................................................................522 TORQUE CONVERTER, TRANSMISSION.......................................................................................................523 REMOVAL.......................................................................................................................... 0 INSTALLATION.....................................................................................................................532 TORQUE CONVERTER.....................................................................................................................534 DISASSEMBLY......................................................................................................................534 ASSEMBLY.........................................................................................................................536 TRANSMISSION.........................................................................................................................538 DISASSEMBLY......................................................................................................................538 ASSEMBLY.........................................................................................................................547 CLUTCH PACK..........................................................................................................................560 DISASSEMBLY......................................................................................................................560 DISASSEMBLY OF FR CLUTCH PACK................................................................................................560 DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK.......................................................................................562 DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK....................................................................................... 0 ASSEMBLY......................................................................................................................... 0 ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK.....................................................................................566 ASSEMBLY OF 1ST AND 3RD CLUTCH PACK..........................................................................................570 ASSEMBLY OF 2ND AND 4TH CLUTCH PACK.......................................................................................... 0 PARKING BRAKE........................................................................................................................578 DISASSEMBLY......................................................................................................................578 ASSEMBLY.........................................................................................................................580 TRANSMISSION CONTROL VALVE...........................................................................................................583 REMOVAL..........................................................................................................................583 INSTALLATION.....................................................................................................................585 DISASSEMBLY......................................................................................................................586 ASSEMBLY......................................................................................................................... 0 TRANSMISSION SOLENOID VALVE..........................................................................................................591 DISASSEMBLY......................................................................................................................591 ASSEMBLY.........................................................................................................................592 ACCUMULATOR VALVE.................................................................................................................... 0 DISASSEMBLY......................................................................................................................593 ASSEMBLY......................................................................................................................... 0 DRIVE SHAFT..........................................................................................................................595 DISASSEMBLY...................................................................................................................... 0 ASSEMBLY......................................................................................................................... 0 FRONT AXLE...........................................................................................................................599 REMOVAL.......................................................................................................................... 0 INSTALLATION.....................................................................................................................601 REAR AXLE............................................................................................................................ 0 REMOVAL..........................................................................................................................602 INSTALLATION..................................................................................................................... 0 DIFFERENTIAL.........................................................................................................................609 DISASSEMBLY......................................................................................................................609 ASSEMBLY.........................................................................................................................613 AXLE HOUSING.........................................................................................................................622 DISASSEMBLY......................................................................................................................622 ASSEMBLY.........................................................................................................................627 CENTER HINGE PIN.....................................................................................................................633 REMOVAL.......................................................................................................................... 0 INSTALLATION.....................................................................................................................640 STEERING VALVE....................................................................................................................... 0 REMOVAL.......................................................................................................................... 0 INSTALLATION.....................................................................................................................646 DISASSEMBLY......................................................................................................................647 DISASSEMBLY OF ROTOR......................................................................................................... 0 ASSEMBLY.........................................................................................................................650 ASSEMBLY OF CONTROL SIDE.....................................................................................................650 ASSEMBLY OF ROTOR............................................................................................................ 0 PRIORITY VALVE.......................................................................................................................655 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 STEERING CYLINDER.................................................................................................................... 0 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 POWER MASTER CYLINDER................................................................................................................ 0 REMOVAL..........................................................................................................................659 INSTALLATION.....................................................................................................................660 DISASSEMBLY......................................................................................................................661 ASSEMBLY......................................................................................................................... 0 PARKING BRAKE DISC...................................................................................................................669 REMOVAL..........................................................................................................................669 INSTALLATION.....................................................................................................................670 HYDRAULIC TANK.......................................................................................................................671 REMOVAL..........................................................................................................................671 INSTALLATION.....................................................................................................................672 HYDRAULIC FILTER..................................................................................................................... 0 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 WORK EQUIPMENT, STEERING PUMP........................................................................................................ 0 REMOVAL..........................................................................................................................674 INSTALLATION.....................................................................................................................675 MAIN CONTROL VALVE................................................................................................................... 0 REMOVAL..........................................................................................................................676 INSTALLATION..................................................................................................................... 0 DISASSEMBLY......................................................................................................................681 ASSEMBLY.........................................................................................................................683 PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES...................................................................................... 0 PPC VALVE............................................................................................................................686 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 CYLINDER.............................................................................................................................688 BUCKET (TILT) CYLINDER........................................................................................................... 0 REMOVAL......................................................................................................................688 INSTALLATION.................................................................................................................689 BOOM (LIFT) CYLINDER.............................................................................................................690 REMOVAL......................................................................................................................690 INSTALLATION.................................................................................................................692 HYDRAULIC CYLINDER...............................................................................................................693 DISASSEMBLY..................................................................................................................693 ASSEMBLY.....................................................................................................................695 BOOM AND PARALLEL TOOL LINKAGE.......................................................................................................698 REMOVAL..........................................................................................................................698 INSTALLATION..................................................................................................................... 0 ECSS SYSTEM.......................................................................................................................... 0 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL........................................................................................ 0 ECSS SOLENOID VALVE.............................................................................................................. 0 REMOVAL......................................................................................................................710 INSTALLATION................................................................................................................. 0 ECSS CONTROL VALVE...............................................................................................................711 REMOVAL......................................................................................................................711 INSTALLATION................................................................................................................. 0 COUNTERWEIGHT........................................................................................................................ 0 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 FUEL TANK............................................................................................................................713 REMOVAL..........................................................................................................................713 INSTALLATION..................................................................................................................... 0 CAB (ROPS)........................................................................................................................... 0 REMOVAL.......................................................................................................................... 0 INSTALLATION..................................................................................................................... 0 MAIN MONITOR.........................................................................................................................717 REMOVAL..........................................................................................................................717 INSTALLATION..................................................................................................................... 0 MAINTENANCE MONITOR..................................................................................................................719 REMOVAL..........................................................................................................................719 INSTALLATION.....................................................................................................................719 AIR CONDITIONER...................................................................................................................... 0 AIR CONDITIONER UNIT.............................................................................................................720 REMOVAL......................................................................................................................720 INSTALLATION.................................................................................................................725 CONDENSER........................................................................................................................726 REMOVAL......................................................................................................................726 INSTALLATION.................................................................................................................727 DRY RECIEVER.....................................................................................................................728 REMOVAL..........................................................................................................................728 INSTALLATION.................................................................................................................729 COMPRESSOR.......................................................................................................................730 REMOVAL...................................................................................................................... 0 INSTALLATION.................................................................................................................731 40 MAINTENANCE STANDARD..................................................................................................................733 TRANSMISSION, ENGINE MOUNT...........................................................................................................735 TORQUE CONVERTER CHARGING PUMP.......................................................................................................736 TORQUE CONVERTER.....................................................................................................................737 TRANSMISSION.........................................................................................................................739 FORWARD, REVERSE CLUTCH..........................................................................................................744 1ST, 3RD CLUTCH..................................................................................................................745 2nd, 4th CLUTCH..................................................................................................................746 TRANSMISSION CONTROL VALVE...........................................................................................................748 UPPER VALVE......................................................................................................................748 LOWER VALVE......................................................................................................................750 SOLENOID VALVE...................................................................................................................751 ACCUMULATOR VALVE....................................................................................................................752 DRIVE SHAFT..........................................................................................................................753 DIFFERENTIAL.........................................................................................................................754 DIFFERENTIAL.........................................................................................................................756 FINAL DRIVE..........................................................................................................................758 AXLE MOUNT...........................................................................................................................760 CENTER HINGE PIN.....................................................................................................................762 STEERING COLUMN......................................................................................................................764 PRIORITY VALVE.......................................................................................................................765 MASTER CYLINDER......................................................................................................................766 BRAKE................................................................................................................................767 PARKING BRAKE........................................................................................................................768 HYDRAULIC PUMP.......................................................................................................................769 MAIN CONTROL VALVE...................................................................................................................770 PILOT SOLENOID VALVE.................................................................................................................772 PPC VALVE............................................................................................................................773 HYDRAULIC CYLINDER...................................................................................................................774 90 OTHERS................................................................................................................................775 OPERATION OF THE PROXIMITY SWITCH....................................................................................................777 ELECTRICAL WIRING DIAGRAM (1/7)......................................................................................................779 ELECTRICAL WIRING DIAGRAM (2/7)......................................................................................................781 ELECTRICAL WIRING DIAGRAM (3/7)......................................................................................................783 ELECTRICAL WIRING DIAGRAM (4/7)......................................................................................................785 ELECTRICAL WIRING DIAGRAM (5/7)......................................................................................................787 ELECTRICAL WIRING DIAGRAM (6/7)......................................................................................................789 ELETRICAL WIRING DIAGRAM (7/7).......................................................................................................791 TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...........................................................................................793 MACHINE MONITOR SYSTEM (1/2).........................................................................................................795 MACHINE MONITOR SYSTEM (2/2).........................................................................................................797
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