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KOMATSU AVANCE PLUS WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL SL NO(WA600-3LK)A53001 and UP – PDF DOWNLOAD
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KOMATSU AVANCE PLUS WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL
SL NO:(WA600-3LK)A53001 and UP
PUBLICATION NUMBER:CEBM005502
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KOMATSU AVANCE PLUS WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL SL NO(WA600-3LK)A53001 and UP
KOMATSU AVANCE PLUS WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL SL NO(WA600-3LK)A53001 AND UP – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU AVANCE PLUS WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL SL NO(WA600-3LK)A53001 and UP
- 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 WA600-3LK WHEEL LOADER SHOP REPAIR MANUAL SL NO(WA600-3LK)A53001 and UP
MAIN MENU............................................................................................................. 0 COVER................................................................................................................. 1 CONTENTS.............................................................................................................. 2 FOREWORD.............................................................................................................. 15 SAFETY............................................................................................................ 15 SAFETY NOTICE................................................................................................. 15 IMPORTANT SAFETY NOTICE................................................................................... 15 GENERAL PRECAUTIONS....................................................................................... 15 PREPARATIONS FOR WORK..................................................................................... 15 PRECAUTIONS DURING WORK................................................................................... 15 GENERAL........................................................................................................... 17 HOW TO READ THE SHOP MANUAL....................................................................................... 18 VOLUMES....................................................................................................... 18 DISTRIBUTION AND UPDATING..................................................................................... 18 FILING METHOD................................................................................................. 18 REVISED EDITION MARK.......................................................................................... 18 REVISIONS..................................................................................................... 18 SYMBOLS....................................................................................................... 18 HOISTING INSTRUCTIONS............................................................................................. 19 HOISTING...................................................................................................... 19 WIRE ROPES.................................................................................................... 19 PUSH-PULL TYPE COUPLER............................................................................................ 20 COATING MATERIALS................................................................................................. 23 STANDARD TIGHTENING TORQUE........................................................................................ 25 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.................................................................. 25 TIGHTENING TORQUE OF HOSE NUTS................................................................................ 26 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....................................................................... 26 TIGHTENING TORQUE FOR FLARED NUTS............................................................................. 26 O-RING BOSS PIPING JOINTS..................................................................................... 27 O-RING BOSS PLUGS............................................................................................. 27 ELECTRIC WIRE CODE................................................................................................ 28 CLASSIFICATION BY THICKNESS................................................................................... 28 CLASSIFICATION BY COLOR AND CODE.............................................................................. 28 CONVERSION TABLES................................................................................................. 29 METHOD OF USING THE CONVERSION TABLE.......................................................................... 29 01 GENERAL............................................................................................................ 35 DIMENSIONS........................................................................................................ 36 SPECIFICATIONS.................................................................................................... 37 WEIGHT TABLE...................................................................................................... 41 FUEL, COOLANT AND LUBRICATNTS..................................................................................... 42 ENGINE OIL.................................................................................................... 43 NORMAL OPERATION.......................................................................................... 43 ARCTIC OPERATION.......................................................................................... 45 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL.............................................................. 45 AXLE OIL...................................................................................................... 45 GREASE........................................................................................................ 46 DIESEL FUEL................................................................................................... 46 COOLANT SPECIFICATIONS........................................................................................ 47 GENERAL................................................................................................... 47 WATER..................................................................................................... 47 ANTIFREEZE................................................................................................ 47 10 STRUCTURE AND FUNCTION............................................................................................. 49 GENERAL POWER TRAIN............................................................................................... 53 POWER TRAIN SYSTEM................................................................................................ 54 RADIATOR, HYDRAULIC OIL COOLER.................................................................................... 56 TORQUE CONVERTER AND TRANSMISSION PIPING.......................................................................... 58 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................. 60 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN..................................................................... 62 ENGINE STOPPED............................................................................................ 62 TORQUE CONVERTER.................................................................................................. 64 REGULATOR VALVE............................................................................................... 67 RELIEF VALVE.................................................................................................. 69 OIL COOLER.................................................................................................... 70 OIL FILTER.................................................................................................... 71 TRANSMISSION...................................................................................................... 73 TRANSMISSION CUT-A-WAY........................................................................................ 74 FORWARD 1ST................................................................................................... 77 FORWARD 2ND................................................................................................... 78 FORWARD 3RD................................................................................................... 79 FORWARD 4TH................................................................................................... 80 REVERSE 1ST................................................................................................... 81 CONTROL VALVE................................................................................................. 82 SOLENOID VALVE............................................................................................ 83 UPPER VALVE AND MAIN RELIEF VALVE......................................................................... 85 LOWER VALVE............................................................................................... 86 PILOT OIL FILTER.......................................................................................... 89 PILOT REDUCING VALVE...................................................................................... 90 PRIORITY VALVE................................................................................................ 91 MODULATING VALVE AND QUICK RETURN VALVE....................................................................... 92 REDUCING VALVE................................................................................................ 95 ACCUMULATOR VALVE............................................................................................. 96 EMERGENCY MANUAL SPOOL........................................................................................ 99 LUBRICATION BYPASS VALVE...................................................................................... 100 HYDRAULIC CIRCUIT SCHEMATIC................................................................................... 102 FORWARD 1ST............................................................................................... 102 TRANSFER.......................................................................................................... 104 DRIVE SHAFT....................................................................................................... 105 CENTER SUPPORT.................................................................................................... 106 CENTER HINGE PIN.................................................................................................. 107 AXLE.............................................................................................................. 108 FRONT AXLE.................................................................................................... 108 REAR AXLE..................................................................................................... 109 MOUNT......................................................................................................... 110 DIFFERENTIAL...................................................................................................... 112 FRONT DIFFERENTIAL............................................................................................ 112 REAR DIFFERENTIAL............................................................................................. 113 LIMITED SLIP DIFFERENTIAL..................................................................................... 115 FINAL DRIVE....................................................................................................... 118 STEERING.......................................................................................................... 120 PIPING........................................................................................................ 120 COLUMN........................................................................................................ 121 STEERING CONTROL VALVE........................................................................................ 122 STEERING DEMAND VALVE......................................................................................... 125 OVERLOAD RELIEF VALVE..................................................................................... 126 MAIN RELIEF VALVE......................................................................................... 128 MAIN RELIEF VALVE OPERATION............................................................................... 129 DEMAND VALVE OPERATION........................................................................................ 130 WHEN STEERING SPOOL IS AT NEUTRAL......................................................................... 130 WHEN STEERING SPOLL IS OPERATED........................................................................... 131 STEERING VALVE OPERATION...................................................................................... 133 NEUTRAL................................................................................................... 133 TURNING RIGHT............................................................................................. 134 TURNING LEFT.............................................................................................. 135 TWO-WAY RESTRICTION VALVE..................................................................................... 136 STOP VALVE.................................................................................................... 137 GROUND-DRIVEN STEERING........................................................................................ 138 DIVERTER VALVE (FOR GROUND-DRIVEN STEERING)............................................................... 139 BRAKE............................................................................................................. 142 PIPING........................................................................................................ 142 BRAKE CIRCUIT DIAGRAM......................................................................................... 144 BRAKE VALVE (RIGHT)........................................................................................... 146 BRAKE VALVE (LEFT)............................................................................................ 147 CHARGE VALVE.................................................................................................. 151 ACCUMULATOR (FOR BRAKE)....................................................................................... 155 SLACK ADJUSTER................................................................................................ 156 BRAKE......................................................................................................... 158 PARKING BRAKE..................................................................................................... 160 CALIPER....................................................................................................... 161 SPRING CYLINDER............................................................................................... 162 SOLENOID VALVE................................................................................................ 163 HYDRAULIC......................................................................................................... 164 WORK EQUIPMENT................................................................................................ 164 LEVER LINKAGE............................................................................................. 164 HYDRAULIC CIRCUIT DIAGRAM................................................................................. 165 HYDRAULIC PIPING.............................................................................................. 166 HYDRAULIC TANK................................................................................................ 168 OIL FILTER BYPASS VALVE................................................................................... 169 BREATHER.................................................................................................. 170 PPC SYSTEM.................................................................................................... 171 ACCUMULATOR............................................................................................... 171 PPC VALVE................................................................................................. 172 RELIEF VALVE.............................................................................................. 176 CUT-OFF VALVE................................................................................................. 178 MAIN CONTROL VALVE............................................................................................ 180 2-SPOOL................................................................................................... 180 3-SPOOL................................................................................................... 182 MAIN RELIEF VALVE......................................................................................... 184 SAFETY VALVE (WITH SUCTION)............................................................................... 185 SUCTION VALVE............................................................................................. 186 FLOAT SELECTOR VALVE AND UNLOADER VALVE................................................................... 187 BOOM AND BUCKET SPOOL HOLD POSITION....................................................................... 188 BOOM SPOOL AT RAISE POSITION.............................................................................. 189 BOOM SPOOL AT LOWER POSITION.............................................................................. 190 BOOM SPOOL AT FLOAT POSITION.............................................................................. 191 BUCKET SPOOL AT DUMP POSITION............................................................................. 192 BUCKET SPOOL AT TILT POSITION............................................................................. 193 WORK EQUIPMENT.................................................................................................... 194 LUBRICATION................................................................................................... 194 LINKAGE....................................................................................................... 196 BUCKET........................................................................................................ 198 BUCKET POSITIONER AND BOOM KICK OUT........................................................................... 199 BUCKET POSITIONER......................................................................................... 200 BOOM KICK OUT............................................................................................. 200 PROXIMITY SWITCH OPERATION................................................................................ 201 ROPS CANOPY....................................................................................................... 207 CAB............................................................................................................... 208 AIR CONDITIONER................................................................................................... 209 PIPING........................................................................................................ 209 CONDENSER..................................................................................................... 210 COMPRESSOR.................................................................................................... 211 DRY RESERVOIR................................................................................................. 212 ELECTRICAL CIRCUIT DIAGRAM........................................................................................ 213 MACHINE MONITOR SYSTEM............................................................................................ 214 MAIN MONITOR.................................................................................................. 215 MAIN MONITOR DISPLAY FUNCTION............................................................................. 216 MAIN MONITOR SWITCH FUNCTION.............................................................................. 217 TROUBLE DATA DISPLAY MODE................................................................................. 218 MAINTENANCE MONITOR........................................................................................... 219 MAINTENANCE MONITOR DISPLAY FUNCTION...................................................................... 220 JOYSTICK AND AUTOMATIC SHIFT CONTROL.............................................................................. 221 ENGINE STARTING CIRCUIT........................................................................................... 240 ENGINE STOP CIRCUIT............................................................................................... 241 PRE-HEATING CIRCUIT............................................................................................... 242 AUTOMATIC PRE-HEATING SYSTEM.................................................................................. 242 ELECTRIC TRANSMISSION CONTROL..................................................................................... 244 COMBINATION SWITCH............................................................................................ 246 KICK DOWN, HOLD SWITCH........................................................................................ 248 KICK DOWN SWITCH.......................................................................................... 248 HOLD SWITCH............................................................................................... 248 KICK DOWN ELECTRICAL CIRCUIT.............................................................................. 249 ELECTRIC PARKING BRAKE CONTROL.................................................................................... 255 PARKING BRAKE SWITCH.......................................................................................... 256 PARKING BRAKE VALVE........................................................................................... 257 PARKING SAFETY RELAY.......................................................................................... 257 NEUTRALIZER RELAY............................................................................................. 257 EMERGENCY BRAKE SWITCH........................................................................................ 257 ECSS SYSTEM....................................................................................................... 264 ECSS ELECTICAL DRAWING........................................................................................ 270 20 TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................. 271 STANDARD VALUE TABLE.............................................................................................. 273 ENGINE IN CHASSIS............................................................................................. 273 CHASSIS....................................................................................................... 274 ELECTRICAL SYSTEM............................................................................................. 279 SERVICE TOOLS - TESTING, ADJUSTING & TROUBLESHOOTING.............................................................. 292 ENGINE SPEEDS..................................................................................................... 294 TORQUE CONVERTER.................................................................................................. 295 TORQUE CONVERTER STALL SPEED.................................................................................. 295 HYDRAULIC STALL SPEED......................................................................................... 295 TORQUE CONVERTER STALL SPEED + HYDRAULIC STALL SPEED.......................................................... 296 ENGINE............................................................................................................ 297 ALTERNATOR BELT TENSION....................................................................................... 297 BLEEDING AIR FROM FUEL CIRCUIT................................................................................ 297 BLOW-BY PRESSURE.............................................................................................. 297 COMPRESSION PRESSURE.......................................................................................... 297 EXHAUST GAS TEMPERATURE (EACH CYLINDER)....................................................................... 297 EXHAUST TEMPERATURE (OVERALL ENGINE).......................................................................... 297 FAN BELT...................................................................................................... 297 FUEL PUMP OUTLET PORT PRESSURE................................................................................ 297 HANDLING EQUIPMENT IN FUEL CIRCUIT............................................................................ 297 INJECTOR LIFT................................................................................................. 297 INTAKE AIR PRESSURE (BOOST PRESSURE).......................................................................... 297 OIL PRESSURE.................................................................................................. 297 PRECAUTIONS WHEN OPERATING ENGINE AS AN INDIVIDUAL PART....................................................... 297 PERFORMANCE TEST STANDARDS.................................................................................... 297 RELEASING REMAINING PRESSURE IN FUEL SYSTEM................................................................... 297 RUN-IN STANDARD............................................................................................... 297 SPEED SENSOR.................................................................................................. 297 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................... 297 STANDARD VALUE TABLE FOR TROUBLESHOOTING...................................................................... 297 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.............................................................. 297 TROUBLE SHOOTING OF CONTROLLER SYSTEM (EA MODE)............................................................... 297 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................... 298 VALVE CLEARANCE............................................................................................... 298 EXHAUST GAS COLOR................................................................................................. 299 AIR CONDITIONER COMPRESSOR........................................................................................ 300 BELT TENSION.................................................................................................. 300 ACCELERATOR PEDAL................................................................................................. 301 OPERATING FORCE............................................................................................... 301 OPERATING ANGLE............................................................................................... 302 TORQUE CONVERTER OIL PRESSURE..................................................................................... 303 TRANSMISSION OIL PRESSURE......................................................................................... 303 FLUSHING THE TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT.................................................. 308 FAILED TRANSMISSION VALVE......................................................................................... 310 MOVING A MACHINE.............................................................................................. 310 STEERING WHEEL.................................................................................................... 313 STEERING WHEEL PLAY........................................................................................... 313 STEERING OIL PRESSURE......................................................................................... 315 STEERING RELIEF VALVE PRESSURE............................................................................ 315 STEERING PILOT PRESSURE (STEERING CONTROL VALVE).......................................................... 316 ADJUSTING THE STEERING RELIEF VALVE....................................................................... 317 STEERING STOP VALVE........................................................................................... 318 BRAKE............................................................................................................. 320 BRAKE PEDAL................................................................................................... 320 BRAKE OIL PRESSURE............................................................................................ 322 BRAKE DISC WEAR............................................................................................... 323 BRAKE PERFORMANCE............................................................................................. 324 PARKING BRAKE..................................................................................................... 325 ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURES............................................................... 327 PPC OIL PRESSURE.................................................................................................. 329 WORK EQUIPMENT.................................................................................................... 332 BUCKET AND BOOM CONTROL LEVERS................................................................................ 332 OPERATING SPEEDS.............................................................................................. 333 LIFTING TIME OF LIFT ARM.................................................................................. 333 LOWERING THE TIME OF THE LIFT ARM......................................................................... 333 DUMPING TIME OF THE BUCKET................................................................................ 333 TILT-BACK TIME OF BUCKET.................................................................................. 333 HYDRAULIC DRIFT............................................................................................... 334 HYDRAULIC PRESSURE............................................................................................ 335 BUCKET POSITIONER............................................................................................. 340 BOOM KICK OUT................................................................................................. 341 PROXIMITY SWITCH ACTUATION PILOT LAMP......................................................................... 342 MACHINE MONITOR (SPEEDOMETER MODULE).............................................................................. 343 SETTING THE MACHINE MODEL..................................................................................... 344 BLEEDING AIR...................................................................................................... 345 BLEEDING THE BRAKE LINES AND WHEEL CYLINDERS.................................................................. 345 BLEEDING THE HYDRAULIC CYLINDERS.............................................................................. 346 RELIEVING REMAINING HYDRAULIC PRESSURE........................................................................ 346 PRESSURE BETWEEN EACH HYDRAULIC CYLINDER AND CONTROL VALVE................................................ 346 PRESSURE IN THE BRAKE ACCUMULATOR CIRCUIT................................................................. 346 PRESSURE IN THE PPC ACCUMULATOR CIRCUIT................................................................... 346 WHEELS AND TIRES.................................................................................................. 347 ADJUSTING JOYSTICK LEVER POTENTIOMETER............................................................................ 348 ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH................................................................. 350 TROUBLESHOOTING GENERAL........................................................................................... 351 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................... 353 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................... 355 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..................................................................... 356 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.............................................................. 356 HANDLING CONTROL BOX...................................................................................... 361 POINTS TO REMEMBER WHEN TRUBLESHOOTING ELECTRIC CIRCUITS.................................................. 361 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...................................................... 362 CHECKS BEFORE TROUBLESHOOTING................................................................................. 364 JUDGEMENT OF POWER TRAIN...................................................................................... 365 PRECAUTIONS WHEN TROUBLESHOOTING.............................................................................. 366 SAFETY.................................................................................................... 366 METHODS FOR TROUBLESHOOTING............................................................................... 366 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING........... 368 PREVENTING RECURRENCE OF TROUBLE.............................................................................. 369 HYDRAULIC EQUIPMENT....................................................................................... 369 OIL CHECKS............................................................................................ 369 CLEANING FRAGMENTS OF DAMAGED PARTS................................................................... 369 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................ 370 CATEGORY OF TROUBLESHOOTING CODE NUMBER................................................................... 370 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE....................................... 370 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................. 372 TROUBLESHOOTING CONNECTORS........................................................................................ 375 CONNECTOR NUMBERS, TYPES AND PINS............................................................................. 377 CONNECTOR ARRANGEMENT DIAGRAM................................................................................. 384 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................... 388 TROUBLESHOOTING SYSTEMS OF ECSS (D-MODE).......................................................................... 409 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.............................................................. 410 ELECTRICAL CIRCUIT DIAGRAM FOR ECSS........................................................................... 411 D-1 ECSS DOES NOT WORK........................................................................................ 412 A. ERROR CODE (d0) IS DISPLAYED........................................................................... 413 B. NO ABNORMALITY DISPLAY IS GIVEN........................................................................ 414 1. DOES NOT WORK AT ALL............................................................................... 414 D-2 ECSS CANNOT BE CANCELED................................................................................... 415 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)..................................................................... 417 ELECTRICAL DIAGRAM............................................................................................ 419 POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING CIRCUIT DIAGRAM............................................ 419 TRANSMISSION, PARKING BRAKE CIRCUIT DIAGRAM............................................................... 420 LAMP, HORN CIRCUIT DIAGRAM................................................................................ 421 BOOM KICK OUT, BUCKET POSITIONER CIRCUIT DIAGRAM.......................................................... 422 E-1 ENGINE DOES NOT START..................................................................................... 424 A. STARTING MOTOR DOES NOT TURN........................................................................... 424 B. INSPECTION OF BATTERY, BATTERY RELAY AND STARTING SWITCH............................................... 429 E-3 ENGINE STOPS WHILE MACHINE IS TRAVELLING.................................................................. 430 E-4B PREHEATING FAULT......................................................................................... 430 E-5 PARKING BRAKE DOES NOT WORK............................................................................... 431 A. PARKING BRAKE DOES NOT WORK WHEN PARKING BRAKE SWITCH IS TURNED ON..................................... 431 B. PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE D......... 431 E-6 PARKING BRAKE ACTIVATES WHILE MACHINE IS TRAVELLING....................................................... 432 E-7 PARKING BRAKE RELEASES WHEN STARTING SWITCH TURNED TO ON.................................................. 434 E-8 PARKING BRAKE WORKS NORMALLY, BUT TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE ............. 434 E-9 TRANSMISSION DOES NOT WORK PROPERLY....................................................................... 436 A. ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH OR NEUTRALIZER RELAY CIRCUIT......... 438 B. NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT....................................................... 442 C. NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT....................................................... 444 D. SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT........................................ 446 1. SHORT CIRCUIT TO CHASSIS GROUND IN TRAVEL FORWARD CIRCUIT.......................................... 446 2. SHORT CIRCUIT TO CHASSIS GROUND IN TRAVEL REVERSE CIRCUIT.......................................... 448 E. ABNORMALITY IN SHIFT SOLENOID CIRCUIT.................................................................. 452 F. SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT.............................................. 455 1. SHORT CIRCUIT TO CHASSIS GROUND IN 1ST SOLENOID CIRCUIT............................................ 455 2. SHORT CIRCUIT TO CHASSIS GROUND IN 2ND SOLENOID CIRCUIT............................................ 456 3. SHORT CIRCUIT TO GROUND CHASSIS IN 3RD SOLENOID CIRCUIT............................................ 457 4. SHORT CIRCUIT TO CHASSIS GROUND IN 4TH SOLENOID CIRCUIT............................................ 458 E-10 KICK-DOWN SWITCH DOES NOT WORK........................................................................... 460 E-11 KICK-DOWN SWITCH WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON..................................... 463 E-12 KICK-DOWN SWITCH WORKS IN ALL GEARS...................................................................... 464 E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELLING FORWARD IN 2ND GEAR.......................................... 466 E-14 BOOM KICK-OUT DOES NOT WORK.............................................................................. 468 E-15 DEFECTIVE BUCKET POSITIONER.............................................................................. 472 E-16 POWER WINDOW DOES NOT WORK............................................................................... 475 A. POWER WINDOW DOES NOT RISE............................................................................. 475 B. POWER WINDOW DOES NOT LOWER............................................................................ 476 E-17 ABNORMALITY IN FRONT WORK LAMP........................................................................... 478 E-18 ABNORMALITY IN REAR WORK LAMP............................................................................ 478 E-19 ABNORMALITY IN TRANSMISSION CUT-OFF...................................................................... 478 E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................ 478 E-21 ABNORMALITY IN BUZZER.................................................................................... 478 TROUBLESHOOTING ENGINE CONTROLLER SYSTEM (EA-MODE)................................................................ 0 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)...................................................... 479 POWER TRAIN................................................................................................... 481 H-1 MACHINE DOES NOT START................................................................................ 481 H-2 TRAVEL SPEED IS SLOW, MACHINE LACKS POWER IN ALL SPEED RANGES......................................... 482 H-3 EXCESSIVE TIME LAG WHEN STARTING ENGINE OR SHIFTING GEARS............................................. 483 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.............................................................. 484 STEERING SYSTEM............................................................................................... 485 H-5 STEERING WHEEL DOES NOT TURN.......................................................................... 485 H-6 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK)........................................................ 486 H-7 POOR TURNING AND STEERING RESPONSE.................................................................... 487 H-8 TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK)......................................... 488 H-9 STEERING IS HEAVY..................................................................................... 490 H-10 JOYSTICK IS HEAVY (MACHINE WITH JOYSTICK)............................................................ 490 H-11 STEERING WHEEL SHAKES OR JERKS....................................................................... 491 H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK).................................. 492 H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING............................... 492 BRAKE SYSTEM.................................................................................................. 494 H-14 WHEEL BRAKES DO NOT WORK OR BRAKIN EFFECT IS POOR.................................................... 494 H-15 WHEEL BRAKES DO NOT RELEASE OR BRAKES DRAG........................................................... 496 H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR................................................ 497 H-17 PARKING BRAKE DOES NOT RELEASE OR DRAGS.............................................................. 498 WORK EQUIPMENT................................................................................................ 499 H-18 NEITHER THE BOOM NOR BUCKET MOVE..................................................................... 499 H-19 BOTH THE BOOM AND BUCKET ARE SLOW OR LACK POWER...................................................... 500 H-20 BOOM DOES NOT MOVE................................................................................... 501 H-21 BOOM DOES NOT MOVE (MACHINES WITH REMOTE BOOM CONTROL)............................................... 502 H-22 BOOM IS SLOW OR LACKS POWER.......................................................................... 503 H-23 BOOM IS SLOW OR BOOM LACKS POWER (MACHINES WITH REMOTE BOOM CONTROL)................................. 504 H-24 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT......................................... 505 H-25 BOOM DROPS MOMENTARILY WHEN CONTROL LEVE IS MOVED FROM HOLD TO RAISE................................. 506 H-26 REMOTE BOOM CONTROL DOES NOT WORK.................................................................... 506 H-27 EXCESSIVE HYDRAULIC DRIFT OF BOOM.................................................................... 507 H-28 BUCKET DOES NOT MOVE................................................................................. 508 H-29 BUCKET IS SLOW OR LACKS POWER........................................................................ 509 H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.................................................................. 510 H-31 ECSS DOES NOT WORK AND THERE IS PITCHING AND BOUNCING................................................ 511 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE)................................................... 513 JUDGEMENT TABLE............................................................................................... 515 ACTION TAKEN BY CONTROLLER.................................................................................... 516 JOYSTICK CONTROLLER SYSTEM................................................................................ 516 ELECTRICAL CIRCUIT DIAGRAM.................................................................................... 520 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED..................... 522 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID - DETECTED WHEN SIGNAL IS OUTPUT)............. 523 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID - DETECTED WHEN SIGNAL IS OUTPUT) ............. 524 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID - POWER SUPPLY SIDE) IS DISPLAYED............. 525 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID - POWER SUPPLY SIDE) IS DISPLAYED.............. 526 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT RELAY) IS DISPLAYED.............. 528 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISP............. 530 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS ............. 531 J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE......................................................... 532 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT.......................................................... 533 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID................................................................. 534 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.................................................................. 535 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)............................................................ 537 MAINTENANCE MONITOR ELECTRICAL CIRCUIT DIAGRAM................................................................ 538 K-1 WITH STARTING SWITCH TURNED ON, NO DISPLAYS APPEAR FOR 3 SECONDS; MAINTENANCE MONITOR DOES NO............. 540 A. NO MAINTENANCE MONITOR LAMPS LIGHT UP.................................................................. 540 B. SOME LAMPS DO NOT LIGHT................................................................................ 540 K-2 ALL MAINTENANCE MONITOR LAMPS REMAIN LIT EVEN AFTER 3 SECONDS WITH STARTING SWITCH TURNED ON.............. 541 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS, NO MA............. 542 K-4 CHECK ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTING SWITCH TURNED TO ON........................... 543 A. ENGINE OIL LEVEL DISPLAY FLASHES....................................................................... 543 B. ENGINE COOLANT LEVEL DISPLAY FLASHES................................................................... 544 K-5 CAUTION ITEM DISPLAY FLASHES WITH ENGINE STOPPED AND STARTING SWITCH TURNED TO ON......................... 545 A. ENGINE OIL PRESSURE DISPLAY FLASHES.................................................................... 545 B. BATTERY CHARGE LEVEL DISPLAY FLASHES................................................................... 546 C. BRAKE OIL PRESSURE DISPLAY FLASHES..................................................................... 547 D. AIR CLEANER CLOGGED DISPLAY FLASHES.................................................................... 548 K-6 CAUTION ITEM DISPLAY FLASHES, BUT CAUTION BUZZER DOES NOT SOUND........................................... 549 K-7 NO MONITOR DISPLAY LIGHTS, BUT CAUTION BUZZER DOES SOUND.................................................. 550 K-8 CAUTION ITEM DISPLAY FLASHES, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH............... 551 A. CHECK LAMP............................................................................................. 551 B. CAUTION LAMP........................................................................................... 551 K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES............. 552 A. CHECK LAMP............................................................................................. 552 B. CAUTION LAMP........................................................................................... 552 K-10 ONLY NIGHT LIGHTING OF MONITOR STAYS OFF WHEN LAMP SWITCH IS TURNED ON................................... 553 K-11 NIGHT LIGHTING OF MONITOR LIGHTS EVEN WITH LAMP SWITCH OFF............................................... 554 K-12 SERVICE METER DOES NOT WORK.............................................................................. 555 K-13 SERVICE METER RUNS EVEN WITH ENGINE STOPPED.............................................................. 555 K-14 ABNORMALITY IN GAUGES.................................................................................... 556 A. ABNORMALITY IN FUEL GAUGE.............................................................................. 556 B. ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE........................................................ 557 C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.................................................. 558 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)................................................................... 559 ELECTRICAL CIRCUIT DIAGRAM.................................................................................... 562 MAIN MONITOR.............................................................................................. 562 LAMP AND HORN............................................................................................. 564 M-1 MAIN MONITOR DOES NOT WORK................................................................................ 565 M-2 ALL LAMPS STAY ON WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED IMMEDIATELY.................. 566 M-3 SPEEDOMETER DOESN’T DISPLAY PROPERLY...................................................................... 567 M-4 ABNORMALITY IN SHIFT INDICATOR............................................................................ 568 A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F......................................................... 568 B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R......................................................... 568 C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N................................................. 568 D. DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROLLER IS AT 1ST.............................................. 569 E. DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROLLER IS AT 2ND.............................................. 569 F. DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROLLER IS AT 3RD.............................................. 569 G. DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROLLER IS AT 4TH.............................................. 570 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT.......................................................................... 571 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT........................................................................ 572 A. LEFT-HAND TURN SIGNAL DOES NOT LIGHT................................................................... 572 B. RIGHT-HAND TURN SIGNAL DOES NOT LIGHT.................................................................. 572 M-7 ABNORMALITY IN PARKING LAMP DISPLAY....................................................................... 574 A. PARKING LAMP DISPLAY DOES NOT LIGHT.................................................................... 574 B. PARKING LAMP DISPLAY STAYS ON.......................................................................... 574 M-8 ABNORMALITY IN PREHEATING DISPLAY......................................................................... 575 A. PREHEATING DISPLAY NOT LIGHTING UP..................................................................... 575 B. PREHEATING DISPLAY STAYS LIT........................................................................... 575 M-9 MONITOR NIGHT LIGHTING DOES NOT WORK...................................................................... 576 M-10 ABNORMALITY IN FRONT WORK LAMP........................................................................... 578 A. NEITHER THE MONITOR DISPLAY NOR THE FRONT WORK LAMP LIGHT.............................................. 578 B. WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT.................................................... 578 C. MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT.................................................... 579 M-11 ABNORMALITY IN REAR WORK LAMP............................................................................ 580 A. NEITHER THE MONITOR DISPLAY NOR THE REAR WORK LAMP LIGHT............................................... 580 B. WORK LAMP LIGHTS BUT MONITOR DISPLAY DOES NOT LIGHT.................................................... 580 C. MONITOR DISPLAY LIGHTS BUT WORK LAMP DOES NOT LIGHT.................................................... 580 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...................................................................... 582 A. TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NO SWITCHED AND DISPLAY DOES NOT CHANGE.... 582 B. TRANSMISSION CUT-OFF SWITCH IS TURNED OFF, CUT-OFF FUNCTION IS ALWAYS ACTUATED........................ 582 C. CUT-OFF FUNCTION DOES NOT ACTUATE WHEN CUT-OFF SWITCH IS TURNED ON..................................... 581 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING............................................................ 584 A. WHEN PARKING BRAKE IS APPLIED, THE BUZZER SOUNDS INTERMITTENTLY AND THE CAUTION LAMPFLASHES EV......... 584 B. WHEN PARKING BRAKE IS APPLIED, THE BUZZER DOES NOT SOUND AND THE CAUTION LAMP DOES NOT LIGHT E......... 584 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP REMAIN ON CONTINUOUSLY............. 586 A. ACTUATED CONTINUOUSLY.................................................................................. 586 B. NOT ACTUATED AT ALL.................................................................................... 586 M-15 ABNORMALITY IN BUZZER.................................................................................... 588 A. BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH TURNED TO ON................ 588 B. BUZZER ALWAYS SOUNDS................................................................................... 588 M-16 CONDITION OF MONITOR SWITCHES NOT STORED IN MEMORY....................................................... 590 M-17 ABNORMALITY IN FAILURE DISPLAY MODE...................................................................... 592 A. FAILURE DISPLAY MODE DOES NOT WORK..................................................................... 592 B. COUNT FOR TIME ELAPSED SINCE LAST FAILURE DISPLAY MODE DOES NOT ADVANCE................................ 592 M-18 ANORMALITY IN GROUND-DRIVEN STEERING DISPLAY............................................................. 594 A. GROUND-DRIVEN STEERING DISPLAY DOES NOT FLASH.......................................................... 594 B. GROUND-DRIVEN STEERING DISPLAY FLASHES ALL THE TIME.................................................... 594 M-20 ABNORMALITY IN ECSS SYSTEM............................................................................... 595 A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED......................................................... 595 B. MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK.............................................. 595 M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)........................................ 596 TROUBLESHOOTING ENGINE MECHANICAL SYSTEM (S-MODE)................................................................. 0 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE)........................................................ 597 METHOD OD DISPLAYING ACTION CODE AND FAILURE CODE............................................................. 599 JUDGEMENT TABLE............................................................................................... 600 TRANSMISSION CONTROLLER SYSTEM-RELATED PARTS.............................................................. 600 ACTION TAKEN BY CONTROLLER.................................................................................... 602 TRANSMISSION CONTROLLER SYSTEM ELECTRICAL CIRCUIT DIAGRAM..................................................... 606 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LA............. 608 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOI............. 609 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOI............. 610 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLEN............. 611 T-5 FAILURE CODE [154] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLE............. 612 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLEN............. 613 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLEN............. 614 T-8 FAILURE CODE [18] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DIS............. 616 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED................ 618 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED..................... 622 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED.................................... 625 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.............. 626 T-13 SHIFT-UP DOES NOT WORK................................................................................... 628 T-14 SHIFT DOWN DOES NOT WORK................................................................................. 628 T-15 TRANSMISSION CUT-OFF DOES NOT WORK OR STAYS WORKING...................................................... 630 T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING............................................................... 631 T-17 BUZZER DOES NOT WORK..................................................................................... 632 T-18 ABNORMALITY IN NETWORK SYSTEM............................................................................ 633 T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY...................................................... 634 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM.............................................................. 635 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS.......................................................... 636 TROUBLESHOOTING AIR CONDITIONER (DENSO)........................................................................... 637 AIR CONDITIONER / HEATER (DENSO).............................................................................. 638 VISUAL AND AUDIBLE INSPECTION............................................................................. 638 TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)................................................. 639 NORMAL CONDITIONS..................................................................................... 639 INSUFFICIENT REFRIGERANT.............................................................................. 639 REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED)....................................................... 640 MOISTURE IN SYSTEM.................................................................................... 640 COMPRESSOR FAILURE.................................................................................... 640 EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING............................................... 641 AIR IN THE SYSTEM..................................................................................... 641 EXPANSION VALVE OPENS TOO FAR......................................................................... 641 TROUBLESHOOTING THE ELECTRICAL CIRCUIT........................................................................ 642 BLOWER TROUBLESHOOTING.................................................................................... 642 ELECTRICAL CIRCUIT CHECKS................................................................................. 644 HEATER RELAY.......................................................................................... 644 BLOWER SWITCH......................................................................................... 644 COOLER CIRCUIT TROUBLESHOOTING............................................................................ 646 AIR CONDITIONER SWITCH................................................................................ 646 MAGNETIC CLUTCH RELAY................................................................................. 646 CONDENSER FAN OPERATION CIRCUIT....................................................................... 647 ERROR MESSAGE TABLES.......................................................................................... 650 A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER................................................... 650 B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER................................................... 650 C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS................................................ 651 D. PROBLEM - NO HEAT...................................................................................... 651 E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE POWER IS TURNED ON.................... 651 F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST BUTTON IS PUSHED........................... 652 WIRING DIAGRAM................................................................................................ 654 WIRE CHART................................................................................................ 655 INSPECTION AREAS.......................................................................................... 656 TROUBLESHOOTING ENGINE FAULT DIAGNOSTICS.......................................................................... 657 ENGINE FAULT DIAGNOSTICS...................................................................................... 658 ERROR CODE DISPLAY........................................................................................ 658 AN ENGINE CONTROLLER DISPLAYS THE ENGINE CONDITIONS IN THE FOLLOWING TWO MODES ....................... 659 DISPLAY OF NATURE AND EXTENT OF ENGINE TROUBLE........................................................ 659 DISPLAY OF ERROR CODE (METHOD FOR CONFIRMING THREE-DIGIT ERROR CODES)................................. 659 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED.......................... 660 30 DISASSEMBLY AND ASSEMBLY........................................................................................... 671 METHOD OF USING MANUAL............................................................................................ 675 PRECAUTIONS DURING OPERATION...................................................................................... 676 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.................................................................... 676 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK............................................................... 677 PRECAUTIONS WHEN COMPLETING THE OPERATIONS.................................................................... 678 OTHER PRECAUTIONS............................................................................................. 678 SPECIAL TOOL LIST................................................................................................. 680 SKETCHES OF SPECIAL TOOLS......................................................................................... 687 ENGINE............................................................................................................ 695 AFTERCOOLER CORE.............................................................................................. 695 ALTERNATOR.................................................................................................... 695 CYLINDER HEAD................................................................................................. 695 ENGINE FRONT SEAL............................................................................................. 695 ENGINE OIL COOLER............................................................................................. 695 ENGINE REAR SEAL.............................................................................................. 695 FUEL INJECTION PUMP........................................................................................... 695 NOZZLE HOLDER................................................................................................. 695 STARTING MOTOR................................................................................................ 695 THERMOSTAT.................................................................................................... 695 TURBOCHARGER.................................................................................................. 695 WATER PUMP.................................................................................................... 695 RADIATOR.......................................................................................................... 696 REMOVAL....................................................................................................... 696 INSTALLATION.................................................................................................. 698 ENGINE AND TORQUE CONVERTER....................................................................................... 699 REMOVAL....................................................................................................... 699 INSTALLATION.................................................................................................. 702 TORQUE CONVERTER.................................................................................................. 703 REMOVAL....................................................................................................... 703 INSTALLATION.................................................................................................. 704 DISASSEMBLY................................................................................................... 705 ASSEMBLY...................................................................................................... 710 TRANSMISSION...................................................................................................... 716 REMOVAL....................................................................................................... 716 INSTALLATION.................................................................................................. 719 DISASSEMBLY................................................................................................... 720 ASSEMBLY...................................................................................................... 735 TRANSMISSION VALVE............................................................................................ 751 REMOVAL................................................................................................... 751 INSTALLATION.............................................................................................. 752 TRANSFER.......................................................................................................... 753 DISASSEMBLY................................................................................................... 753 ASSEMBLY...................................................................................................... 761 CENTER SUPPORT.................................................................................................... 772 REMOVAL....................................................................................................... 772 INSTALLATION.................................................................................................. 773 DISASSEMBLY................................................................................................... 773 ASSEMBLY...................................................................................................... 775 DRIVE SHAFT....................................................................................................... 778 DISASSEMBLY................................................................................................... 778 ASSEMBLY...................................................................................................... 780 FRONT AXLE........................................................................................................ 783 REMOVAL....................................................................................................... 783 INSTALLATION.................................................................................................. 784 REAR AXLE......................................................................................................... 785 REMOVAL....................................................................................................... 785 INSTALLATION.................................................................................................. 789 DIFFERENTIAL...................................................................................................... 790 REMOVAL (FRONT)............................................................................................... 790 INSTALLATION (FRONT).......................................................................................... 792 REMOVAL (REAR)................................................................................................ 793 INSTALLATION (REAR)........................................................................................... 794 DIFFERENTIAL, NORMAL - STANDARD............................................................................... 795 DISASSEMBLY............................................................................................... 795 FINE DISASSEMBLY OF THE PINION ASSEMBLY................................................................... 797 FINE DISASSEMBLY OF THE DIFFERENTIAL GEAR CASE ASSEMBLY................................................... 798 FINE ASSEMBLY OF THE DIFFERENTIAL GEAR CASE............................................................... 799 FINE ASSEMBLY OF PINION ASSEMBLY.......................................................................... 800 ASSEMBLY.................................................................................................. 801 DIFFERENTIAL, LIMITED SLIP.................................................................................... 807 DISASSEMBLY............................................................................................... 807 FINE DISASSEMBLY OF THE PINION ASSEMBLY................................................................... 809 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY....................................................... 810 ASSEMBLY.................................................................................................. 811 FINE ASSEMBLY OF PINION ASSEMBLY.......................................................................... 812 ASSEMBLY OF DIFFERENTIAL ASSEMBLY......................................................................... 813 FINAL DRIVE....................................................................................................... 821 REMOVAL & DISASSEMBLY......................................................................................... 821 ASSEMBLY & INSTALLATION....................................................................................... 823 STEERING.......................................................................................................... 827 STEERING CONTROL VALVE........................................................................................ 827 REMOVAL................................................................................................... 827 INSTALLATION.............................................................................................. 828 STEERING CYLINDER............................................................................................. 829 REMOVAL................................................................................................... 829 INSTALLATION.............................................................................................. 830 DISASSEMBLY............................................................................................... 831 ASSEMBLY.................................................................................................. 833 STEERING VALVE................................................................................................ 835 REMOVAL................................................................................................... 835 INSTALLATION.............................................................................................. 836 CUT-OFF VALVE................................................................................................. 837 REMOVAL................................................................................................... 837 INSTALLATION.............................................................................................. 837 STOP VALVE.................................................................................................... 838 REMOVAL................................................................................................... 838 INSTALLATION.............................................................................................. 838 GROUND-DRIVEN STEERING............................................................................................ 839 GROUND-DRIVEN STEERING PUMP................................................................................... 839 INSTALLATION.............................................................................................. 840 DIVERTER VALVE................................................................................................ 841 REMOVAL................................................................................................... 841 INSTALLATION.............................................................................................. 842 BRAKE............................................................................................................. 843 BRAKE VALVE................................................................................................... 843 REMOVAL................................................................................................... 843 INSTALLATION.............................................................................................. 843 BRAKE VALVE (RIGHT SIDE)...................................................................................... 844 DISASSEMBLY............................................................................................... 844 ASSEMBLY.................................................................................................. 846 BRAKE VALVE (LEFT SIDE)....................................................................................... 848 DISASSEMBLY............................................................................................... 848 ASSEMBLY.................................................................................................. 850 SLACK ADJUSTER................................................................................................ 852 REMOVAL................................................................................................... 852 INSTALLATION.............................................................................................. 852 DISASSEMBLY............................................................................................... 853 ASSEMBLY.................................................................................................. 854 ACCUMULATOR................................................................................................... 855 REMOVAL................................................................................................... 856 INSTALLATION.............................................................................................. 856 BRAKE......................................................................................................... 857 REMOVAL................................................................................................... 857 INSTALLATION.............................................................................................. 858 DISASSEMBLY (FRONT OR REAR)............................................................................... 859 ASSEMBLY (FRONT OR REAR).................................................................................. 861 PARKING BRAKE..................................................................................................... 865 SOLENOID VALVE................................................................................................ 865 REMOVAL................................................................................................... 865 INSTALLATION.............................................................................................. 865 PARKING BRAKE................................................................................................. 866 REMOVAL................................................................................................... 866 INSTALLATION.............................................................................................. 867 CALIPERS...................................................................................................... 868 DISASSEMBLY............................................................................................... 868 ASSEMBLY.................................................................................................. 869 PAD........................................................................................................... 870 REMOVAL................................................................................................... 870 INSTALLATION.............................................................................................. 871 HYDRAULICS........................................................................................................ 872 PUMP.......................................................................................................... 872 REMOVAL................................................................................................... 872 INSTALLATION.............................................................................................. 873 TANK.......................................................................................................... 874 REMOVAL................................................................................................... 874 INSTALLATION.............................................................................................. 875 FILTER........................................................................................................ 876 REMOVAL................................................................................................... 876 INSTALLATION.............................................................................................. 876 PPC VALVE..................................................................................................... 877 REMOVAL................................................................................................... 877 INSTALLATION.............................................................................................. 878 DISASSEMBLY............................................................................................... 879 ASSEMBLY.................................................................................................. 879 MAIN CONTROL VALVE............................................................................................ 880 REMOVAL................................................................................................... 880 INSTALLATION.............................................................................................. 881 DISASSEMBLY............................................................................................... 882 ASSEMBLY.................................................................................................. 886 DUMP CYLINDER................................................................................................. 889 REMOVAL................................................................................................... 889 INSTALLATION.............................................................................................. 890 LIFT CYLINDER................................................................................................. 891 REMOVAL................................................................................................... 891 INSTALLATION.............................................................................................. 892 LIFT CYLINDER AND DUMP CYLINDER............................................................................... 893 DISASSEMBLY............................................................................................... 893 ASSEMBLY.................................................................................................. 895 CENTER HINGE PIN.................................................................................................. 898 REMOVAL....................................................................................................... 898 INSTALLATION.................................................................................................. 904 WORK EQUIPMENT.................................................................................................... 907 REMOVAL....................................................................................................... 907 INSTALLATION.................................................................................................. 911 BULKHEAD.......................................................................................................... 913 REMOVAL....................................................................................................... 913 INSTALLATION.................................................................................................. 914 FLOOR FRAME....................................................................................................... 915 REMOVAL....................................................................................................... 915 INSTALLATION.................................................................................................. 917 CAB............................................................................................................... 918 REMOVAL....................................................................................................... 918 INSTALLATION.................................................................................................. 920 MONITOR........................................................................................................... 921 REMOVAL....................................................................................................... 921 INSTALLATION.................................................................................................. 921 AIR CONDITIONER................................................................................................... 922 COMPRESSOR.................................................................................................... 922 REMOVAL................................................................................................... 922 INSTALLATION.............................................................................................. 922 CONDENSER..................................................................................................... 923 REMOVAL................................................................................................... 923 INSTALLATION.............................................................................................. 924 RECEIVER TANK................................................................................................. 925 REMOVAL................................................................................................... 925 INSTALLATION.............................................................................................. 927 AIR CONDITIONER UNIT.......................................................................................... 926 REMOVAL................................................................................................... 926 INSTALLATION.............................................................................................. 927 FUEL TANK......................................................................................................... 928 REMOVAL....................................................................................................... 928 INSTALLATION.................................................................................................. 929 COUNTERWEIGHT..................................................................................................... 930 REMOVAL....................................................................................................... 930 INSTALLATION.................................................................................................. 930 FRONT TIRES....................................................................................................... 931 REMOVAL....................................................................................................... 931 INSTALLATION.................................................................................................. 931 REAR TIRES........................................................................................................ 932 REMOVAL....................................................................................................... 932 INSTALLATION.................................................................................................. 932 40 MAINTENANCE STANDARD............................................................................................... 934 ENGINE MOUNT...................................................................................................... 936 TRANSMISSION MOUNT................................................................................................ 937 TORQUE CONVERTER.................................................................................................. 938 REGULATOR VALVE............................................................................................... 941 TRANSMISSION...................................................................................................... 943 CLUTCH SPRINGS................................................................................................ 943 GEARS......................................................................................................... 945 TRANSMISSION CONTROL VALVE.................................................................................... 947 UPPER VALVE............................................................................................... 947 RELIEF VALVE.............................................................................................. 947 LOWER VALVE............................................................................................... 949 SOLENOID VALVE................................................................................................ 951 TRANSFER.......................................................................................................... 953 DRIVE SHAFT....................................................................................................... 955 CENTER SUPPORT.................................................................................................... 957 CENTER HINGE PIN.................................................................................................. 959 AXLE MOUNT........................................................................................................ 961 DIFFERENTIAL...................................................................................................... 963 STANDARD...................................................................................................... 963 LIMITED SLIP.................................................................................................. 967 FINAL DRIVE....................................................................................................... 969 STEERING.......................................................................................................... 971 STEERING COLUMN............................................................................................... 971 STEERING DEMAND VALVE......................................................................................... 973 GROUND DRIVEN STEERING PUMP................................................................................... 974 DIVERTER VALVE................................................................................................ 975 STEERING CYLINDER MOUNT....................................................................................... 976 BRAKES............................................................................................................ 977 BRAKE VALVE - LEFT............................................................................................ 977 BRAKE VALVE - RIGHT........................................................................................... 979 SLACK ADJUSTER................................................................................................ 981 BRAKE......................................................................................................... 983 PARKING BRAKE................................................................................................. 985 HYDRAULIC......................................................................................................... 986 TORQUE CONVERTER CHARGING PUMP [SAL(3)-125] AND PPC PUMP [SAL(1)-32].......................................... 986 WORK EQUIPMENT PUMPS [SAL(4)-125] (2 EA.)..................................................................... 987 STEERING PUMP [SAL(4)-125] AND SWITCH PUMP [SAL(4)-100]....................................................... 988 PPC VALVE FOR BOOM............................................................................................ 989 PPC VALVE FOR BUCKET.......................................................................................... 989 PPC VALVE FOR ATTACHMENT...................................................................................... 990 CUT-OFF VALVE................................................................................................. 991 MAIN CONTROL VALVE............................................................................................ 993 STEERING CYLINDER............................................................................................. 995 BUCKET CYLINDER............................................................................................... 996 BOOM CYLINDER................................................................................................. 997 WORK EQUIPMENT.................................................................................................... 999 LINKAGE....................................................................................................... 999 BUCKET........................................................................................................1001 BUCKET POSITIONER.............................................................................................1002 BOOM KICK OUT.................................................................................................1002 ROPS CANOPY.......................................................................................................1003 90 OTHERS ............................................................................................................1004 HYDRAULIC.........................................................................................................1006 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................1006 ELECTRICAL........................................................................................................1008 CIRCUIT DIAGRAM (SHEET 1, PART 1 OF 6)........................................................................1008 CIRCUIT DIAGRAM (SHEET 1, PART 2 OF 6)........................................................................1010 CIRCUIT DIAGRAM (SHEET 1, PART 3 OF 6)........................................................................1012 CIRCUIT DIAGRAM (SHEET 1, PART 4 OF 6)........................................................................1014 CIRCUIT DIAGRAM (SHEET 1, PART 5 OF 6)........................................................................1016 CIRCUIT DIAGRAM (SHEET 1, PART 6 OF 6)........................................................................1018 CIRCUIT DIAGRAM (SHEET 2, PART 1 OF 4)........................................................................1020 CIRCUIT DIAGRAM (SHEET 2, PART 2 OF 4)........................................................................1022 CIRCUIT DIAGRAM (SHEET 2, PART 3 OF 4)........................................................................1024 CIRCUIT DIAGRAM (SHEET 2, PART 4 OF 4)........................................................................1026 CIRCUIT DIAGRAM (SHEET 3, PART 1 OF 2)........................................................................1028 CIRCUIT DIAGRAM (SHEET 3, PART 2 OF 2)........................................................................1030
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