Komatsu Galeo WA200-5L WA200PT-5L Wheel Loader Shop Manual PDF

Description

Komatsu Galeo WA200-5L WA200PT-5L Wheel Loader Shop Manual CEBM013003 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Galeo WA200-5L WA200PT-5L Wheel Loader Shop Manual CEBM013003 – PDF DOWNLOAD 

Language : English
Pages : 960
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Galeo WA200-5L WA200PT-5L Wheel Loader Shop Manual CEBM013003 – PDF DOWNLOAD 

SERIAL NUMBERS
WA200-5L A82001 and UP
WA200PT-5L A89001 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu Galeo WA200-5L WA200PT-5L Wheel Loader Shop Manual CEBM013003 – PDF DOWNLOAD 

SERIAL NUMBERS
WA200-5L A82001 and UP
WA200PT-5L A89001 and UP

COVER 1
FOREWORD 2
CONTENTS 2
SAFETY 11
SAFETY NOTICE 11
IMPORTANT SAFETY NOTICE 11
GENERAL PRECAUTIONS 11
PREPARATIONS FOR WORK 11
PRECAUTIONS DURING WORK 11
GENERAL 13
HOW TO READ THE SHOP MANUAL 14
VOLUMES 14
DISTRIBUTION AND UPDATING 14
FILING METHOD 14
REVISED EDITION MARK 14
REVISIONS 14
SYMBOLS 14
HOISTING INSTRUCTIONS 15
HOISTING 15
WIRE ROPES 15
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 25
CLASSIFICATION BY THICKNESS 25
CLASSIFICATION BY COLOR AND CODE 25
CONVERSION TABLES 26
METHOD OF USING THE CONVERSION TABLE 26
01 GENERAL 33
GENERAL ASSEMBLY DRAWINGS 34
SPECIFICATIONS 35
WEIGHT TABLE 39
FLUID USE ACCORDING TO AMBIENT TEMPERATURE 40
COOLANT SPECIFICATIONS 42
SUPERCOOLANT (AF-NAC) 42
10 STRUCTURE AND FUNCTION 43
ENGINE AND DRIVE SYSTEM MOUNTING 49
DRIVE SYSTEM DAMPER 50
COOLING SYSTEM 51
REVERSING FAN SYSTEM 52
REVERSING FAN MANIFOLD 53
PROPORTIONAL RELIEF VALVE 54
2-POSITION, 4-WAY SPOOL VALVE 55
FAN CONTROLLER 56
POWER TRAIN 58
POWER TRAIN SYSTEM DIAGRAM 59
DRIVE SHAFT 61
HST HYDRAULIC PIPING DIAGRAM 62
HST PUMP 63
OPERATION 64
FLOW OF OIL 65
HIGH-PRESSURE RELIEF VALVE 66
LOW-PRESSURE RELIEF VALVE 68
CHARGE PUMP 69
SPEED-RELATED VALVE (DA VALVE) 70
HIGH-PRESSURE CUT-OFF VALVE 71
HST MOTOR 72
HST MOTOR 1 72
HST MOTOR 2 74
EP SERVO VALVE 76
HA SERVO VALVE 77
FORWARD-REVERSE SHUTTLE VALVE 78
TRANSFER 79
OUTLINE 79
INPUT SHAFT PORTION 82
OUTPUT SHAFT PORTION 84
CLUTCH OPERATION 87
LOW-SPEED MODE 88
HIGH-SPEED MODE 89
CLUTCH SOLENOID VALVE 90
OPERATION 90
AXLE 91
FRONT AXLE 91
REAR AXLE 92
DIFFERENTIAL 93
FRONT DIFFERENTIAL 93
REAR DIFFERENTIAL 95
OUTLINE 97
LIMITED SLIP DIFFENTIAL 98
OPERATION 99
WHEN TRAVELING IN A STRAIGHT LINE 100
WHEN TURNING 101
FINAL DRIVE 102
OUTLINE 103
AXLE MOUNTING AND CENTER HINGE PIN 104
OUTLINE 105
STEERING PIPING SYSTEM 108
STEERING COLUMN 109
PRIORITY VALVE 110
OUTLINE 111
OPERATION 111
STRAIGHT TRAVEL 111
STEERING WHEEL TURNED TO LEFT 112
STEERING CYLINDER AT END OF STROKE 112
ORBIT-ROLL VALVE 113
OUTLINE 114
STRUCTURE 114
OPERATION 115
STEERING WHEEL AT NEUTRAL 115
STEERING WHEEL TURNED (TURNING LEFT) 117
STEERING WHEEL STOPPED 118
CONNECTION BETWEEN HAND PUMP AND SLEEVE 119
ROLE OF CENTERING SPRING 120
2-WAY RESTRICTOR VALVE 121
FUNCTION 121
OPERATION 121
CUSHION VALVE 122
OUTLINE 122
FUNCTION 122
STEERING CYLINDER 123
EMERGENCY STEERING PIPING 125
EMERGENCY STEERING VALVE 126
OPERATION 127
WHEN ENGINE AND STEERING PUMP ARE NORMAL 127
WHEN ENGINE OR STEERING PUMP IS ABNORMAL 128
BRAKE PIPING 129
BRAKE VALVE 130
OUTLINE 131
OPERATION 131
WHEN BRAKE PEDAL IS PRESSED 131
WHEN BALANCED 132
WHEN BRAKE PEDAL IS RELEASED 133
INCHING VALVE 134
OUTLINE 134
CHARGE VALVE 135
FUNCTION 136
OPERATION 137
WHEN OIL IS NOT SUPPLIED TO ACCUMULATOR 137
WHEN OIL IS SUPPLIED TO ACCUMULATOR 137
WHEN INPUT PRESSURE TO VALVE RISES ABOVE SET PRESSURE 138
BRAKE ACCUMULATOR 139
FUNCTION 139
SPECIFICATIONS 139
SLACK ADJUSTER 140
FUNCTION 141
OPERATION 141
WHEN BRAKE IS APPLIED 141
WHEN BRAKE IS RELEASED 141
BRAKE 142
OUTLINE 143
WHEN BRAKE IS APPLIED 143
WHEN BRAKE IS RELEASED 143
PARKING BRAKE CONTROL 144
OUTLINE 144
PARKING BRAKE 145
OUTLINE 145
HYDRAULIC PIPING 146
WA200-5L 146
WA200PT-5L 148
OUTLINE 149
WORK EQUIPMENT LEVER LINKAGE 150
WA200-5L 150
MULTI-FUNCTION JOYSTICK 150
STANDARD JOYSTICK 151
WA200PT-5L 152
MULTI-FUNCTION JOYSTICK 152
STANDARD JOYSTICK 153
HYDRAULIC TANK 154
SPECIFICATIONS 155
BREATHER 155
PREVENTION OF NEGATIVE PRESSURE IN TANK 155
PREVENTION OF RISE OF PRESSURE IN TANK 155
4-GEAR PUMP UNIT 156
OUTLINE 156
PPC CIRCUIT ACCUMULATOR 158
OUTLINE 158
SPECIFICATIONS 158
LOCK VALVE 158
OUTLINE 158
BYPASS VALVE 159
BOOM CYLINDER (WA200-5L AND WA200PT-5L) 159
OPERATION 160
BUCKET CYLINDER (WA200PT-5L) 162
OPERATION 163
QUICK COUPLER SOLENOID VALVE 165
OUTLINE 165
E C S S VALVE 166
ECSS ACCUMULATOR 168
FUNCTION 168
SPECIFICATIONS 168
HYDRAULIC PIPING OF COOLING SYSTEM 169
OUTLINE 169
COOLING FAN MOTOR 170
SPECIFICATIONS 170
FUNCTION 171
PRINCIPLE OF OPERATION 171
WORK EQUIPMENT CONTROL VALVE 172
2-SPOOL VALVE 172
3-SPOOL VALVE 175
RELIEF VALVE 178
SAFETY-SUCTION VALVE 179
SUCTION VALVE 180
OPERATION OF THE WORK EQUIPMENT CONTROL VALVE 181
WORK EQUIPMENT PPC VALVE 187
MONO-LEVER TYPE 187
OPERATION 189
ATTACHMENT PPC VALVE 192
OPERATION 194
AT THE NEUTRAL POSITION 194
AT THE FINE CONTROL POSITION 194
AT FULL STROKE 195
WORK EQUIPMENT LINKAGE 196
WA200-5L 196
WA200PT-5L 198
BUCKET 200
CONTROL FOR BUCKET AND BOOM 202
FOR WA200-5L 202
OUTLINE 203
OPERATION OF PROXIMITY SWITCH 204
FUNCTION OF PROXIMITY SWITCH 206
OPERATION OF BOOM KICK-OUT 207
FUNCTION OF PROXIMITY SWITCH 209
FOR WA200PT-5L 210
OUTLINE 211
BUCKET POSITIONER OR FORK POSITIONER 211
BOOM KICK-OUT 211
DUMP SPEED CONTROL 211
OPERATION OF PROXIMITY SWITCH 212
WHEN BUCKET IS TILTED 212
FUNCTION OF PROXIMITY SWITCH 214
WHEN LIFT ARM IS RAISED 215
FUNCTION OF PROXIMITY SWITCH 217
WHEN BUCKET IS DUMPED 218
FUNCTION OF PROXIMITY SWITCH 219
WORK EQUIPMENT CYLINDER 220
WA200-5L 220
LIFT CYLINDER 220
BUCKET CYLINDER 220
WA200PT-5L 221
LIFT CYLINDER 221
BUCKET CYLINDER 221
COUPLER PLUNGER 221
AIR CONDITIONER 223
AIR CONDITIONER PIPING 223
MACHINE MONITORING SYSTEM 224
OUTLINE 224
NORMAL MODE 224
SERVICE MODE 225
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR 227
STARTING AND LIGHTING 227
POWER SUPPLY AND NETWORK 229
SENSING 230
HST SAFETY CONTROL 231
AUTOMATIC PREHEATING 232
MACHINE MONITOR 233
LIST OF ITEMS DISPLAYED ON MONITOR 234
SERVICE MODE FUNCTIONS 240
OUTLINE 240
OPERATING METHOD 242
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM 243
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM 246
REAL-TIME MONITOR FUNCTION 248
MAINTENANCE FUNCTIONS 251
FUNCTION OF SELECTING OPTIONAL DEVICE 255
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM) 259
SYSTEM DIAGRAM 259
CONTROL FUNCTION 259
HST CONTROLLER 262
INPUT AND OUTPUT SIGNALS 262
DIRECTIONAL SELECTOR SWITCH 263
OUTLINE 263
FUNCTION 263
OPERATION 264
WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL LEVER 264
WHEN DIRECTIONAL SELECTOR SWITCH IS SELECTED TO BE USED 264
WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL SELECTOR SWITCH 264
WHEN DIRECTIONAL LEVER HAS PRIORITY 264
ENGINE STARTING CIRCUIT 265
FUNCTION 265
OPERATION 266
ENGINE STOP CIRCUIT 267
OPERATION 267
PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM) 268
OUTLINE 268
OPERATION 268
PARKING BRAKE CIRCUIT 269
OPERATION 270
WHEN PARKING BRAKE LEVER IS RETURNED (ON o OFF) 270
WHEN PARKING BRAKE LEVER IS PULLED (OFF to ON) 271
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM 272
FUNCTION 272
COUPLER PLUNGER CONTROL SYSTEM 273
WA200PT-5L 273
OUTLINE 273
OPERATION 273
SENSORS 274
ENGINE SPEED SENSOR 274
FUNCTION 274
SPEED SENSOR 274
FUNCTION 274
ENGINE OIL PRESSURE SENSOR 275
FUNCTION 275
FUEL LEVEL SENSOR 275
FUNCTION 275
COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR) 276
FUNCTION 276
COOLANT TEMPERATURE SENSOR (FOR PREHEATING) 276
FUNCTION 276
AXLE OIL TEMPERATURE SENSOR 277
FUNCTION 277
HST OIL PRESSURE SENSOR 277
FUNCTION 277
STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR 278
FUNCTION 278
HST FILTER CLOGGING SENSOR 278
FUNCTION 278
COOLANT LEVEL SENSOR 279
FUNCTION 279
20 TESTING, ADJUSTING AND TROUBLESHOOTING 281
STANDARD VALUE TABLE 283
ENGINE 283
CHASSIS 284
SPECIAL TOOLS 290
T-ADAPTER PROCEDURES AND KITS 293
ENGINE COMPONENTS 294
MEASURING EXHAUST SMOKE 294
MEASURING EXHAUST TEMPERATURE 294
ADJUSTING VALVE CLEARANCE 294
MEASURING COMPRESSION PRESSURE 294
MEASURING CRANKCASE PRESSURE 294
MEASURING ENGINE OIL PRESSURE 294
MEASURING BOOST PRESSURE 294
MEASURING FUEL PRESSURE 294
ADJUSTING ENGINE SPEED SENSOR 294
BLEEDING AIR FROM FUEL SYSTEM 294
MEASURING ENGINE SPEED 295
MEASURING (LOW AND HIGH IDLE) 295
MEASURING HST STALL SPEED 296
MEASURING HYDRAULIC STALL 296
MEASURING FULL STALL SPEED 296
MEASURING, OPERATING FORCE OF ACCELERATOR PEDAL 297
TESTING OPERATING FORCE 297
OPERATING ANGLE OF PEDAL 298
ADJUSTING ENGINE STOP SOLENOID 299
ADJUSTING ENGINE SPEED SENSOR 300
REFRIGERENT COMPRESSOR BELT 301
MEASURING DIRECTIONAL LEVER 302
HST OIL PRESSURE 303
MEASURING 303
ADJUSTING 306
MEASURING CLUTCH CONTROL PRESSURE 308
STEERING WHEEL 309
MEASURING WHEEL END PLAY 309
MEASURING OPERATING FORCE 309
MEASURING OPERATING TIME 310
STEERING OIL PRESSURE 311
MEASURING MAIN RELIEF PRESSURE 311
ADJUSTING MAIN RELIEF PRESSURE 311
BLEEDING AIR FROM STEERING CIRCUIT 312
HYDRAULIC FAN 313
MEASURING FAN SPEED 313
MEASURING OIL PRESSURE 314
MEASURING BRAKE PEDAL 316
BRAKE PEDAL LINKAGE 317
MEASURING BRAKE PERFORMANCE 318
ACCUMULATOR CHARGE PRESSURE 319
MEASURING BRAKE OIL PRESSURE 320
MEASURING WEAR ON BRAKE DISC 322
BLEEDING AIR FROM BRAKE CIRCUIT 323
PARKING BRAKE PERFORMANCE 324
PARKING BRAKE LINKAGE 325
WORK EQUIPMENT CONTROL LEVER 326
WORK EQUIPMENT PRESSURE 327
WORK EQUIPMENT PPC OIL PRESSURE 328
TESTING AND ADJUSTING 328
BLEEDING AIR 330
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 331
BUCKET POSITIONER 332
BOOM KICK-OUT 333
CHECKING PROXIMITY SWITCH 334
CONNECTING T-ADAPTER TO HST CONTROLLER 335
SPECIAL FUNCTIONS OF MACHINE MONITOR 338
FLOW OF MODES AND FUNCTIONS 339
PM CLINIC INSPECTION CHART 356
TROUBLESHOOTING (GENERAL) 359
POINTS TO REMEMBER WHEN TROUBLESHOOTING 360
SEQUENCE OF EVENTS IN TROUBLESHOOTING 362
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 363
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT 363
HANDLING CONTROL BOX 368
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 369
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 370
CHECKS BEFORE TROUBLESHOOTING 372
USING TROUBLESHOOTING CHARTS 373
PHENOMENA CONSIDERED TO BE FAILURES 374
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 377
T-ADAPTER TABLE 401
CONNECTOR TYPES AND MOUNTING LOCATIONS 404
CONNECTOR LAYOUT DRAWING 410
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 415
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 416
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL 416
USER CODE MEMORY RETENTION FUNCTION 416
HST CONTROLLER SYSTEM DIAGRAM 417
TROUBLESHOOTING CODE DISPLAY 419
ERROR CODE AND POSSIBLE CAUSE TABLE 419
FUSE SYSTEM CHECK 420
FUSE PANNEL CONNECTION TABLE 420
INFORMATION CONTAINED IN TESTING PROCEDURES 421
CODE KEY TABLE 422
ERROR CODE: [989F00] 423
TRANSMISSION PROTECTION ALERT (00) 423
ERROR CODE: [DDD7KX] 424
SPEEDOMETER SYSTEM INPUT SIGNAL OUT OF RANGE 424
ERROR CODE: [DHH1KX] 427
HST OIL PRESSURE SIGNAL OUT OF RANGE 427
ERROR CODE: [DLE2LC] 429
ENGINE SPEED SENSOR OUT OF RANGE 429
ERROR CODE: [DLT3KA] 431
TRAVEL SPEED DOES NOT REGISTER ON SPEEDOMETER 431
ERROR CODE: [DW26KZ] 434
MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED 434
ERROR CODE: [DX19KZ] 438
MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED 438
ERROR CODE: [DX20KZ] 440
CLUTCH SOLENOID SYSTEM OPEN OR SHORTED 440
TROUBLESHOOTING CODE: [HST-1] 442
DEFECTIVE HST POWER CONTROLLER SOURCE 442
TROUBLESHOOTING CODE: [HST-2] 446
TRAVEL SPEED RANGES DO NOT CHANGE 446
TROUBLESHOOTING CODE: [HST-3] 450
TRACTION CONTROL FOR HST SYSTEM CANNOT BE CONTROLLED 450
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) 453
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 456
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL 456
USER CODE MEMORY RETENTION FUNCTION 456
MONITOR SYSTEM CIRCUIT DIAGRAM 457
TROUBLESHOOTING CODE DISPLAY 461
ERROR CODE AND POSSIBLE CAUSE TABLE 461
FUSE SYSTEM CHECK 462
FUSE PANEL CONNECTION TABLE 462
INFORMATION CONTAINED IN TESTING PROCEDURES 463
CODE KEY TABLE 464
ERROR CODE: [15B0NX] 465
HST OIL FILTER SHOWING CLOGGED CONDITION 465
ERROR CODE: [2G42ZG] 467
LOW ACCUMULATOR OIL PRESSURE INDICATED 467
ERROR CODE: [989F00] 469
TRANSMISSION PROTECTION CAUTION INDICATED 469
ERROR CODE: [989FN1] 470
HST OVERSPEED CONDITION 470
ERROR CODE: [AB00L6] 471
DEFECTIVE BATTERY CHARGING CIRCUIT 471
ERROR CODE: [AB00MA] 473
DEFECTIVE BATTERY CHARGING CIRCUIT 473
ERROR CODE: [B@BAZG] 475
ABNORMAL ENGINE OIL PRESSURE INDICATED 475
ERROR CODE: [B@BCNS] 477
ENGINE COOLANT INDICATING OVERHEAT CONDITION 477
ERROR CODE: [B@BCZK] 479
ABNORMAL COOLANT LEVEL INDICATION 479
ERROR CODE: [B@C7NS] 481
BRAKE COOLING OIL INDICATING OVERHEATING CONDITION 481
ERROR CODE: [B@CRNS] 483
HST OIL SHOWING OVERHEATING CONDITION 483
ERROR CODE: [D5ZHL6] 485
STARTING SWITCH “C” (IGN) INPUT FAILURE INDICATED 485
ERROR CODE: [DAF0KT] 487
CONTROLLER INTERNAL FAILURE) 487
ERROR CODE: [DAJ0KR] 489
HST CONTROLLER COMMUNICATION FAILURE 489
ERROR CODE: [DD15LD] 491
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 491
ERROR CODE: [DD16LD] 493
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 493
ERROR CODE: [DD17LD] 495
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 495
ERROR CODE: [DD18LD] 497
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 497
ERROR CODE: [DDK3KB] 499
IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER 499
ERROR CODE: [DDS5L6] 501
DECREASED STEERING OIL PRESSURE 501
ERROR CODE: [DGE2KX] 503
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE 503
ERROR CODE: [DGE3KX] 505
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE 505
ERROR CODE: [DGH1KX] 507
HST OIL SHOWING OVERHEATING CONDITION 507
ERROR CODE: [DGR4KA] 509
BRAKE COOLING OIL INDICATING SHORT CIRCUIT 509
ERROR CODE: [DGR4KX] 511
BRAKE COOLING OIL INDICATING OPEN CIRCUIT 511
ERROR CODE: [DHE4KA] 513
ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM 513
TROUBLESHOOTING CODE: [MON-1] 515
PARKING BRAKE INDICATOR LAMP DOES NOT WORK 515
TROUBLESHOOTING CODE: [MON-2] 519
BRAKE OIL PRESSURE NOT INDICATING CORRECTLY 519
TROUBLESHOOTING CODE: [MON-3] 521
ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY 521
TROUBLESHOOTING CODE: [MON-4] 523
HST OIL TEMPERATURE NOT INDICATING CORRECTLY 523
TROUBLESHOOTING CODE: [MON-5] 525
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY 525
TROUBLESHOOTING CODE: [MON-6] 527
ABNORMAL COOLANT LEVEL INDICATION 527
TROUBLESHOOTING CODE: [MON-7] 529
STEERING OIL PRESSURE NOT READING CORRECTLY 529
TROUBLESHOOTING CODE: [MON-8] 531
EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY 531
TROUBLESHOOTING CODE: [MON-9] 533
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 533
TROUBLESHOOTING CODE: [MON-10] 535
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 535
TROUBLESHOOTING CODE: [MON-11] 537
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 537
TROUBLESHOOTING CODE: [MON-12] 539
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 539
TROUBLESHOOTING CODE: [MON-13] 541
ALARM BUZZER DOES NOT STOP OR REMAINS ON 541
TROUBLESHOOTING CODE: [MON-14] 543
FRONT WINDSHIELD WIPER DOES NOT WORK 543
REAR WINDSHIELD WIPER DOES NOT WORK 545
TROUBLESHOOTING CODE: [MON-15] 547
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION 547
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 551
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 553
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL 553
USER CODE MEMORY RETENTION FUNCTION 553
ELECTRICAL SYSTEM CIRCUIT DIAGRAM 554
FUSE SYSTEM CHECK 560
FUSE PANEL CONNECTION TABLE 560
INFORMATION CONTAINED IN TESTING PROCEDURES 561
CODE: (E-1) 563
ENGINE WILL NOT CRANK 563
CODE: (E-2) 566
THE ENGINE DOES NOT SHUT DOWN 566
CODE: (E-3) 568
COLD START PREHEATER DOES NOT WORK PROPERLY 568
CODE: (E-4) 571
PARKING BRAKE DOES NOT FUNCTION PROPERLY 571
CODE: (E-5) 574
BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY 574
CODE: (E-6) 577
BUCKET LEVER FUNCTION NOT WORKING PROPERLY 577
CODE: (E-7) 580
FLOAT HOLD FUNCTION NOT WORKING PROPERLY 580
CODE: (E-8) 583
FRONT WINDSHIELD WIPER DOES NOT WORK 583
CODE: (E-8) 587
REAR WINDSHIELD WIPER DOES NOT WORK 587
CODE: (E-9) 589
THE WINDOW WASHER DOES NOT WORK 589
CODE: (E-10) 591
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION 591
CODE: (E-10) 594
HEADLAMPS (LO BEAM) DO NOT FUNCTION 594
CODE: (E-10) 597
HEADLAMPS (HI BEAM) DO NOT FUNCTION 597
CODE: (E-10) 600
CLEARANCE LAMPS DO NOT FUNCTION 600
CODE: (E-10) 603
TURN SIGNALS DO NOT FUNCTION 603
CODE: (E-10) 606
WORK LAMPS DO NOT FUNCTION 606
CODE: (E-11) 609
HORN DOES NOT SOUND 609
CODE: (E-12) 611
AIR CONDITIONER SYSTEM DOES NOT WORK 611
CODE: (E-12) 614
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED 614
CODE: (E-12) 618
AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED 618
CODE: (E-12) 622
CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS 622
CODE: (E-12) 624
CANNOT SWITCH VENT FUNCTIONS 624
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 627
METHOD OF USING TROUBLESHOOTING CHART 629
FAILURE CODE AND CAUSE TABLE 632
CODE: (H-1) 635
THE MACHINE DOES NOT START 635
CODE: (H-2) 636
THE TRAVEL SPEED IS SLOW 636
CODE: (H-3) 637
THE THRUST FORCE IS WEAK 637
CODE: (H-4) 638
ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY 638
CODE: (H-5) 639
THE GEARS DO NOT CHANGE SPEED RANGE 639
CODE: (H-6) 640
THE STEERING WHEEL DOES NOT TURN 640
CODE: (H-7) 641
STEERING WHEEL MOVEMENT IS HEAVY 641
CODE: (H-8) 642
STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT 642
CODE H-9 642
MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING 642
CODE: (H-10) 643
BRAKES DO NOT WORK OR WORKS POORLY 643
CODE: (H-11) 644
BRAKES IS NOT RELEASING OR DRAGGED 644
CODE: (H-12) 645
THE LIFT ARM DOES NOT RISE OR LOWER 645
CODE: (H-13) 646
LIFT ARM MOVES SLOW OR RISING FORCE IS POOR 646
CODE: (H-14) 647
WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS 647
CODE: (H-15) 647
THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES) 647
CODE: (H-16) 647
HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN 647
CODE: (H-17) 647
THE LIFT ARM WOBBLES DURING OPERATION 647
CODE: (H-18) 648
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY 648
CODE: (H-19) 649
THE BUCKET DOES NOT TILT BACK 649
CODE: (H-20) 650
BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT 650
CODE: (H-21) 651
THE BUCKET OPERATES SLOWLY IN TILTING-BACK 651
CODE: (H-22) 651
BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 651
CODE: (H-23) 651
HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN 651
CODE: (H-24) 651
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 651
CODE: (H-25) 652
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 652
CODE: (H-26) 652
CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY 652
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 653
METHOD OF USING TROUBLESHOOTING CHARTS 654
(S-1) ENGINE STARTING PERFORMANCE IS POOR 658
(S-2) ENGINE HAS STARTING PROBLEMS 660
ENGINE DOES NOT CRANK 660
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK 661
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START 662
(S-3) ENGINE DOES NOT RUN SMOOTHLY 663
(S-4) ENGINE STOPS DURING OPERATIONS 664
(S-5) ENGINE SPEED HUNTS 665
(S-6) ENGINE LACKS POWER 666
(S-7) EXHAUST SMOKE IS BLACK 667
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 668
(S-9) OIL BECOMES CONTAMINATED QUICKLY 669
(S-10) FUEL CONSUMPTION IS EXCESSIVE 670
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR 671
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP 672
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) 673
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) 674
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG 675
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING 676
30 DISASSEMBLY AND ASSEMBLY 677
HOW TO READ THIS MANUAL 680
REMOVAL AND INSTALLATION (DISASSEMBLY AND ASSEMBLY) OF ASSEMBLIES 680
SPECIAL TOOLS 680
REMOVAL AND/OR DISASSEMBLY OF PARTS 680
INSTALLATION AND/OR ASSEMBLY OF PARTS 681
SKETCHES OF SPECIAL TOOLS 681
PRECAUTIONS WHEN PERFORMING OPERATION 682
SPECIAL TOOL LIST 685
SKETCHES OF SPECIAL TOOLS 688
FUEL INJECTION PUMP ASSEMBLY 695
SPECIAL TOOLS 688
REMOVAL 695
INSTALLATION 698
BLEEDING AIR 700
NOZZLE HOLDER ASSEMBLY 701
SPECIAL TOOLS 0
REMOVAL 701
INSTALLATION 702
CYLINDER HEAD ASSEMBLY 703
SPECIAL TOOLS 0
REMOVAL 703
INSTALLATION 710
ENGINE ASSEMBLY 714
REMOVAL 714
INSTALLATION 721
RADIATOR ASSEMBLY 723
REMOVAL 723
INSTALLATION 724
AIR AFTERCOOLER 725
REMOVAL 725
INSTALLATION 726
HYDRAULIC OIL COOLER 727
REMOVAL 727
INSTALLATION 729
COOLING FAN AND FAN MOTOR 730
REMOVAL 730
INSTALLATION 731
FUEL TANK 732
REMOVAL 732
INSTALLATION 734
TRANSFER 735
REMOVAL 735
INSTALLATION 737
TRANSFER ASSEMBLY 738
SPECIAL TOOLS 0
DISASSEMBLY 738
ASSEMBLY 749
PARKING BRAKE ASSEMBLY 763
REMOVAL 763
INSTALLATION 764
DISASSEMBLY 765
SPECIAL TOOLS 0
ASSEMBLY 768
FRONT AXLE ASSEMBLY 772
REMOVAL 772
INSTALLATION 774
REAR AXLE ASSEMBLY 775
REMOVAL 775
INSTALLATION 777
AXLE HOUSING ASSEMBLY 779
SPECIAL TOOLS 0
DISASSEMBLY 779
ASSEMBLY 783
DIFFERENTIAL ASSEMBLY 790
SPECIAL TOOLS 0
DISASSEMBLY 790
ASSEMBLY 803
HST PUMP AND 4-GEAR PUMP ASSEMBLY 822
REMOVAL 822
INSTALLATION 825
HST PUMP ASSEMBLY 826
DISASSEMBLY 826
ASSEMBLY 838
HST MOTOR 1 ASSEMBLY 855
REMOVAL 855
INSTALLATION 856
HST MOTOR 2 ASSEMBLY 857
REMOVAL 857
INSTALLATION 858
HST MOTOR ASSEMBLY 859
DISASSEMBLY 859
ASSEMBLY 869
WORK EQUIPMENT CONTROL VALVE ASSEMBLY 880
REMOVAL 880
INSTALLATION 881
TRAVEL DAMPER VALVE ASSEMBLY 882
REMOVAL 882
INSTALLATION 883
HYDRAULIC TANK 884
REMOVAL 884
INSTALLATION 886
WORK EQUIPMENT 887
REMOVAL 887
INSTALLATION 890
PROCEDURE FOR INSTALLING BUCKET LINK AND PIN 890
PROCEDURE FOR INSTALLING BUCKET HINGE PIN 891
PROCEDURE FOR INSTALLING BUCKET CYLINDER PIN (ON ROD SIDE) 891
PROCEDURE FOR INSTALLING BOOM CYLINDER PIN (ON ROD SIDE) 892
PROCEDURE FOR INSTALLING BOOM PIN (ON FRAME SIDE) 893
PROCEDURE FOR INSTALLING BUCKET LINK PIN 893
HYDRAULIC CYLINDER ASSEMBLY 895
SPECIAL TOOLS 0
DISASSEMBLY 895
ASSEMBLY 898
OPERATOR’S CAB ASSEMBLY 904
SPECIAL TOOLS 0
REMOVAL 904
INSTALLATION 909
OPERATOR’S CAB GLASS 910
SPECIAL TOOLS 0
REMOVAL 910
INSTALLATION 911
COATING MATERIALS 919
CENTER HINGE PIN 920
REMOVAL 920
INSTALLATION 926
COUNTERWEIGHT 931
REMOVAL 931
INSTALLATION 932
AIR CONDITIONER UNIT ASSEMBLY 933
SPECIAL TOOLS 0
REMOVAL 933
INSTALLATION 936
AIR CONDITIONER COMPRESSOR ASSEMBLY 937
SPECIAL TOOLS 0
REMOVAL 937
INSTALLATION 942
MONITOR PANEL 938
REMOVAL 938
INSTALLATION 942
90 OTHERS 943
HYDRAULIC CIRCUIT DIAGRAM 944
ELECTRICAL CIRCUIT DIAGRAM 946
FLOOR HARNESS 946
MONITOR CIRCUIT 946
CAB HARNESS 947
TO FRONT AND BULK HEAD HARNESS 948
TO REAR AND HST HARNESS 949
AIR CONDITIONER RELAY HARNESS 950
TO HST CONTROLLER AND WORK LAMPS 951
VARIABLE SHIFT CONTROL 952
SWITCHES 953
HST AND BULK HEAD HARNESS 954
GRILL AND ENGINE HARNESS 955
REAR AND POWER SUPPLY HARNESS 956
CAB, EMERGENCY STEERING AND MULTI-FUNCTION HARNESS 957
FRONT HARNESS 958
REVERSING FAN WIRING DIAGRAM 959
PROPOSAL FOR MANUAL OR CSS REVISION 960

S.V 15/12/24