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Komatsu Galeo WA320-5L Wheel Loader Shop Manual A32001 and up – PDF DOWNLOAD
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Komatsu Galeo WA320-5L Wheel Loader Shop Manual
SERIAL NUMBERS WA320-5L A32001 and up
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Description
Komatsu Galeo WA320-5L Wheel Loader Shop Manual A32001 and up
FILE DETAILS:
Komatsu Galeo WA320-5L Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA320-5L GALEO
Serial Number: A32001 and up
Book Code: CEBM012004
Language: English
Pages: 1033
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Galeo WA320-5L Wheel Loader Shop Manual
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Galeo WA320-5L Wheel Loader Shop Manual
COVER.................................................................................................... 1 CONTENTS................................................................................................. 2 FOREWORD................................................................................................. 13 SAFETY............................................................................................... 13 SAFETY NOTICE.................................................................................... 13 IMPORTANT SAFETY NOTICE...................................................................... 13 GENERAL PRECAUTIONS.......................................................................... 13 PREPARATIONS FOR WORK........................................................................ 13 PRECAUTIONS DURING WORK...................................................................... 13 GENERAL.............................................................................................. 15 HOW TO READ THE SHOP MANUAL.......................................................................... 16 VOLUMES.......................................................................................... 16 DISTRIBUTION AND UPDATING........................................................................ 16 FILING METHOD.................................................................................... 16 REVISED EDITION MARK............................................................................. 16 REVISIONS........................................................................................ 16 SYMBOLS.......................................................................................... 16 HOISTING INSTRUCTIONS................................................................................ 17 HOISTING......................................................................................... 17 WIRE ROPES....................................................................................... 17 PUSH-PULL TYPE COUPLER............................................................................... 18 COATING MATERIALS.................................................................................... 20 STANDARD TIGHTENING TORQUE........................................................................... 22 BOLTS AND NUTS STANDARD TIGHTENING TORQUE........................................................ 22 HOSE NUTS TIGHTENING TORQUE...................................................................... 23 SPLIT FLANGE BOLTS TIGHTENING TORQUE............................................................. 23 FLARED NUTS TIGHTENING TORQUE.................................................................... 23 O-RING BOSS PIPING JOINTS TIGHTENING TORQUE...................................................... 24 O-RING BOSS PLUGS TIGHTENING TORQUE.............................................................. 24 102 ENGINE SERIES TIGHTENING TORQUE.............................................................. 25 HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE..................................... 26 ELECTRIC WIRE CODE................................................................................... 27 CLASSIFICATION BY THICKNESS...................................................................... 27 CLASSIFICATION BY COLOR AND CODE................................................................. 27 CONVERSION TABLES.................................................................................... 28 METHOD OF USING THE CONVERSION TABLE............................................................. 28 UNITS............................................................................................ 34 01 GENERAL............................................................................................... 35 GENERAL ASSEMBLY DRAWINGS............................................................................ 36 SPECIFICATIONS....................................................................................... 37 WEIGHT TABLE......................................................................................... 41 LIST OF LUBRICANTS AND COOLANT....................................................................... 42 10 STRUCTURE AND FUNCTION................................................................................ 45 ENGINE AND DRIVE SYSTEM MOUNTING..................................................................... 51 DRIVE DAMPER ASSEMBLY................................................................................ 52 DRIVE DAMPER OPERATION........................................................................... 52 COOLING SYSTEM ASSEMBLY.............................................................................. 53 REVERSING FAN SYSTEM................................................................................. 54 REVERSING FAN MANIFOLD............................................................................... 55 PROPORTIONAL RELIEF VALVE............................................................................ 56 2-POSITION, 4-WAY SPOOL VALVE........................................................................ 57 FAN CONTROLLER....................................................................................... 58 POWER TRAIN.......................................................................................... 59 POWER TRAIN SYSTEM................................................................................... 60 POWER TRAIN OPERATION............................................................................ 61 FRONT AND REAR DRIVE LINES........................................................................... 62 DRIVE LINE OPERATION............................................................................. 62 HST HYDRAULIC PIPING DIAGRAM......................................................................... 63 HST PUMP............................................................................................. 64 HST PUMP OPERATION............................................................................... 65 POWER FLOW................................................................................... 65 OIL FLOW..................................................................................... 66 PRESSURE RELIEF VALVES............................................................................... 67 HIGH PRESSURE.................................................................................... 67 FUNCTION..................................................................................... 67 VALVE OPERATION.............................................................................. 68 LOW PRESSURE..................................................................................... 69 VALVE OPERATION.............................................................................. 69 HST CHARGE PUMP...................................................................................... 70 PUMP OPERATION................................................................................... 71 FUNCTION..................................................................................... 71 SPEED RELATED VALVE (DA VALVE)....................................................................... 72 FUNCTION......................................................................................... 72 DA VALVE OPERATION............................................................................... 72 HIGH-PRESSURE CUT-OFF VALVE.......................................................................... 73 FUNCTION......................................................................................... 73 CUT-OFF VALVE OPERATION.......................................................................... 73 HST MOTORS........................................................................................... 74 HST MOTOR 1...................................................................................... 74 HST MOTOR 2...................................................................................... 75 HST OPERATING PRINCIPLE.......................................................................... 76 STRUCTURE.................................................................................... 76 MOTOR OPERATION.............................................................................. 76 EP SERVO VALVE....................................................................................... 77 FUNCTION......................................................................................... 77 VALVE OPERATION.................................................................................. 77 HA SERVO VALVE....................................................................................... 78 FUNCTION......................................................................................... 78 VALVE OPERATION.................................................................................. 78 FORWARD-REVERSE SHUTTLE VALVE........................................................................ 79 FUNCTION......................................................................................... 79 SHUTTLE VALVE OPERATION.......................................................................... 79 TRANSFER SYSTEM...................................................................................... 80 INTERNAL VIEW OF TRANSFER........................................................................ 81 INPUT SHAFT SPECIFICATIONS....................................................................... 82 OUTPUT SHAFT SPECIFICATIONS...................................................................... 84 SPECIFICATIONS............................................................................... 86 CLUTCH OPERATION................................................................................. 86 WHEN “ON”.................................................................................... 86 WHEN “OFF”................................................................................... 86 LOW SPEED MODE................................................................................... 87 MODE OPERATION............................................................................... 87 HIGH SPEED MODE.................................................................................. 88 MODE OPERATION............................................................................... 88 CLUTCH SOLENOID VALVE................................................................................ 89 SOLENOID VALVE OPERATION......................................................................... 89 AXLES................................................................................................ 90 FRONT AXLE....................................................................................... 90 REAR AXLE........................................................................................ 91 STANDARD DIFFERENTIALS............................................................................... 92 FRONT DIFFERENTIAL............................................................................... 92 SPECIFICATIONS............................................................................... 93 REAR DIFFERENTIAL................................................................................ 94 SPECIFICATIONS............................................................................... 95 DIFFERENTIAL FUNCTION............................................................................ 96 DIFFERENTIAL OPERATION....................................................................... 96 TORQUE PROPORTIONING............................................................................. 97 DIFFERENTIAL OPERATION....................................................................... 97 LIMITED-SLIP DIFFERENTIAL............................................................................ 98 FRONT DIFFERENTIAL............................................................................... 98 SPECIFICATIONS............................................................................... 99 LIMITED-SLIP OPERATION....................................................................... 99 FINAL DRIVE.......................................................................................... 102 SPECIFICATIONS................................................................................... 102 FINAL DRIVE OUTLINE.............................................................................. 103 AXLE MOUNTING AND CENTER HINGE PIN................................................................... 104 AXLE MOUNTING.................................................................................... 104 AXLE MOUNTING OUTLINE........................................................................ 105 CENTER HINGE PIN ASSEMBLY........................................................................ 106 SPECIFICATIONS............................................................................... 107 SPECIFICATIONS............................................................................... 108 STEERING PIPING...................................................................................... 109 STEERING COLUMN...................................................................................... 110 PRIORITY VALVE....................................................................................... 111 PRIORITY VALVE OUTLINE........................................................................... 112 ORBIT-ROLL VALVE..................................................................................... 114 ORBITAL-ROLL VALVE OPERATION..................................................................... 115 STRUCTURE.................................................................................... 115 STEERING WHEEL IN NEUTRAL POSITION........................................................... 116 STEERING WHEEL TURNING LEFT.................................................................. 117 STEERING WHEEL STOPPED....................................................................... 118 CONNECTION BETWEEN HAND PUMP AND SLEEVE.......................................................... 119 ROLE OF CENTERING SPRING..................................................................... 120 CUSHION VALVE........................................................................................ 121 CUSHION VALVE OPERATION.......................................................................... 121 FUNCTION..................................................................................... 121 CYLINDER LAY-OUT AND STEERING CYLINDER............................................................... 122 STEERING CYLINDER................................................................................ 123 EMERGENCY STEERING PIPING............................................................................ 124 EMERGENCY STEERING VALVE............................................................................. 125 STEERING SYSTEM DURING NORMAL OPERATION.......................................................... 126 STEERING SYSTEM WHEN FAILURE OCCURS.............................................................. 127 BRAKE PIPING......................................................................................... 128 BRAKE VALVE ASSEMBLY................................................................................. 129 VALVE ASSEMBLY OUTLINE........................................................................... 130 WHEN BRAKE PEDAL IS PRESSED.................................................................. 130 WHEN BRAKE IS BALANCED....................................................................... 131 WHEN BRAKE IS RELEASED....................................................................... 132 INCHING VALVE FUNCTION........................................................................... 133 INCHING VALVE OUTLINE........................................................................ 133 CHARGE VALVE ASSEMBLY................................................................................ 134 FUNCTION OF CHARGE VALVE......................................................................... 136 VALVE OPERATION.............................................................................. 136 ACCUMULATOR (BRAKE SYSTEM)........................................................................... 138 ACCUMULATOR FUNCTION............................................................................. 138 SLACK ADJUSTER....................................................................................... 139 SLACK ADJUSTER FUNCTION.......................................................................... 140 BRAKE................................................................................................ 141 BRAKE OUTLINE.................................................................................... 142 PARKING BRAKE CONTROL................................................................................ 143 BRAKE SYSTEM OUTLINE............................................................................. 143 PARKING BRAKE UNIT............................................................................... 144 PARKING BRAKE OUTLINE........................................................................ 144 HYDRAULIC PIPING..................................................................................... 145 PIPING OUTLINE................................................................................... 146 WORK EQUIPMENT CONTROL LINKAGE....................................................................... 147 MULTI FUNCTION MONO LEVER........................................................................ 148 HYDRAULIC TANK....................................................................................... 149 SYSTEM SPECIFICATIONS............................................................................ 150 BREATHER..................................................................................... 150 4-GEAR PUMP UNIT..................................................................................... 151 PUMP OUTLINE..................................................................................... 151 ACCUMULATOR (PPC CIRCUIT)............................................................................ 153 ACCUMULATOR OUTLINE.............................................................................. 153 SPECIFICATIONS............................................................................... 153 LOCK VALVE........................................................................................... 154 LOCK VALVE OUTLINE............................................................................... 154 TRAVEL DAMPER VALVE.................................................................................. 155 ACCUMULATOR (TRAVEL DAMPER).......................................................................... 157 ACCUMULATOR FUNCTION............................................................................. 157 SPECIFICATIONS............................................................................... 157 HYDRAULIC PIPING FOR COOLING SYSTEM.................................................................. 158 PIPING OUTLINE................................................................................... 158 COOLING FAN MOTOR.................................................................................... 159 FAN MOTOR SPECIFICATIONS......................................................................... 160 MOTOR FUNCTION............................................................................... 160 PRINCIPLE OF OPERATION....................................................................... 160 WORK EQUIPMENT CONTROL VALVE......................................................................... 162 2-SPOOL VALVE.................................................................................... 162 3-SPOOL VALVE.................................................................................... 165 3-RELIEF VALVE................................................................................... 168 VALVE FUNCTION............................................................................... 168 VALVE OPERATION.............................................................................. 168 4-RELIEF VALVE................................................................................... 169 VALVE FUNCTION............................................................................... 169 VALVE OPERATION.............................................................................. 169 SUCTION VALVE.................................................................................... 170 VALVE FUNCTION............................................................................... 170 VALVE OPERATION.............................................................................. 170 CUT-OFF VALVE.................................................................................... 171 VALVE FUNCTION............................................................................... 172 WORK EQUIPMENT CONTROL VALVE OPERATION........................................................... 174 WORK EQUIPMENT PPC VALVE............................................................................. 180 2-LEVER TYPE..................................................................................... 180 PPC VALVE OPERATION.............................................................................. 182 WHEN BUCKET IS IN NEUTRAL.................................................................... 182 FINE CONTROL MODE (NEUTRAL ¤ FINE)........................................................... 183 (FINE ¤ NEUTRAL)............................................................................. 183 LEVER IS MOVED TO END OF STRTOKE............................................................. 184 LEVER IS IN “FLOAT”.......................................................................... 184 MONO-LEVER TYPE.................................................................................. 185 MONO-LEVER OPERATION............................................................................. 187 IN NEUTRAL POSITION.......................................................................... 187 FINE CONTROL MODE (NEUTRAL ¤ FINE)........................................................... 188 (FINE ¤ NEUTRAL)............................................................................. 188 LEVER IS MOVED TO END OF STROKE.............................................................. 189 LEVER IS IN “FLOAT”.......................................................................... 189 ATTACHMENT PPC VALVE................................................................................. 190 PPC VALVE OPERATION.............................................................................. 191 IN NEUTRAL POSITION.......................................................................... 191 AT FULL STROKE............................................................................... 193 WORK EQUIPMENT LINKAGE............................................................................... 194 BUCKET............................................................................................... 196 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................. 197 POSITIONER SYSTEM OUTLINE........................................................................ 198 BUCKET POSITIONER............................................................................ 198 BOOM KICK-OUT................................................................................ 198 PROXIMITY SWITCH OPERATION................................................................... 198 FUNCTION OF PROXIMITY SWITCH................................................................. 201 FUNCTION OF PROXIMITY SWITCH................................................................. 204 WORK EQUIPMENT CYLINDER.............................................................................. 205 LIFT CYLINDER.................................................................................... 205 BUCKET CYLINDER.................................................................................. 205 AIR CONDITIONER SYSTEM............................................................................... 206 AIR CONDITIONER PIPING........................................................................... 206 MACHINE MONITORING SYSTEM............................................................................ 207 SYSTEM OUTLINE AND CIRCUIT DIAGRAMS.............................................................. 207 MACHINE MONITOR (Starting And Lighting)...................................................... 209 POWER SUPPLY NETWORK......................................................................... 210 MACHINE MONITOR (STANDARD)........................................................................... 217 MACHINE MONITOR (OPTIONAL LOAD METER)................................................................ 218 ITEMS DISPLAYED ON MONITOR........................................................................... 219 MONITOR MODE FUNCTIONS........................................................................... 224 ELECTRICAL SYSTEM FAILURE HISTORY............................................................ 224 MACHINE SYSTEM FAILURE HISTORY............................................................... 224 REAL-TIME MONITOR............................................................................ 225 SPEED METER SPECIFICATIONS................................................................... 227 ITEMS RELATED TO THE FAULT HISTORY OF ELECTRICAL SYSTEM.......................................... 229 ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM............................................. 232 REAL-TIME MONITOR FUNCTION....................................................................... 234 SPEED METER SPECIFICATION.................................................................... 234 LOAD METER SPECIFICATION..................................................................... 237 TUNING FUNCTION.................................................................................. 244 LOAD METER SPECIFICATIONS.................................................................... 244 MAINTENANCE FUNCTION............................................................................. 246 HOW TO INPUT INTERVAL........................................................................ 248 FUNCTION OF SELECTING OPTIONAL DEVICE............................................................ 250 SPEED METER.................................................................................. 250 SELECTION OF TIRE............................................................................ 251 LOAD METER....................................................................................... 252 SETTING MACHINE SERIAL NUMBER................................................................ 254 LOAD METER FUNCTION.......................................................................... 255 INPUT/OUTPUT SIGNAL.............................................................................. 263 SPEED METER SPECIFICATIONS................................................................... 263 LOAD METER SPECIFICATIONS.................................................................... 265 ELECTRICAL SYSTEM (HST CONTROLLER)................................................................... 270 CONTROL FUNCTION................................................................................. 271 HST CONTROLLER....................................................................................... 274 FORWARD-REVERSE SELECTOR SWITCH (IF EQUIPPED)........................................................ 276 SYSTEM OUTLINE................................................................................... 276 FUNCTION..................................................................................... 276 ENGINE START CIRCUIT................................................................................. 278 CIRCUIT OPERATION................................................................................ 278 FUNCTION..................................................................................... 279 ENGINE STOP CIRCUIT.................................................................................. 280 CIRCUIT OPERATION................................................................................ 280 AUTOMATIC PREHEAT SYSTEM CIRCUIT..................................................................... 281 SYSTEM OUTLINE................................................................................... 281 PREHEAT OPERATION............................................................................ 281 PARKING BRAKE CIRCUIT................................................................................ 282 PARKING BRAKE OPERATION.......................................................................... 283 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.......................................................... 285 SYSTEM FUNCTION.................................................................................. 285 SENSORS.............................................................................................. 286 ENGINE SPEED SENSOR.............................................................................. 286 SYSTEM FUNCTION.............................................................................. 286 TRAVEL SPEED SENSOR.............................................................................. 286 SYSTEM FUNCTION.............................................................................. 286 ENGINE OIL PRESSURE SENSOR....................................................................... 287 SYSTEM FUNCTION.............................................................................. 287 FUEL LEVEL SENSOR................................................................................ 287 SYSTEM FUNCTION.............................................................................. 287 ENGINE COOLANT AND HST OIL TEMPERATURE SENSOR.................................................... 288 SYSTEM FUNCTION.............................................................................. 288 PREHEATING COOLANT TEMPERATURE SENSOR............................................................ 288 SYSTEM FUNCTION.............................................................................. 288 AXLE OIL TEMPERATURE SENSOR...................................................................... 289 SYSTEM FUNCTION.............................................................................. 289 HST OIL PRESSURE SENSOR (LOAD METER)............................................................. 289 SYSTEM FUNCTION.............................................................................. 289 EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)............................................. 290 SYSTEM FUNCTION.............................................................................. 290 HST FILTER CLOG SENSOR........................................................................... 290 SYSTEM FUNCTION.............................................................................. 290 COOLANT LEVEL SENSOR............................................................................. 291 SYSTEM FUNCTION.............................................................................. 291 ENGINE OIL LEVEL SENSOR.......................................................................... 292 SYSTEM FUNCTION.............................................................................. 292 AIR CLEANER CLOG SENSOR.......................................................................... 292 SYSTEM FUNCTION.............................................................................. 292 LIFT ARM ANGLE SENSOR (IF EQUIPPED).............................................................. 293 SYSTEM FUNCTION.............................................................................. 293 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................................................ 295 STANDARD VALUE TABLE................................................................................. 297 ENGINE........................................................................................... 297 CHASSIS.......................................................................................... 298 SPECIAL TOOLS........................................................................................ 303 ENGINE COMPONENTS.................................................................................... 306 MEASURING EXHAUST SMOKE.......................................................................... 306 MEASURING EXHAUST TEMPERATURE.................................................................... 306 ADJUSTING VALVE CLEARANCE........................................................................ 306 MEASURING COMPRESSION PRESSURE................................................................... 306 MEASURING CRANCASE PRESSURE...................................................................... 306 MEASURING ENGINE OIL PRESSURE.................................................................... 306 MEASURING BOOST PRESSURE......................................................................... 306 MEASURING FUEL PRESSURE.......................................................................... 306 ADJUSTING ENGINE SPEED SENSOR.................................................................... 306 BLEEDING AIR FROM FUEL SYSTEM.................................................................... 306 MEASURING ENGINE SPEED........................................................................... 307 MEASURING LOW AND HIGH IDLE.................................................................. 307 MEASURING HST STALL SPEED.................................................................... 308 MEASURING HYDRAULIC STALL.................................................................... 308 MEASURING FULL STALL SPEED................................................................... 308 ACCELERATOR PEDAL.................................................................................... 309 TESTING PEDAL FORCE.............................................................................. 309 OPERATING ANGLE OF PEDAL......................................................................... 310 ADJUSTING ENGINE STOP SOLENOID....................................................................... 311 ADJUSTING ENGINE SPEED SENSOR........................................................................ 312 REFRIGERENT COMPRESSOR BELT.......................................................................... 313 DIRECTIONAL LEVER.................................................................................... 314 HST OIL PRESSURE..................................................................................... 315 MEASURING........................................................................................ 315 ADJUSTING........................................................................................ 318 CLUTCH CONTROL PRESSURE.............................................................................. 320 STEERING WHEEL....................................................................................... 321 MEASURING STEERING WHEEL END PLAY................................................................ 321 MEASURING OPERATING FORCE ON STEERING WHEEL...................................................... 321 MEASURING OPERATING TIME FOR STEERING WHEEL...................................................... 322 STEERING OIL PRESSURE................................................................................ 323 MEASURING MAIN RELIEF PRESSURE................................................................... 323 ADJUSTING MAIN RELIEF PRESSURE................................................................... 323 BLEEDING AIR FROM STEERING CIRCUIT............................................................... 324 HYDRAULIC FAN........................................................................................ 325 MEASURING FAN SPEED.............................................................................. 325 MEASURING OIL PRESSURE........................................................................... 325 REVERSING FAN CONTROLLER, IF EQUIPPED................................................................ 326 LED INDICATORS................................................................................... 326 MEASURING BRAKE PEDAL................................................................................ 327 BRAKE PEDAL LINKAGE.................................................................................. 328 MEASURING BRAKE PERFORMANCE.......................................................................... 329 ACCUMULATOR CHARGE PRESSURE.......................................................................... 330 BRAKE OIL PRESSURE................................................................................... 331 MEASURING WEAR OF BRAKE DISC......................................................................... 333 BLEEDING AIR FROM BRAKE CIRCUIT...................................................................... 334 PARKING BRAKE PERFORMANCE............................................................................ 335 PARKING BRAKE LINKAGE................................................................................ 336 WORK EQUIPMENT CONTROL LEVER......................................................................... 338 WORK EQUIPMENT PRESSURE.............................................................................. 339 WORK EQUIPMENT PPC OIL PRESSURE...................................................................... 341 TESTING AND ADJUSTING............................................................................ 341 BLEEDING AIR..................................................................................... 343 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................... 344 BUCKET POSITIONER.................................................................................... 345 BOOM KICK-OUT........................................................................................ 346 PROXIMITY SWITCH ACTUATION DISPLAY LAMP.............................................................. 347 PROCEDURE FOR CHECKING DIODE......................................................................... 349 SPECIAL FUNCTIONS OF MACHINE MONITOR................................................................. 350 FLOW OF MODES AND FUNCTIONS.......................................................................... 351 REAL-TIME MONITORING ITEMS........................................................................... 375 PM CLINIC INSPECTION CHART........................................................................... 0 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................. 384 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................ 386 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................ 387 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT..................................................... 387 HANDLING CONTROL BOX............................................................................. 392 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS........................................ 393 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT............................................. 394 CHECKS BEFORE TROUBLESHOOTING........................................................................ 396 USING TROUBLESHOOTING CHARTS..................................................................... 397 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING.......................................... 398 TABLE FOR CONNECTOR PIN NUMBERS...................................................................... 401 T-ADAPTER TABLE...................................................................................... 425 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................... 428 CONNECTOR LAYOUT DRAWING............................................................................. 434 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).................................................. 439 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 440 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................ 440 USER CODE MEMORY RETENTION FUNCTION.......................................................... 440 ERROR CODE AND POSSIBLE CAUSE TABLE.............................................................. 441 FUSE SYSTEM CHECK................................................................................ 443 FUSE PANNEL CONNECTION TABLE................................................................. 443 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 444 CODE KEY TABLE............................................................................... 445 ERROR CODE: [989F00]............................................................................. 446 TRANSMISSION PROTECTION ALERT (00)........................................................... 446 ERROR CODE: [DDD7KX]............................................................................. 448 SPEEDOMETER SIGNAL OUT OF RANGE.............................................................. 448 ERROR CODE: [DHH1KX]............................................................................. 450 HST OIL PRESSURE SIGNAL OUT OF RANGE......................................................... 450 ERROR CODE: [DLE2LC]............................................................................. 452 ENGINE SPEED SENSOR OUT OF RANGE............................................................. 452 ERROR CODE: [DLT3KA]............................................................................. 454 ON SPEEDOMETER SIGNAL........................................................................ 454 ERROR CODE: [DW26KZ]............................................................................. 456 MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED...................................................... 456 ERROR CODE: [DX19KZ]............................................................................. 460 MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED...................................................... 460 ERROR CODE: [DX20KZ]............................................................................. 464 CLUTCH SOLENOID SYSTEM OPEN OR SHORTED....................................................... 464 TROUBLESHOOTING CODE: [HST-1].................................................................... 468 DEFECTIVE HST POWER CONTROLLER SOURCE........................................................ 468 TROUBLESHOOTING CODE: [HST-2].................................................................... 472 TRAVEL SPEED RANGES DO NOT CHANGE............................................................ 472 TROUBLESHOOTING CODE: [HST-3].................................................................... 476 TRACTION CONTROL INNOPERABLE................................................................. 476 TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)..................................................... 479 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 482 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................ 482 USER CODE MEMORY RETENTION FUNCTION.......................................................... 482 ERROR CODE AND POSSIBLE CAUSE TABLE.............................................................. 483 FUSE SYSTEM CHECK................................................................................ 485 FUSE PANNEL CONNECTION TABLE................................................................. 485 FUSE SYSTEM CHECK................................................................................ 486 FUSE PANNEL CONNECTION TABLE................................................................. 486 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 487 CODE KEY TABLE............................................................................... 488 ERROR CODE: [15B0NX]............................................................................. 489 HST OIL FILTER SHOWING CLOGGED CONDITION..................................................... 489 ERROR CODE: [2G42ZG]............................................................................. 491 LOW ACCUMULATOR OIL PRESSURE INDICATED....................................................... 491 ERROR CODE: [989F00]............................................................................. 493 TRANSMISSION PROTECTION CAUTION INDICATED.................................................... 493 ERROR CODE: [989FN1]............................................................................. 494 HST OVERSPEED CONDITION...................................................................... 494 ERROR CODE: [AA1ANX]............................................................................. 495 CLOGGED AIR CLEANER INDICATED (STANDARD)..................................................... 495 CLOGGED AIR CLEANER INDICATED (LOAD METER)................................................... 497 ERROR CODE: [AB00L6]............................................................................. 499 DEFECTIVE BATTERY CHARGING CIRCUIT........................................................... 499 ERROR CODE: [AB00MA]............................................................................. 501 DEFECTIVE BATTERY CHARGING CIRCUIT........................................................... 501 ERROR CODE: [B@BAZG]............................................................................. 503 ABNORMAL ENGINE OIL PRESSURE INDICATED....................................................... 503 ERROR CODE: [B@BAZK]............................................................................. 505 ABNORMAL ENGINE OIL LEVEL INDICATION......................................................... 505 ERROR CODE: [B@BCNS]............................................................................. 507 ENGINE COOLANT INDICATING OVERHEAT CONDITION................................................. 507 ERROR CODE: [B@BCZK]............................................................................. 509 ABNORMAL COOLANT LEVEL INDICATION............................................................ 509 ERROR CODE: [B@C7NS]............................................................................. 511 BRAKE COOLING OIL INDICATING OVERHEATING CONDITION........................................... 511 ERROR CODE: [B@CRNS]............................................................................. 513 HST OIL SHOWING OVERHEATING CONDITION........................................................ 513 ERROR CODE: [D5ZHL6]............................................................................. 515 IGNITION SWITCH “C” (IGN) INPUT FAILURE INDICATED............................................ 515 ERROR CODE: [DAF3KK]............................................................................. 519 WITH IGNITION SWITCH ON, POWER SUPPLY FOR MEMORY IS OFF...................................... 519 ERROR CODE: [DAF5KP]............................................................................. 521 DEFECTIVE 5-V POWER SUPPLY OUTPUT (KP)....................................................... 521 ERROR CODE: [DAF6KP]............................................................................. 523 DEFECTIVE 24-V POWER SUPPLY OUTPUT (KP)...................................................... 523 ERROR CODE: [DAF0KT]............................................................................. 525 CONTROLLER INTERNAL FAILURE)................................................................. 525 ERROR CODE: [DAJ0KR]............................................................................. 527 HST CONTROLLER COMMUNICATION FAILURE......................................................... 527 ERROR CODE [D182KZ].............................................................................. 531 THE PREHEATER RELAY COIL IS OPEN OR SHORTED.................................................. 531 ERROR CODE [D1B0KB].............................................................................. 533 HST SAFETY (TRANSMISSION CUT-OFF) RELAY OPEN OR SHORTED (KB)................................. 533 ERROR CODE: [DD1CLD]............................................................................. 535 DEFECTIVE SUBTOTAL SWITCH.................................................................... 535 ERROR CODE: [DD15LD]............................................................................. 537 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 537 ERROR CODE: [DD16LD]............................................................................. 539 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 539 ERROR CODE: [DD17LD]............................................................................. 541 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 541 ERROR CODE: [DD18LD]............................................................................. 543 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 543 ERROR CODE: [DDK3KB]............................................................................. 545 IMPROPER INPUT FOR MULTIPLE SHIFT (FNR) LEVER (STANDARD)..................................... 545 IMPROPER INPUT FOR MULTIPLE SHIFT (FNR) LEVER (LOAD METER)................................... 547 ERROR CODE: [DDS5L6]............................................................................. 549 DECREASED STEERING OIL PRESSURE.............................................................. 549 ERROR CODE: [DDY0LD]............................................................................. 551 DEFECTIVE CANCEL SWITCH...................................................................... 551 ERROR CODE: [DGE2KX]............................................................................. 553 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE............................................... 553 ERROR CODE: [DGE3L6]............................................................................. 555 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE............................................... 555 ERROR CODE: [DGH1KX]............................................................................. 557 HST OIL SHOWING OVERHEATING CONDITION........................................................ 557 ERROR CODE: [DGR4KA]............................................................................. 559 AXLE OIL INDICATING SHORT CIRCUIT............................................................ 559 ERROR CODE: [DGR4KX]............................................................................. 561 BRAKE COOLING OIL INDICATING OPEN CIRCUIT.................................................... 561 ERROR CODE: [DHE4L6]............................................................................. 563 ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM................................. 563 ERROR CODE: [DHPCKX]............................................................................. 565 POSSIBLE DEFECTIVE BOTTOM PRESSURE SENSOR.................................................... 565 ERROR CODE: [DHPDKX]............................................................................. 567 POSSIBLE DEFECTIVE ROD PRESSURE SENSOR....................................................... 567 ERROR CODE: [DKA0KX]............................................................................. 569 POSSIBLE DEFECTIVE BOOM ANGLE SENSOR......................................................... 569 ERROR CODE: [DV00KB]............................................................................. 571 POSSIBLE SHORT OR OPEN IN ALARM BUZZER....................................................... 571 TROUBLESHOOTING CODE: [MON-1].................................................................... 573 PARKING BRAKE INDICATOR LAMP DOES NOT WORK................................................... 573 TROUBLESHOOTING CODE: [MON-2].................................................................... 577 BRAKE OIL PRESSURE NOT INDICATING CORRECTLY.................................................. 577 TROUBLESHOOTING CODE: [MON-3].................................................................... 579 ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY............................................... 579 TROUBLESHOOTING CODE: [MON-4].................................................................... 581 HST OIL TEMPERATURE NOT INDICATING CORRECTLY................................................. 581 TROUBLESHOOTING CODE: [MON-5].................................................................... 583 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY.................................................. 583 TROUBLESHOOTING CODE: [MON-6].................................................................... 585 ABNORMAL COOLANT LEVEL INDICATION............................................................ 585 TROUBLESHOOTING CODE: [MON-7].................................................................... 587 STEERING OIL PRESSURE NOT READING CORRECTLY.................................................. 587 TROUBLESHOOTING CODE: [MON-8].................................................................... 589 EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY........................................ 589 TROUBLESHOOTING CODE: [MON-9].................................................................... 591 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 591 TROUBLESHOOTING CODE: [MON-10]................................................................... 593 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 593 TROUBLESHOOTING CODE: [MON-11]................................................................... 595 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 595 TROUBLESHOOTING CODE: [MON-12]................................................................... 597 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 597 TROUBLESHOOTING CODE: [MON-13]................................................................... 599 ALARM BUZZER DOES NOT STOP OR REMAINS ON..................................................... 599 TROUBLESHOOTING CODE: [MON-14]................................................................... 601 ABNORMAL ENGINE OIL LEVEL INDICATION......................................................... 601 TROUBLESHOOTING CODE: [MON-15]................................................................... 603 CLOGGED AIR CLEANER INDICATED (STANDARD)..................................................... 603 CLOGGED AIR CLEANER INDICATED (LOAD METER)................................................... 605 TROUBLESHOOTING CODE: [MON-16]................................................................... 607 DEFECTIVE CANCEL SWITCH...................................................................... 607 TROUBLESHOOTING CODE: [MON-17]................................................................... 609 DEFECTIVE SUBTOTAL SWITCH.................................................................... 609 TROUBLESHOOTING CODE: [MON-18]................................................................... 611 POSSIBLE DEFECTIVE BOTTOM PRESSURE SENSOR.................................................... 611 TROUBLESHOOTING CODE: [MON-19]................................................................... 613 POSSIBLE DEFECTIVE ROD PRESSURE SENSOR....................................................... 613 TROUBLESHOOTING CODE: [MON-20]................................................................... 615 FRONT WINDSHIELD WIPER DOES NOT WORK......................................................... 615 REAR WINDSHIELD WIPER DOES NOT WORK.......................................................... 617 TROUBLESHOOTING CODE: [MON-21]................................................................... 619 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION............................................... 619 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................ 623 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 624 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL.......................................... 624 USER CODE MEMORY RETENTION FUNCTION.......................................................... 624 FUSE SYSTEM CHECK................................................................................ 625 FUSE PANEL CONNECTION TABLE.................................................................. 625 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 626 CODE: (E-1)...................................................................................... 628 ENGINE WILL NOT CRANK........................................................................ 628 CODE: (E-2)...................................................................................... 632 THE ENGINE DOES NOT SHUT DOWN................................................................ 632 CODE: (E-3)...................................................................................... 635 COLD START PREHEATER DOES NOT WORK PROPERLY.................................................. 635 CODE: (E-4)...................................................................................... 639 PARKING BRAKE DOES NOT FUNCTION PROPERLY..................................................... 639 EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION..................................................... 643 CODE: (E-5)...................................................................................... 644 BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY.................................................. 644 CODE: (E-6)...................................................................................... 647 BUCKET LEVER FUNCTION NOT WORKING PROPERLY................................................... 647 CODE: (E-7)...................................................................................... 650 FLOAT HOLD FUNCTION NOT WORKING PROPERLY..................................................... 650 CODE: (E-8)...................................................................................... 653 FRONT WINDSHIELD WIPER DOES NOT WORK......................................................... 653 REAR WINDSHIELD WIPER DOES NOT WORK.......................................................... 657 CODE: (E-9)...................................................................................... 659 THE WINDOW WASHER DOES NOT WORK.............................................................. 659 CODE: (E-10)..................................................................................... 661 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION............................................... 661 HEADLAMPS (LO BEAM) DO NOT FUNCTION.......................................................... 666 HEADLAMPS (HI BEAM) DO NOT FUNCTION.......................................................... 670 CLEARANCE LAMPS DO NOT FUNCTION.............................................................. 674 TURN SIGNALS DO NOT FUNCTION................................................................. 678 WORK LAMPS DO NOT FUNCTION................................................................... 682 CODE: (E-11)..................................................................................... 686 HORN DOES NOT SOUND.......................................................................... 686 CODE: (E-12)..................................................................................... 688 AIR CONDITIONER SYSTEM DOES NOT WORK......................................................... 688 AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED......................................... 691 AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED.......................................... 695 CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS.......................................... 699 CANNOT SWITCH VENT FUNCTIONS................................................................. 701 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE).............................................. 703 METHOD OF USING TROUBLESHOOTING CHART............................................................ 705 FAILURE CODE AND CAUSE TABLE..................................................................... 708 CODE: (H-1)...................................................................................... 710 THE MACHINE DOES NOT START................................................................... 710 CODE: (H-2)...................................................................................... 711 THE TRAVEL SPEED IS SLOW..................................................................... 711 CODE: (H-3)...................................................................................... 712 THE THRUST FORCE IS WEAK..................................................................... 712 CODE: (H-4)...................................................................................... 713 ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY.............................................. 713 CODE: (H-5)...................................................................................... 714 THE GEARS DO NOT CHANGE SPEED RANGE.......................................................... 714 CODE: (H-6)...................................................................................... 715 THE STEERING WHEEL DOES NOT TURN............................................................. 715 CODE: (H-7)...................................................................................... 716 STEERING WHEEL MOVEMENT IS HEAVY............................................................. 716 CODE: (H-8)...................................................................................... 717 STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT.................................................. 717 CODE: (H-10)..................................................................................... 718 BRAKES DO NOT WORK OR WORKS POORLY........................................................... 718 CODE: (H-11)..................................................................................... 719 BRAKES IS NOT RELEASING OR DRAGGED........................................................... 719 CODE: (H-11)..................................................................................... 720 THE PARKING BRAKE INNOPERABLE................................................................ 720 CODE: (H-12)..................................................................................... 721 THE LIFT ARM DOES NOT RISE OR LOWER.......................................................... 721 CODE: (H-13)..................................................................................... 722 LIFT ARM MOVES SLOW OR RISING FORCE IS POOR.................................................. 722 CODE: (H-14)..................................................................................... 723 WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS................................... 723 CODE: (H-15)..................................................................................... 723 THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)....................... 723 CODE: (H-16)..................................................................................... 723 HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN................................................. 723 CODE: (H-17)..................................................................................... 723 THE LIFT ARM WOBBLES DURING OPERATION........................................................ 723 CODE: (H-18)..................................................................................... 724 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY.... 724 CODE: (H-19)..................................................................................... 725 THE BUCKET DOES NOT TILT BACK................................................................ 725 CODE: (H-20)..................................................................................... 726 BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT.................................. 726 CODE: (H-21)..................................................................................... 727 THE BUCKET OPERATES SLOWLY IN TILTING-BACK................................................... 727 CODE: (H-22)..................................................................................... 727 BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.................................................. 727 CODE: (H-23)..................................................................................... 727 HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN.................................................. 727 CODE: (H-24)..................................................................................... 727 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)...... 727 CODE: (H-25)..................................................................................... 728 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY....... 728 CODE: (H-26)..................................................................................... 728 CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY.............................. 728 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................ 729 METHOD OF USING TROUBLESHOOTING CHARTS........................................................... 730 (S-1) ENGINE STARTING PERFORMANCE IS POOR........................................................ 734 (S-2) ENGINE HAS STARTING PROBLEMS............................................................... 736 ENGINE DOES NOT CRANK........................................................................ 736 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK........................................ 737 SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START........................................... 738 (S-3) ENGINE DOES NOT RUN SMOOTHLY............................................................... 739 (S-4) ENGINE STOPS DURING OPERATIONS............................................................. 740 (S-5) ENGINE SPEED HUNTS......................................................................... 741 (S-6) ENGINE LACKS POWER......................................................................... 742 (S-7) EXHAUST SMOKE IS BLACK..................................................................... 743 (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE...................................... 744 (S-9) OIL BECOMES CONTAMINATED QUICKLY........................................................... 745 (S-10) FUEL CONSUMPTION IS EXCESSIVE............................................................. 746 (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR..................................... 747 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP....................................................... 748 (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)............................................ 749 (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)................................................ 750 (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG............................................ 751 (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING................................................ 752 30 DISASSEMBLY AND ASSEMBLY.............................................................................. 753 HOW TO USE THIS MANUAL............................................................................... 756 REMOVAL AND INSTALLATION OF COMPONANTS........................................................... 756 SPECIAL TOOLS................................................................................ 756 REMOVAL...................................................................................... 756 INSTALLATION................................................................................. 756 OVERHAUL OF COMPONANTS........................................................................... 757 SPECIAL TOOLS................................................................................ 757 DISASSEMBLY.................................................................................. 757 ASSEMBLY..................................................................................... 757 PRECAUTIONS WHEN CARRYING OUT AN OPERATION........................................................... 758 SPECIAL TOOL LIST.................................................................................... 760 SKETCH OF SPECIAL TOOLS.......................................................................... 763 CONNECTOR REPAIR PROCEDURES.......................................................................... 768 CONTACT TERMINAL REMOVAL (HD30 TYPE)............................................................. 768 STRIPING INSULATION.............................................................................. 769 CRIMPING CONTACT TERMINAL (HD30 TYPE)............................................................ 770 INSERTION OF CONTACT TERMINAL (HD30 TYPE)........................................................ 771 CONTACT TERMINAL REMOVAL (DT TYPE)............................................................... 772 STRIPING INSULATION.............................................................................. 773 CRIMPING CONTACT TERMINAL (DT TYPE).............................................................. 774 INSERTION OF CONTACT TERMINAL (DT TYPE).......................................................... 775 ENGINE ASSEMBLY...................................................................................... 776 REMOVAL PROCEDURES............................................................................... 776 ENGINE INSTALLATION.............................................................................. 783 RADIATOR, AFTERCOOLER AND OIL COOLER................................................................. 785 RADIATOR REMOVAL PROCEDURES...................................................................... 785 RADIATOR INSTALLATION PROCEDURES................................................................. 786 AFTERCOOLER REMOVAL PROCEDURES................................................................... 786 AFTERCOOLER INSTALLATION PROCEDURES.............................................................. 788 OIL COOLER REMOVAL PROCEDURES.................................................................... 788 OIL COOLER INSTALLATION PROCEDURES............................................................... 790 COOLING FAN AND FAN MOTOR ASSEMBLY................................................................... 791 REMOVAL PROCEDURES............................................................................... 791 INSTALLATION PROCEDURES.......................................................................... 792 FUEL TANK ASSEMBLY................................................................................... 793 REMOVAL PROCEDURES............................................................................... 793 INSTALLATION PROCEDURES.......................................................................... 795 TRANSFER ASSEMBLY.................................................................................... 796 REMOVAL PROCEDURES............................................................................... 796 INSTALLATION PROCEDURES.......................................................................... 798 SPECIAL TOOLS.................................................................................... 799 DISASSEMBLY PROCEDURES........................................................................... 799 ASSEMBLY PROCEDURES.............................................................................. 810 PARKING BRAKE ASSEMBLY............................................................................... 824 REMOVAL PROCEDURES............................................................................... 824 INSTALLATION PROCEDURES.......................................................................... 825 SPECIAL TOOLS.................................................................................... 826 DISASSEMBLY PROCEDURES........................................................................... 826 ASSEMBLY PROCEDURES.............................................................................. 828 FRONT AXLE ASSEMBLY.................................................................................. 832 REMOVAL PROCEDURES............................................................................... 832 INSTALLATION PROCEDURES.......................................................................... 834 REAR AXLE ASSEMBLY................................................................................... 835 REMOVAL PROCEDURES............................................................................... 835 INSTALLATION PROCEDURES.......................................................................... 837 FRONT AND REAR AXLE HOUSING.......................................................................... 839 SPECIAL TOOLS.................................................................................... 839 DISASSEMBLY PROCEDURES........................................................................... 839 ASSEMBLY PROCEDURES.............................................................................. 845 DIFFERENTIAL CARRIER................................................................................. 853 SPECIAL TOOLS.................................................................................... 853 DISSEMBLY PROCEDURES............................................................................. 853 Disassembly Of Standard Differential Carrier................................................. 859 Disassembly Of Anti-slip Differential........................................................ 861 ASSEMBLY PROCEDURES.............................................................................. 866 ASSEMBLY OF ANTI-SLIP DIFFERENTIAL........................................................... 866 ASSEMBLY OF STANDARD DIFFERENTIAL CARRIER.................................................... 870 HST AND 4-GEAR PUMP ASSEMBLY......................................................................... 881 REMOVAL PROCEDURES............................................................................... 881 INSTALLATION PROCEDURES.......................................................................... 883 HST MOTOR 1 ASSEMBLY................................................................................. 884 REMOVAL PROCEDURES............................................................................... 884 INSTALLATION PROCEDURES.......................................................................... 885 HST MOTOR 2 ASSEMBLY................................................................................. 886 REMOVAL PROCEDURES............................................................................... 886 INSTALLATION PROCEDURES.......................................................................... 887 WORK EQUIPMENT CONTROL VALVE......................................................................... 888 REMOVAL PROCEDURES............................................................................... 888 INSTALLATION PROCEDURES.......................................................................... 889 TRAVEL DAMPER VALVE.................................................................................. 890 REMOVAL PROCEDURES............................................................................... 890 INSTALLATION PROCEDURES.......................................................................... 891 HYDRAULIC TANK....................................................................................... 892 REMOVAL PROCEDURES............................................................................... 892 INSTALLATION PROCEDURES.......................................................................... 894 WORK EQUIPMENT....................................................................................... 895 REMOVAL PROCEDURES............................................................................... 895 INSTALLATION PROCEDURES.......................................................................... 898 BUCKET LINK PIN.............................................................................. 898 BUCKET HINGE PIN............................................................................. 899 BUCKET CYLINDER PIN (ON ROD SIDE)............................................................ 899 BOOM CYLINDER PIN (ON ROD SIDE).............................................................. 900 BOOM PIN (ON FRAME SIDE)..................................................................... 900 BUCKET LINK PIN.............................................................................. 901 BELL CRANK CENTER PIN........................................................................ 901 HST PUMP............................................................................................. 903 SPECIAL TOOLS LIST............................................................................... 903 DISASSEMBLY PROCEDURES........................................................................... 903 ASSEMBLY PROCEDURES.............................................................................. 916 HST MOTOR............................................................................................ 935 SPECIAL TOOLS LIST............................................................................... 935 DISASSEMBLY PROCEDURES........................................................................... 935 ASSEMBLY PROCEDURES.............................................................................. 946 HYDRAULIC CYLINDER................................................................................... 955 SPECIAL TOOLS.................................................................................... 955 DISASSEMBLY PROCEDURES........................................................................... 956 ASSEMBLY PROCEDURES.............................................................................. 958 OPERATOR'S CAB ASSEMBLY.............................................................................. 962 SPECIAL TOOLS.................................................................................... 962 REMOVAL PROCEDURES............................................................................... 962 INSTALLATION PROCEDURES.......................................................................... 967 OPERATOR'S CAB GLASS................................................................................. 968 SPECIAL TOOLS.................................................................................... 968 REMOVAL PROCEDURES............................................................................... 968 INSTALLATION PROCEDURES.......................................................................... 969 COATING MATERIALS................................................................................ 978 CENTER HINGE PIN..................................................................................... 979 SPECIAL TOOLS.................................................................................... 979 REMOVAL PROCEDURES............................................................................... 979 INSTALLATION PROCEDURES.......................................................................... 986 REAR COUNTERWEIGHT................................................................................... 992 REMOVAL PROCEDURES............................................................................... 992 INSTALLATION PROCEDURES.......................................................................... 993 AIR CONDITIONER UNIT................................................................................. 994 SPECIAL TOOLS.................................................................................... 994 REMOVAL PROCEDURES............................................................................... 994 LOAD METER SPECIFICATION..................................................................... 995 INSTALLATION PROCEDURES.......................................................................... 997 REFRIGERENT COMPRESSOR ASSEMBLY...................................................................... 998 SPECIAL TOOLS.................................................................................... 998 REMOVAL PROCEDURES............................................................................... 998 INSTALLATION PROCEDURES.......................................................................... 999 MONITOR PANEL........................................................................................1000 REMOVAL PROCEDURES...............................................................................1000 INSTALLATION PROCEDURES..........................................................................1004 90 OTHERS................................................................................................1005 HYDRAULIC CIRCUIT DIAGRAM............................................................................1006 ELECTRICAL CIRCUIT DIAGRAM...........................................................................1007 STANDARD FLOOR HARNESS...........................................................................1007 LIGHT SWITCH AND FRONT WIPER.................................................................1007 MONITOR CONTROLLER...........................................................................1008 TO CAB HARNESS...............................................................................1009 TO REAR AND BULKHEAD HARNESS.................................................................1010 TO HST HARNESS...............................................................................1011 TO SHORT CONNECTOR...........................................................................1012 TO HST CONTROLLER............................................................................1013 AIR CONDITIONER RELAY HARNESS................................................................1014 JOINT CONNECTOR..............................................................................1015 FLOOR HARNESS FOR LOAD METER.....................................................................1016 LIGHT SWITCH AND FRONT WIPER.................................................................1016 MONITOR CONTROLLER...........................................................................1017 TO CAB HARNESS...............................................................................1018 TO REAR AND BULKHEAD HARNESS.................................................................1019 TO HST HARNESS...............................................................................1020 TO KOMTRAX...................................................................................1021 HST CONTROLLER...............................................................................1022 AIR CONDITIONER RELAY HARNESS................................................................1023 JOINT CONNECTOR..............................................................................1024 HST AND BULK HEAD HARNESS........................................................................1025 GRILL HARNESS....................................................................................1026 ENGINE AND POWER SUPPLY HARNESS..................................................................1027 CAB HARNESS......................................................................................1028 EMERGENCY STEERING AND MULTI-FUNCTION HARNESS....................................................1029 LOAD METER AND PRINTER HARNESS...................................................................1030 FRONT HARNESS....................................................................................1031 REVERSE FAN WIRING DIAGRAM...........................................................................1032
KOMATSU GALEO WA320-5L WHEEL LOADER SHOP MANUAL A32001 AND UP – PDF DOWNLOAD:
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2 reviews for Komatsu Galeo WA320-5L Wheel Loader Shop Manual A32001 and up – PDF DOWNLOAD
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Dakari Ridge –
If I get the manual it will have been great
Colson Titus –