Komatsu GALEO WA320-5L Wheel Loader Shop Manual CEBM012004 PDF  

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Komatsu GALEO WA320-5L Wheel Loader Shop Manual CEBM012004 – PDF DOWNLOAD

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Komatsu GALEO WA320-5L Wheel Loader Shop Manual CEBM012004 – PDF DOWNLOAD 

Language : English
Pages : 1033
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu GALEO WA320-5L Wheel Loader Shop Manual CEBM012004 – PDF DOWNLOAD 

SERIAL NUMBERS WA320-5L A32001 and up

FOREWORD :
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 CEBM012004 – PDF DOWNLOAD 

SERIAL NUMBERS WA320-5L A32001 and up

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

S.V 15/12/24