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Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual 50001 and up – PDF DOWNLOAD
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Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual
Book Code: SEBM005910
Machine model Serial number
WA250-3 50001 and up
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Description
Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-3 Avance Loader
Serial Number: 50001 and up
Book Code: SEBM005910
Language: English
Pages: 743
File Format: Portable Document Format (PDF)
KOMATSU WA250-3 AVANCE LOADER WHEEL LOADER SHOP MANUAL 50001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual
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 chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA250-3 Avance Loader Wheel Loader Shop Manual
COVER.................................................................................................................................................................. 1 CONTENTS............................................................................................................................................................... 2 01 GENERAL............................................................................................................................................................. 29 GENERAL ASSENBLY DRAWING........................................................................................................................................... 30 SPECIFICATIONS..................................................................................................................................................... 32 WEIGHT TABLE....................................................................................................................................................... 35 LIST OF LUBRICANT AND WATER........................................................................................................................................ 37 10 STRUCTURE AND FUNCTION.............................................................................................................................................. 39 POWER TRAIN........................................................................................................................................................ 40 PATH OF POWER TRANSMISSOM.......................................................................................................................................... 41 TORQUE CONVERTER, TRANSMISSION PIPING.............................................................................................................................. 43 TORQUE CONVERTER,TRANSMISSION HYDRAULIC SISTEM DIAGRAM............................................................................................................. 44 TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM............................................................................................................ 45 TORQUE CONVERTER................................................................................................................................................... 46 TORQUE CONVERTER OIL FILTER........................................................................................................................................ 48 TRANSMISSION....................................................................................................................................................... 49 TRANSMISSION CONTROL VALVE......................................................................................................................................... 60 DRIVE SHAFT........................................................................................................................................................ 81 AXLE............................................................................................................................................................... 82 FINAL DRIVE........................................................................................................................................................ 88 AXLE MOUNT......................................................................................................................................................... 89 CENTER HINGE PIN................................................................................................................................................... 91 STEERING PIPING.................................................................................................................................................... 92 STEERING COLUMN.................................................................................................................................................... 93 PRIORITY VALVE..................................................................................................................................................... 94 STEERING VALVE (ORBIT-ROLL)........................................................................................................................................ 97 2-WAY RESTRICTOR VALVE.............................................................................................................................................105 BRAKE PIPING.......................................................................................................................................................106 POWER MASTER CYLINDER..............................................................................................................................................107 BRAKE..............................................................................................................................................................111 PARKING BRAKE CONTROL..............................................................................................................................................113 HYDRAULIC PIPING...................................................................................................................................................115 STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM..................................................................................................................117 STEERING,HYDRAULIC PUMP CIRCUIT DIAGRAM............................................................................................................................118 WORK EQUIPMENT CONTROL LEVER LINKAGE...............................................................................................................................119 HYDRAULIC TANK.....................................................................................................................................................120 WORK EQUIPMENT LINKAGE.............................................................................................................................................136 BUCKT..............................................................................................................................................................138 BUKKET POSITIONER AND BOOM KICKOUT.................................................................................................................................139 CAB................................................................................................................................................................143 MACHINE MOINTOR SISTEM.............................................................................................................................................144 MAIN MONITOR.......................................................................................................................................................145 MAINTENANCE MONITOR DISPLAY FUNCTION...............................................................................................................................150 SENSORS AND SWITCHES...............................................................................................................................................152 ENGINE STARTING CIRCUIT............................................................................................................................................157 ENGINE STOP CIRCUIT................................................................................................................................................159 PREHEATING CIRCUIT.................................................................................................................................................161 STARTING AID.......................................................................................................................................................163 ELECTRICAL TRANSMISSION CONTROL....................................................................................................................................164 COMBINATION SWITCH.................................................................................................................................................165 TRANSMISSION CUT-OFF FUNCTION......................................................................................................................................166 PARKING BRAKE NEUTRALIZER RELAY FUNCTION...........................................................................................................................168 KICK-DOWN SWITCH...................................................................................................................................................169 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................170 TRANSMISSION AUTO SHIFT CONTRCL SYSTEM (IF EQUIPPED)...............................................................................................................175 20 TESTING AND ADJUSTING...............................................................................................................................................183 STANDARD VALUE TABLE FOR ENGINE....................................................................................................................................184 STANDARD VALUE TABLE FOR CHASSIS...................................................................................................................................186 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..........................................................................................................................189 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................................................................................191 ADJUSTING VALUE CLEARANCE..........................................................................................................................................193 MEASURING COMPRESSION PRESSURE.....................................................................................................................................195 TESTING AND ADJUSTING FUEL INGECTION TIMING........................................................................................................................196 MEASURING EXHAUST COLOR............................................................................................................................................198 MEASURING BLOW-BY PRESSURE.........................................................................................................................................199 TESTING AND ADJUSTING FAN BELT TENSION.............................................................................................................................201 MEASURING ENGINE SPEED.............................................................................................................................................202 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE.......................................................................................................................204 ADJUSTING ENGINE STOP SOLENOID.....................................................................................................................................206 MEASURING ENGINE OIL PRESSURE......................................................................................................................................207 MEASURING INTAKE AIR PRESSURE (BOSST PRESSURE).....................................................................................................................208 MEASURING EXHAUST GAS TEMPERATURE..................................................................................................................................209 MEASURING ACCELERATOR PEDAL........................................................................................................................................210 MEASURING SHIFT LEVER..............................................................................................................................................212 MEASURING STALL SPEED..............................................................................................................................................213 MEASURING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...............................................................................................................215 METHOD OF OPERATING EMERGENCY MANUAL SPOOL.........................................................................................................................217 TESTING AND ADJUSTING STEERING WHEEL...............................................................................................................................219 MEASURING STEERING OIL PRESSURE....................................................................................................................................222 MEASURING BRAKE PEDAL..............................................................................................................................................224 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE..........................................................................................................................225 MEASURING BRAKE PERFORMANCE........................................................................................................................................227 MEASURING BRAKE OIL PRESSURE.......................................................................................................................................228 MEASURING WEAR OF BRAKE DISC.......................................................................................................................................229 BLEEDING AIR FROM BRAKE SISTEM.....................................................................................................................................230 MEASURING PARKING BRAKE PERFORMANCE................................................................................................................................231 TESTING AND ADJUSTING PARKING BRAKE LINKAGE........................................................................................................................232 TESTING PARKING BRAKE PISTON STROKE................................................................................................................................233 MEASURING WEAR OF PARKING BRAKE DISC...............................................................................................................................234 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...............................................................................................................235 MEASURING STROKE F WORK EQUIPMENT VALVE SPOOL......................................................................................................................238 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................................239 MEASURING WORK EQUIPMENT...........................................................................................................................................241 TESTING AND ADJUSTING BUCKET POSITIONER............................................................................................................................243 TESTING AND ADJUSTING BOOM KICK-OUT................................................................................................................................244 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)........................................................................................................................246 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR......................................................................................................................247 TROUBLESHOOTING....................................................................................................................................................248 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................................................249 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................................................................................250 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................................................................................251 HANDLING CONNECTORS............................................................................................................................................258 CHECKS BEOORE TROUBLESHOOTING..................................................................................................................................259 JUDGEMENT OF POWER TRAIN.......................................................................................................................................260 METHOD OF USING TROUBLESHOOTING CHARTS.........................................................................................................................261 CONNECTOR TYPES AND MOUNTING LOCATIONS.........................................................................................................................269 CONNECTOR PIN ARRANGEMENT DIAGRAM..............................................................................................................................270 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................................................................................273 TROUBLESHOOTING OF ENGINE (S6D95L) SYSTEM (SMODE)[SERIAL NO.53001-52999].......................................................................................281 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..............................................................................................282 S-2 ENGINE DOES NOT START .................................................................................................................................283 (1) ENGINE DOES NOT TURN...............................................................................................................................283 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED).............................................................................284 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED............................................................................285 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................................................................286 S-4 ENGINE STOPS DURING OPERATIONS.........................................................................................................................287 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..............................................................................................................288 S-6 ENGINE LACKS OUTPUT (NO POWER).........................................................................................................................289 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...........................................................................................................290 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..................................................................................................291 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................................292 S-10 FUEL CONSUMPTION IS EXCESSIVE.........................................................................................................................293 S-11 OIL IS COLLING WATER, OR WATER SPURTS BACKS, OR WATER LEVEL GOSE DOWN.................................................................................294 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................295 S-13 OIL LEVEL RISES.......................................................................................................................................296 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................................................................297 S-15 ABNORMAL NOISE IS MADE................................................................................................................................298 S-16 VIBRATION IS EXCESSIVE................................................................................................................................299 TROULESHOOTING OF ENGINE (S6D102E) SYSTEM (S MODE) [SERIAL NO.53001 AND UP]....................................................................................300 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..............................................................................................301 S-2 ENGINE DOES NOT START..................................................................................................................................302 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................................................................305 S-4 ENGINE STOPS DURING OPERATIONS.........................................................................................................................306 S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)..............................................................................................................307 S-6 ENGINE LACKS OUTPUT (NO POWER).........................................................................................................................308 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...........................................................................................................309 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..................................................................................................310 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................................311 S-10 FUEL CONSUMPTION IS EXCESSIVE.........................................................................................................................312 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...............................................................................313 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................314 S-13 OIL LEVEL RISES.......................................................................................................................................315 S-14 WATER TEMPERATURE BECOME TOO HIGH (OVERHEATING).......................................................................................................316 S-15 ABNORMAL NOISE IS MADE................................................................................................................................317 S-16 VIBRATION IS EXCESSIVE................................................................................................................................318 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)..................................................................................319 POWEER TRAIN ..............................................................................................................................................320 T-1 MACHINE DOES NOT START.............................................................................................................................320 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...............................................................................322 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.............................................................................................324 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR..........................................................................................325 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...........................................................................................................326 STEERING SYSTEM............................................................................................................................................327 T-6 STEERING WHEEL DOES NOT TURN.......................................................................................................................327 T-7 STEERING IS HEAVY..................................................................................................................................328 T-8 STEERING WHEEL SHAKES OR THERE EXCESSIVE SHOCK.....................................................................................................329 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING..............................................................................................329 BRAKE SYSTEM...............................................................................................................................................330 T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR......................................................................................................330 T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS................................................................................................................331 WORK EQUIPMENT.............................................................................................................................................332 T-12 BOOM DOES NOT RISE................................................................................................................................332 T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.................................................................................................333 T-14 WHEN MOON IS RAISED IT MOVES SLOWLY AT A CERTAIN HEIGHT...........................................................................................334 T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)........................................................................................334 T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM.................................................................................................................334 T-17 BOOM SHAKES DURING OPERATION......................................................................................................................335 T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FORM HOLD TO RAISE..........................................................................335 T-19 BUCKET DOES NOT TILT BACK.........................................................................................................................336 T-20 BUCKET MOVEMENT IS SLOW OR TILT-LACKS POWER.......................................................................................................337 T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...........................................................................................338 T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER......................................................................................................338 T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...............................................................................................................338 T-24 BUCKET SHAKETS DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)..............................................................................339 T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.........................................................................339 T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVE OR NOT MOVE SMOOTHLY........................................................................................340 TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE, TRANMISSION (E MODE)..........................................................................................341 E-1 ENGINE DOES NOT START..................................................................................................................................342 (a) STARTING MOTOR DOES NOT TURN.......................................................................................................................342 1) CHECK STARTING CIRCUIT..........................................................................................................................342 2) CHECK BETWEEN BATTERY RELAY AND STARTING SWITCH.................................................................................................343 (b) STARTING MOTOR TURNS...............................................................................................................................344 E-2 ENGINE DOES NOT STOP...................................................................................................................................350 E-3 ENGIN STOPS WHEN MACHINE IS TRAVELLING.................................................................................................................351 E-4 TRAMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)........................................................352 E-5 TRAMISSION DOES NOT WORK NORMALLY......................................................................................................................353 (a) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRALIZER RELAY CIRCUIT...................................................................354 (b) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUITY..................................................................................................356 (c) DEFECTIVE CONTINUITY IN REVERSE SOLENOID CIRCUIT...................................................................................................358 (d) CONTACT IS DIRECTIONAL CIRCUIT.....................................................................................................................360 1) FORWARD IS CONTINUOUS...........................................................................................................................360 2) REVERSE IS CONTINUOUS...........................................................................................................................362 (e) PROBLEM WITH SPEED SOLENOID OR ALWAYS STAYS IN 2ND.................................................................................................364 (f) CONTACT IN SPEED CIRCULT...........................................................................................................................366 1) BATTERY VOITAGE FORMED IN 1ST (SPEED) SOLENOID).................................................................................................366 2) BATTERY VOLTAGE FORMED IN 3RD (H-L) SOLENOLD....................................................................................................368 E-6 KICK-DOWN SWITCH DOES NOT WORK (USUAL F1-F4 SHIFTS NORMALLY)...........................................................................................370 E-7 KICK-DOWN IS ACTUATED ONLY WHEN KICK-DOWN SWITCH IS ON (SELF-HOLD FUNCTION OF KICK-DOWN SWITCH RETAY DOES NOT WORK)....................................372 E-8 KICK-DOWN IS NOT CANCELED..............................................................................................................................373 (a) KICK-DOWN IS NOT CANCELED WHEN DIRECTIONAL LEVER IS MOVED FROM FORWARD TO NEUTRAL OR REVERSE.......................................................373 (b) KICK-DOWN IS NOT CANCELED WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER SPEED RANGE..................................................................374 E-9 KICK-DOWN SWITCH IS WRONGLY ACTUATED WHEN TRAVELING IN F2..............................................................................................376 E-10 PREHEATING IS NOT CARRIED OUT.........................................................................................................................377 E-11 PREHEATING REMAINS ACTUATED...........................................................................................................................382 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)................................................................................................................387 TROUBLE DATE DISPLY........................................................................................................................................389 TABLE OF ACTION CODES AND FAILURE CODES....................................................................................................................390 M-1 MAIN MONITOR DOES NOT WORK.............................................................................................................................391 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.........................................................392 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.............................................................................................................393 M-4 ABNORMALITY IN SHIFT INDICATOR.........................................................................................................................394 (a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F.....................................................................................................394 (b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R.....................................................................................................394 (c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F...............................................394 (d) DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R....................................................395 (e) DOES NOT PLAY 1ST, 4TH.............................................................................................................................395 (f) DOES NOT DISPLAY 3RD, 4TH..........................................................................................................................395 (e-1) DOES NOT DISPLAY 1ST, 4TH........................................................................................................................396 (f-1) DOES NOT DISPLAY 3RD, 4TH........................................................................................................................396 (g) DOES NOT DISPLAY 2ND, 3RD..........................................................................................................................397 (h) DOES NOT DISPLAY 1ST, 2ND..........................................................................................................................397 M-5 HIGH BEAM DOES NOT LIGHT UP............................................................................................................................398 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP..................................................................................................................399 (a) L.H. TURN SIGNAL DOES NOT LIAGT UP.................................................................................................................399 (b) R.N. TURN SINGNAL DOES NOT LIGHT UP................................................................................................................399 M-7 ABNORMALITY IN PARKING DISPLAY.........................................................................................................................400 (a) PARKING LAMP DOES NOT LIGHT UP.....................................................................................................................400 (b) PARKING LAMP STAYS LIGHTED UP......................................................................................................................400 M-8 ABNORMALITY IN PREHEATING SYSTEM.......................................................................................................................401 (a) DOES NOT CARRY OUT PREHEATING......................................................................................................................401 (b) ONLY MONITOR DISPLAY DOES NOT LIGHT UP.............................................................................................................402 (c) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE.........................................................................................................402 (d) PREHEATING STAYS ON................................................................................................................................402 (e) PREHEATING TIME BECOMES SHORTER, OR IS UNSTABLE....................................................................................................403 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.......................................................................................................................409 M-10 ABNORMALITY IN FRONT WORKING LAMP.....................................................................................................................410 (a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LIGHT UP.................................................................................................410 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................410 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................410 M-11 ABNORMALITY IN REAR WORKING LAMP......................................................................................................................411 (a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.............................................................................................411 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................411 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................411 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...................................................................................................................413 (a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN..........................................................413 (b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON.............................................................................................413 (c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED.....................................................................................414 (a) WHEN MONITOR SWITCH IS PRESSED,SUT-OFF FUNCTION AND DISPLAY DO NOT CHANGE..........................................................................415 (b) DISPLAY ON MONITOR GOES OFF BUT-OFF FUNCTION OPERATES IF PEDAL IS PRESSED..........................................................................415 (c) IF DISPLAY OF MONITOR IS TURNED OFF, SUT-OFF FUNCTION ALWAYS OPERATES..............................................................................415 (d) CUT-OFF FUNCTION OPERATES, REGARDLESS OF DISPLAY ON MOMITOR........................................................................................415 (e) DISPLAY ON MONITOR LIGHTS UP BUT CUT-OFF FUNCTION DOES NOT OPERATE.................................................................................416 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.........................................................................................................417 (a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS(INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES.........................417 (b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVEL IS AT POSITION OTHER THEN N....417 M-14 WHEN PARKING BRAKE DRAGGING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED.....................................418 (a) ACTUATED CONTINUOUSLY..............................................................................................................................418 (b) NOT ACTUATED.......................................................................................................................................418 M-15 ABNOMALITY IN BUZZER..................................................................................................................................419 (a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)........................................................................419 (b) BUZZER ALWAYS SOUNDS...............................................................................................................................419 M-16 CONDITION OF MONITOR OF SWITCHES IS NOT STORED IN MEMORY..............................................................................................420 M-17 ABNORMALITY IN FAILURE DISPLAY MODE...................................................................................................................421 (a) DOES NOT ENTER FAILURE DISPLAY MODE................................................................................................................421 (b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE NOT ADVANCE............................................................................421 TROUBLESHING OF MAINTENANCE MONITOR SYSTEM(K MODE).............................................................................................................422 K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK.....................423 (a)ALL LUMPS ON MAINTENANCE MONITIOR DO NOT LIGHT UP FOR 3 SECONDS.....................................................................................423 (b)SOME LAMPS DO NOT LIGHT UP..........................................................................................................................424 K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT..........................................................424 K-3 WHEN ENGINE IS STARTING IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON(WITHIN 3 SECONDS),ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT................425 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH...................................................................................426 (a) ENGINE OIL LEVEL DISPLAY FLASHES...................................................................................................................426 (b) ENGINE WATER LEVEL DISPLAY FLASHES.................................................................................................................427 (c) BRAKE OIL LEVEL DISPLAY FLASHES....................................................................................................................428 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH.................................................................................429 (a) ENGINE OIL PRESSURE DISPLAY FLASHES................................................................................................................429 (b)BATTERY CHARGE LEVEL DISPLAY FLASHES................................................................................................................430 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.............................................................................................431 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS....................................................................................432 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP)DOES NOT LIGHT UP.................................................................433 (a)CHECK LAMP..........................................................................................................................................433 (b)CAUTION LAMP........................................................................................................................................433 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP) LIGHTS UP.........................................................434 (a) CHECK LAMP.........................................................................................................................................434 (b) CAUTION LAMP.......................................................................................................................................434 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTEANCE MONITOR DOESNOT LIGHT UP).................................435 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP................................................................436 K-12 SERVICE METER DOES NOT WORK...........................................................................................................................437 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED..................................................................................................437 K-14 ABNORMALITY IN GAUGE ITEMS............................................................................................................................438 (a) ABNORMALITY IN FUEL GAUGE .........................................................................................................................438 (b) ABNORMALITY IN ENGINE WATER TEMPURATURE GAUGE......................................................................................................439 (c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................440 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).....................................................................................................441 1. FUNCTION................................................................................................................................................442 2. NOTE ON TROUBLESHOOTING.................................................................................................................................442 3. FAILURE CODES LIST......................................................................................................................................442 4. TABLE OF FAILURE MODES AND CAUSES.......................................................................................................................443 5. SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROLLER.......................................................................................................444 A-1. FAILURE CODE [12] F SOLENOID SIGNAL SYSTEM............................................................................................................446 A-2. FAILURE CODE [13] R SOLENOID SIGNAL SYSTEM............................................................................................................446 A-3. FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...........................................................................................447 A-4. FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.........................................................................................448 A-5. FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM......................................................................................449 A-6. FAILURE CODE [21] ABNORMALITY IN GEARSHIFT LEVER SIGNAL SYSTEM........................................................................................450 A-7. FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...........................................................................................451 A-8. FAILURE CODE [23] ABNORMALITY IN SPEED SIGNAL.........................................................................................................452 A-9. HOLDING SWITCH SYSTEM.................................................................................................................................453 A-10. KICK-DOWN SWITCH SYSTEM..............................................................................................................................453 A-11. TRANSMISSION CUT-OFF SIGNAL SYSTEM...................................................................................................................454 A-12. NEUTRALIZER RELAY SIGNAL SYSTEM......................................................................................................................455 A-13. ALARM BUZZER SIGNAL SYSTEM...........................................................................................................................456 A-14. NETWORK SIGNAL SYSTEM................................................................................................................................457 A-15. CONTROLLER POWER SUPPLY SYSTEM.......................................................................................................................458 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................459 METHOD OF USING MANUAL.............................................................................................................................................461 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................................462 SPECIAL TOOL LIST..................................................................................................................................................464 STARTING MOTOR.....................................................................................................................................................466 REMOVAL AND INSTALLATION.......................................................................................................................................466 ALTERNATOR.........................................................................................................................................................467 REMOVAL AND INSTALLATION.......................................................................................................................................467 ENGINE OIL COOLER .................................................................................................................................................469 REMOVAL AND INSTALLATION.......................................................................................................................................469 FUEL OF INJECTION PUMP.............................................................................................................................................471 REMOVAL........................................................................................................................................................471 INSTALLATION...................................................................................................................................................472 WATER PUMP.........................................................................................................................................................478 REMOVAL AND INSTALLATION.......................................................................................................................................478 TURBOCHARGER.......................................................................................................................................................480 REMOVAL AND INSTALLATION.......................................................................................................................................480 NOZZLE HOLDER .....................................................................................................................................................482 REMOVAL AND INSTALLATION.......................................................................................................................................482 THERMOSTAT.........................................................................................................................................................485 REMOVAL AND INSTALLATION.......................................................................................................................................485 CYLINDER HEAD......................................................................................................................................................487 REMOVAL........................................................................................................................................................487 INSTALLATION...................................................................................................................................................489 RADIATOR ..........................................................................................................................................................499 REMOVAL........................................................................................................................................................499 INSTALLATION...................................................................................................................................................502 RADIATOR, HYDRAULIC COOLER ........................................................................................................................................503 REMOVAL........................................................................................................................................................503 INSTALLATION...................................................................................................................................................504 ENGINE.............................................................................................................................................................505 REMOVAL .......................................................................................................................................................505 INSTALLATION...................................................................................................................................................508 TORQUE CONVERTER CHARGING PUMP.....................................................................................................................................513 REMOVAL AND INSTALLATION.......................................................................................................................................513 TORQUE CONVERTER, TRANSMISSION.....................................................................................................................................514 REMOVAL........................................................................................................................................................514 INSTALLATION...................................................................................................................................................523 TORQUE CONVERTER...................................................................................................................................................525 DISASSEMBLY....................................................................................................................................................525 ASSEMBLY.......................................................................................................................................................527 TRANSMISSION ......................................................................................................................................................529 DISASSEMBLY....................................................................................................................................................529 ASSEMBLY ......................................................................................................................................................538 CLUTCH PACK .......................................................................................................................................................551 DISASSEMBLY....................................................................................................................................................551 ASSEMBLY ......................................................................................................................................................557 PARKING BRAKE......................................................................................................................................................569 DISASSEMBLY....................................................................................................................................................569 ASSEMBLY ......................................................................................................................................................571 TRANSMISSION CONTROL VLVE..........................................................................................................................................574 REMOVAL .......................................................................................................................................................574 INSTALLATION...................................................................................................................................................575 DISASSEMBLY....................................................................................................................................................576 ASSEMBLY ......................................................................................................................................................578 TRANSMISSION SOLENOID VALVE........................................................................................................................................580 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................580 ACCUMULATOR VALVE..................................................................................................................................................581 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................581 DRIVE SHAFT........................................................................................................................................................583 DISASSEMBLY....................................................................................................................................................583 ASSEMBLY.......................................................................................................................................................585 FRONT AXLE.........................................................................................................................................................587 REMOVAL........................................................................................................................................................587 INSTALLATION...................................................................................................................................................589 REAR AXLE..........................................................................................................................................................590 REMOVAL........................................................................................................................................................590 ASSEMBLY.......................................................................................................................................................594 DIFFERENTIAL.......................................................................................................................................................597 DISASSEMBLY....................................................................................................................................................597 ASSEMBLY.......................................................................................................................................................601 AXLE HOUSING.......................................................................................................................................................610 DISASSEMBLY....................................................................................................................................................610 ASSEMBLY.......................................................................................................................................................615 CENTER HINGE PIN...................................................................................................................................................621 REMOVAL........................................................................................................................................................621 INSTALLATION...................................................................................................................................................628 STEERING VALVE.....................................................................................................................................................631 REMOVAL .......................................................................................................................................................631 INSTALLATION ..................................................................................................................................................633 DISASSEMBLY ...................................................................................................................................................634 ASEMBLY........................................................................................................................................................637 PRIORITY...........................................................................................................................................................642 REMOVAL .......................................................................................................................................................642 INSTALLATION...................................................................................................................................................643 STEERING CYLINDER..................................................................................................................................................644 REMOVAL AND INSTALLATION.......................................................................................................................................644 POWER MASTER CYLINDER .............................................................................................................................................645 REMOVAL .......................................................................................................................................................645 INSTALLATION...................................................................................................................................................646 DISASSEMBLY ...................................................................................................................................................647 ASSEMBLY ......................................................................................................................................................650 PARKING BRAKE DISC.................................................................................................................................................655 REMOVAL........................................................................................................................................................655 INSTALLATION...................................................................................................................................................656 HYDRAULIC TANK ....................................................................................................................................................657 REMOVAL........................................................................................................................................................657 INSTALLATION...................................................................................................................................................658 HYDRAULIC FILTER ..................................................................................................................................................659 REMOVAL AND INSTALLATION.......................................................................................................................................659 WORK EQUIPMENT, STEERING PUMP .....................................................................................................................................660 REMOVAL AND INSTALLATION.......................................................................................................................................660 MAIN CONTROL VALVE ................................................................................................................................................661 REMOVAL .......................................................................................................................................................661 INSTALLATION...................................................................................................................................................662 DISASSEMBLY AND ASSEMBLY ......................................................................................................................................663 BUCKET CYLINDER....................................................................................................................................................665 REMOVAL........................................................................................................................................................665 INSTALLATION...................................................................................................................................................666 BOOM CYLINDER......................................................................................................................................................667 REMOVAL........................................................................................................................................................667 INSTALLATION...................................................................................................................................................668 HYDRAULIC CYLINDER.................................................................................................................................................669 DISASSEMBLY....................................................................................................................................................669 ASSEMBLY ......................................................................................................................................................671 WORK EQUIPMENT.....................................................................................................................................................673 REMOVAL........................................................................................................................................................673 INSTALLATION...................................................................................................................................................676 COUNTERWEIGHT......................................................................................................................................................678 REMOVAL AND INSTALLATION.......................................................................................................................................678 FUEL TANK..........................................................................................................................................................679 REMOVAL .......................................................................................................................................................679 INSTALLATION...................................................................................................................................................680 CAB ...............................................................................................................................................................681 REMOVAL........................................................................................................................................................681 INSTALLATION...................................................................................................................................................682 MAIN MONITOR.......................................................................................................................................................683 REMOVAL........................................................................................................................................................683 INSTALLATION...................................................................................................................................................684 MAINTENANCE MONITOR................................................................................................................................................685 REMOVAL AND INSTALLATION.......................................................................................................................................685 AIR CONDITIONER UNIT...............................................................................................................................................686 REMOVAL........................................................................................................................................................686 INSTALLATION...................................................................................................................................................691 AIR CONDITIONER CONDENSER..........................................................................................................................................692 REMOVAL........................................................................................................................................................692 INSTALLATION...................................................................................................................................................693 DPY RECEIVER.......................................................................................................................................................694 REMOVAL AND INSTALLATION.......................................................................................................................................694 AIR CONDITIONER COMPRESSOR ........................................................................................................................................695 REMOVAL AND INSTALLATION.......................................................................................................................................695 40 MAINTENANCE STANDARD................................................................................................................................................696 TRANSMISSION, ENGINE MOUNT.........................................................................................................................................697 TORQUE CONVERTER...................................................................................................................................................699 TRANSMISSION.......................................................................................................................................................700 TRANSMISSION CONTROL VALVE.........................................................................................................................................706 ACCUMULATOR VALVE..................................................................................................................................................710 DRIVE SHAFT........................................................................................................................................................711 DIFFERENTIAL.......................................................................................................................................................712 FINAL DRIVE........................................................................................................................................................716 AXLE MOUNT.........................................................................................................................................................718 CENTER HINGE PIN...................................................................................................................................................720 STEERING COLUMN ...................................................................................................................................................722 PRIORITY VALVE.....................................................................................................................................................723 MASTER CYLINDER....................................................................................................................................................724 BRAKE..............................................................................................................................................................725 PARKING BRAKE......................................................................................................................................................726 MAIN CONTROL VALVE.................................................................................................................................................727 HYDRAULIC CYLINDER.................................................................................................................................................731 STEERING CYLINDER MOUNT............................................................................................................................................732 WORK EQUIPMENT LINKAGE.............................................................................................................................................733 BUCKET.............................................................................................................................................................735 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................736 90 OTHERS..............................................................................................................................................................737 ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO. : 50001-53000)........................................................................................................738 ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO. : 50001-53000)........................................................................................................739 ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO. : 53001 AND UP )......................................................................................................740 ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO. : 53001 AND UP).......................................................................................................741 ELECTRICAL CIRCUIT DIAGRAM (1/2) FOR AUTO SHIFT CONTROL SPEC. (SERIAL NO. : 53001 AND UP).........................................................................742 ELECTRICAL CIRCUIT DIAGRAM (2/2) FOR AUTO SHIFT CONTROL SPEC. (SERIAL NO. : 53001 AND UP).........................................................................743
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