Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 PDF
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Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA250-3 A75001 and up
Description
Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 – PDF DOWNLOAD
Language : English
Pages : 716
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA250-3 A75001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu WA250-3 Parallel Tool Carrier Shop Manual CEBM001801 – PDF DOWNLOAD
MAIN MENU 0
COVER 1
CONTENTS 2
01 GENERAL 24
SPECIFICATION DRAWINGS 25
SPECIFICATIONS 31
WEIGHT TABLE 34
FUEL, COOLANT AND LUBRICANTS 35
ENGINE OIL SPECIFICATIONS 36
DIESEL FUEL SPECIFICATIONS 37
COOLANT SPECIFICATIONS 38
10 STRUCTURE AND FUNCTION 44
POWER TRAIN 46
PATH OF POWER TRANSMISSION 47
TORQUE CONVERTER, TRANSMISSION PIPING 49
TORQUE CONVERTER, TRANSMISSION HYDRUALIC SYSTEM DIAGRAM 51
TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 52
TORQUE CONVERTER 53
TORQUE CONVERTER OIL FILTER 55
TRANSMISSION 56
TRANSMISSION CONTROL VALVE 68
DRIVE SHAFT 89
AXLE 90
FINAL DRIVE 96
AXLE MOUNT 97
CENTER HINGE PIN 99
STEERING PIPING 100
STEERING COLUMN 101
PRIORITY VALVE 102
STEERING VALVE (ORBIT-ROLL) 105
STEERING VALVE 107
2-WAY RESTRICTOR VALVE 113
BRAKE PIPING 114
POWER MASTER CYLINDER 115
BRAKE 119
PARKING BRAKE CONTROL 121
HYDRAULIC PIPING 123
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM 125
STEERING, HYDRAULIC PUMP HYDRAULIC CIRCUIT DIAGRAM 126
WORK EQUIPMENT LEVER LINKAGE 128
HYDRAULIC TANK 129
MAIN CONTROL VALVE 132
WORK EQUIPMENT LINKAGE 158
BUCKET 160
BUCKET POSITIONER AND BOOM KICK-OUT 161
ROPS CAB 167
AIR CONDITIONER/HEATER PIPING 168
AIR CONDITIONER/HEATER WIRING DIAGRAM (EAGLE) 169
MACHINE MONITOR SYSTEM 170
MAIN MONITOR 171
MAINTENANCE MONITOR DISPLAY FUNCTION 176
SENSORS AND SWITCHES 179
ELECTRIC WIRING DIAGRAM (1/4) 184
ELECTRIC WIRING DIAGRAM (2/4) 191
ELECTRIC WIRING DIAGRAM (3/4) 196
ELECTRIC WIRING DIAGRAM (4/4) 202
ENGINE STARTING CIRCUIT 204
ENGINE STOP CIRCUIT 205
AUTOMATIC PREHEATING CIRCUIT (Q H S CIRCUIT) 206
ELECTRICAL TRANSMISSION CONTROL 209
COMBINATION SWITCH 210
TRANSMISSION CUT-OFF FUNCTION 211
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 213
KICK DOWN SWITCH 214
KICK DOWN ELECTRIC CIRCUIT DIAGRAM 215
DUMP SPEED SWITCH 220
QUICK COUPLER SWITCH 221
20 TESTING AND ADJUSTING 222
STANDARD VALUE TABLE FOR ENGINE 224
STANDARD VALUE TABLE FOR CHASSIS 225
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 229
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING 231
MEASURING ENGINE SPEED 233
MEASURING ENGINE LUBRICATING OIL PRESSURE 234
MEASURING FUEL FILTER INLET RESTRICTION 234
MEASURING BLOW-BY PRESSURE 234
MEASURING COMPRESSION PRESSURE 235
MEASURING EXHAUST COLOR 236
MEASURING COOLANT TEMPERATURE 237
MEASURING AND ADJUSTING VALVE CLEARANCE 237
MEASURING ACCELERATOR PEDAL 238
MEASURING SHIFT LEVER 240
MEASURING STALL SPEEDS 241
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE 243
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 245
TESTING AND ADJUSTING STEERING WHEEL 247
MEASURING STEERING OIL PRESSURE 249
MEASURING BRAKE PEDAL 251
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 252
MEASURING BRAKE PERFORMANCE 254
MEASURING BRAKE OIL PRESSURE 255
MEASURING WEAR OF BRAKE DISC 256
BLEEDING AIR FROM BRAKE SYSTEM 257
MEASURING PARKING BRAKE PERFORMANCE 258
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 259
TESTING PARKING BRAKE PISTON STROKE 260
MEASURING WEAR OF PARKING BRAKE DISC 261
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER 262
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 265
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 266
MEASURING WORK EQUIPMENT 269
TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED) 271
TESTING AND ADJUSTING BUCKET/FORK POSITIONER 272
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 274
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR 275
TROUBLESHOOTING TABLE OF CONTENTS 276
POINTS TO REMEMBER WHEN TROUBLESHOOTING 277
SEQUENCE OF EVENTS IN TROUBLESHOOTING 278
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 279
1 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 279
2 HANDLING CONTROL BOX 284
3 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 285
CHECKS BEFORE TROUBLESHOOTING 287
JUDGEMENT OF POWER TRAIN 288
PRECAUTIONS WHEN TROUBLESHOOTING 289
PREVENTING RECURRANCE OF TROUBLE 291
METHODS OF USING TORUBLESHOOTING CHARTS 293
CONNECTOR TYPES AND MOUNTING LOCATIONS 301
CONNECTOR PIN ARRANGEMENT DIAGRAM (1/3) 302
CONNECTOR PIN ARRANGEMENT DIAGRAM (2/3) 304
CONNECTOR PIN ARRANGEMENT DIAGRAM (3/3) 306
CONNECTOR TYPE AND PIN IDENTIFICATIONS 307
ELECTRICAL CIRCUIT DIAGRAM 316
PREHEATING SYSTEM 317
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 318
MACHINE MONITOR SYSTEM 319
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT 322
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 324
S-1 STARTING PERFORMANCE IS POOR, (STARTING ALWAYS TAKES TIME) 325
S-2 ENGINE DOES NOT START 326
1) ENGINE DOES NOT TURN 326
2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 327
3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 328
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 329
S-4 ENGINE STOPS DURING OPERATIONS 330
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 331
S-6 ENGINE LACKS OUTPUT (NO POWER) 332
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 333
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 334
S-9 OIL BECOMES CONTAMINATED QUICKLY 335
S-10 FUEL CONSUMPTION IS EXCESSIVE 336
S-11 OIL IS IN COOLANT WATER, OR COOLANT WATER SPURTS BACK, OR COOLAN LEVEL GOES DOWN 337
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 338
S-13 OIL LEVEL RISES 339
S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 340
S-15 ABNORMAL NOISE IS MADE 341
S-16 VIBRATION IS EXCESSIVE 342
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T-MODE) 344
POWER TRAIN 345
T-1 MACHINE DOES NOT START 345
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 346
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS 347
T-4 EXCESSIVE TIME LAG WHEN STARTING TO MOVE MACHINE OR AFTER SHIFTING GEARS 348
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 349
STEERING SYSTEM 350
T-6 STEERING WHEEL DOES NOT TURN 350
T-7 STEERING WHEEL IS HEAVY 351
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 352
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 352
BRAKE SYSTEM 353
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 353
T-11 BRAKES ARE NOT RELEASED OR BRAKES DRAG 354
WORK EQUIPMENT 355
T-12 BOOM DOES NOT RAISE 355
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 356
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 357
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 357
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 357
T-17 BOOM SHAKES DURING OPERATION 358
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 358
T-19 BUCKET DOES NOT TILT BACK 359
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 360
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 361
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 361
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 361
T-24 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 362
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 362
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 363
T-27 TWO SPEED BUCKET DUMP SPEED IS NOT FUCTIONING PROPERLY 364
TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE TRANSMISSION AND WORK EQUIPMENT (E-MODE) 366
E-1 ENGINE DOES NOT START (1/2) 367
(A) CHECK STARTING CIRCUIT 367
E-1 ENGINE DOES NOT START (2/2) 369
(B) CHECK FUEL SHUT-OFF SOLENOID 369
E-2 ENGINE DOES NOT STOP 370
E-3 NOT APPLICABLE TO THIS MODEL 371
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL) 372
E-5 TRANSMISSION DOES NOT WORK NORMALLY 373
(A) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRALIZER RELAY CIRCUIT 374
(B) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUIT 376
(C) DEFECTIVE CONTINUIT IN REVERSE SOLENOID CIRCUIT 378
(D) CONTRACT IN DIRECTIONAL CIRCUIT 380
1) F IS CONTINUOUS 380
2) R IS CONTINUOUS 382
(E) PROBLEM WITH SPEED SOLENOID OR ALWAYS STAYS IN 2ND 384
(F) CONTACT IN SPEED CIRCUIT 386
1) BATTERY VOLTAGE FORMED IN 1ST (SPEED) SOLENOID 386
2) BATTERY VOLTAGE FORMED IN 3RD (H-L) SOLENOID 388
E-6 KICK-DOWN SWITCH DOES NOT WORK (USUALY F1-F4 SHIFTS NORMALLY) 390
E-7 KICK-DOWN IS ACTUATED ONLY WHEN KICK-DOWN SWITCH IS ON (SELF-HOLD FUNCTION OF KICK-DOWN SWITCH RELAY DOES NOT WORK 392
E-8 KICK-DOWN IS NOT CANCELED 393
(A) KICK-DOWN IS NOT CANCELED WHEN DIRECTIONAL LEVER IS MOVED FROM FORWARD TO NEUTRAL OR REVERSE 393
(B) KICK-DOWN IS NOT CANCELED WHEN SPEED LEVER IS MOVED FROM 2ND TO ANY OTHER SPEED RANGE 394
E-9 KICK-DOWN SWITCH IS WRONGLY ACTUATED WHEN TRAVELING IN F2 396
E-10 PREHEATING IS NOT CARRIED OUT 397
E-11 PREHEATING REMAINS ACTUATED 399
E-12 ABNORMALITY IN QUICK COUPLER SYSTEM 401
E-13 ABNORMALITY IN TILT CYLINDER OPERATION 402
A ONLY SLOW DUMP SPEED IS AVAILABLE 402
B DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE 403
C TILT BACK IS NOT AVAILABLE 403
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 404
TROUBLE DATA DISPLAY 406
TABLE OF ACTION CODES AND FAILURE CODES 407
M-1 MAIN MONITOR DOES NOT WORK 408
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT 409
M-3 SPEEDOMETER DISPLAY DOES NOT WORK 410
M-4 ABNORMALITY IN SHIFT INDICATOR 411
(A) STAYS AT N EVEN WHEN DIRECTION LEVER IS AT F 411
(B) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 411
(C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F 411
(D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R 412
(E) DOES NOT DISPLAY 1ST, 4TH 412
(F) DOES NOT DISPLAY 3RD, 4TH 412
(G) DOES NOT DISPLAY 2ND, 3RD 413
(H) DOES NOT DISPLAY 1ST, 2ND 413
M-5 HIGH BEAM DOES NOT LIGHT UP 414
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 415
(A) LEFT HAND TURN SIGNAL DOES NOT LIGHT UP 415
(B) RIGHT HAND TURN SIGNAL DOES NOT LIGHT UP 415
M-7 ABNORMALITY IN PARKING DISPLAY 416
(A) PARKING LAMP DOES NOT LIGHT UP 416
(B) PARKING LAMP STAYS LIT UP 416
M-8 ABNORMALITY IN PREHEATING SYSTEM 417
(A) DOES NOT CARRY OUT PREHEATING 417
(1) MONITOR DISPLAY ALSO DOES NOT LIGHT UP 417
(2) ONLY MONITOR DISPLAY LIGHT UP 417
(B) ONLY MONITOR DISPLAY DOES NOT LIGHT UP 418
(C) ALWAYS CARRY OUT PREHEATING FOR 1 MINUTE 418
(D) PREHEATING STAYS ON 418
(E) PREHEATING TIME BECOMES SHORTER, OR IS UNSTABLE 419
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 421
M-10 ABNORMALITY IN FRONT WORKING LAMP 422
(A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 422
(B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 422
(C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 422
M-11 ABNORMALITY IN REAR WORKING LAMP 423
(A) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 423
(B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 423
(C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 423
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 425
(A) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 425
(B) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 425
(C) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 426
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 427
(A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT POSITION N, AND CAUTION L 427
(B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER ID AT 427
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATE 428
(A) ACTUATED CONTINUOUSLY 428
(B) NOT ACTUATED 428
M-15 ABNORMALITY IN BUZZER 429
(A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 429
(B) BUZZER ALWAYS SOUNDS 429
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 430
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 431
(A) DOES NOT ENTER FAILURE DISPLAY MODE 431
(B) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 431
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 432
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 433
(A) ALL LAMPS ON MAINTENANCE MONITOR DOE NOT LIGHT UP FOR 3 SECONDS 433
(B) SOME LAMPS DO NOT LIGHT UP 433
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT 434
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITO 435
K-4 WHEN STARTER SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH 436
(A) ENGINE OIL LEVEL DISPLAY FLASHES 436
(B) ENGINE WATER LEVEL DISPLAY FLASHES 437
(C) BRAKE OIL LEVEL DISPLAY FLASHES 438
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 439
(A) ENGINE OIL PRESSURE DISPLAY FLASHES 439
(B) BATTERY CHARGE LEVEL DISPLAY FLASHES 440
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 441
K-7 THERE IS NO ABNORMALTIY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 442
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP 443
(A) CHECK LAMP 443
(B) CAUTION LAMP 443
K-9 THERE IS NO ABNORMALTIY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHT UP 444
(A) CHECK LAMP 444
(B) CAUTION LAMP 444
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 445
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIT 446
K-12 SERVICE METER DOES NOT WORK 447
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 447
K-14 ABNORMALITY IN GAUGE ITEMS 448
(A) ABNORMALITY IN FUEL GAUGE 448
(B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 449
(C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 450
TROUBLESHOOTING-EAGLE AIR CONDITIONER 452
30 DISASSEMBLY AND ASSEMBLY 458
METHOD OF USING MANUAL 462
PRECAUTIONS WHEN CARRYING OUT OPERATION 463
1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 463
2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 464
3 PRECAUTIONS WHEN COMPLETING THE OPERATIONS 465
SPECIAL TOOL LIST 466
STARTING MOTOR 468
REMOVAL 468
INSTALLATION 468
ALTERNATOR 469
REMOVAL 469
INSTALLATION 469
FUEL INJECTION PUMP 470
REMOVAL 470
INSTALLLATION 470
ENGINE OIL COOLER 471
REMOVAL 471
INSTALLATION 471
WATER PUMP 472
REMOVAL 472
INSTALLATION 472
NOZZLE HOLDER 473
REMOVAL 473
INSTALLLATION 473
THERMOSTAT 474
REMOVAL 474
INSTALLATION 474
TURBOCHARGER 475
REMOVAL 475
INSTALLATION 475
CYLINDER HEAD 476
REMOVAL 476
INSTALLATION 476
RADIATOR 477
REMOVAL 477
INSTALLATION 479
ENGINE 480
REMOVAL 480
INSTALLATION 483
ENGINE HOOD 484
REMOVAL 484
INSTALLATION 484
MUFFLER AND AIR CLEANER 485
REMOVAL 485
INSTALLATION 485
TORQUE CONVERTER CHARGING PUMP 486
REMOVAL 486
INSTALLATION 486
TORQUE CONVERTER, TRANSMISSION 487
REMOVAL 487
INSTALLATION 496
TORQUE CONVERTER 498
DISASSEMBLY 498
ASSEMBLY 500
TRANSMISSION 502
DISASSEMBLY 502
ASSEMBLY 511
TRANSMISSION CLUTCH PACK 524
DISASSEMBLY 524
DISASSEMBLY OF FR CLUTCH PACK 524
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK 526
DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK 528
ASSEMBLY 530
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK 530
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK 534
ASSEMBLY OF 2ND AND 4TH CLUTCH PACK 538
PARKING BRAKE ASSEMBLY 542
DISASSEMBLY 542
ASSEMBLY 544
TRANSMISSION CONTROL VALVE 547
REMOVAL 547
INSTALLATION 548
DISASSEMBLY 549
ASSEMBLY 551
TRANSMISSION SOLENOID VALVE 553
DISASSEMBLY 553
ASSEMBLY 553
ACCUMULATOR VALVE 554
DISASSEMBLY 554
ASSEMBLY 555
DRIVE SHAFT 556
DISASSEMBLY 556
ASSEMBLY 558
FRONT AXLE 560
REMOVAL 560
INSTALLATION 562
REAR AXLE 563
REMOVAL 563
INSTALLATION 567
DIFFERENTIAL 570
DISASSEMBLY 570
ASSEMBLY 574
AXLE HOUSING 583
DISASSEMBLY 583
ASSEMBLY 588
CENTER HINGE PIN 594
REMOVAL 594
INSTALLATION 601
STEERING VALVE 605
REMOVAL 605
INSTALLATION 607
DISASSEMBLY 608
ASSEMBLY 611
PRIORITY VALVE 616
REMOVAL 616
INSTALLATION 617
MAIN CONTROL VALVE 618
REMOVAL 618
INSTALLATION 620
DISASSEMBLY 622
ASSEMBLY 622
STEERING CYLINDER 623
REMOVAL 623
INSTALLATION 623
POWER MASTER CYLINDER 624
REMOVAL 624
INSTALLATION 625
DISASSEMBLY 626
ASSEMBLY 629
PARKING BRAKE DISC 634
REMOVAL 634
INSTALLATION 635
HYDRAULIC TANK 636
REMOVAL 636
INSTALLATION 637
HYDRAULIC FILTER 638
REMOVAL 638
INSTALLATION 638
WORK EQUIPMENT, STEERING PUMP 639
REMOVAL 639
INSTALLATION 639
TILT CYLINDER 640
REMOVAL 640
INSTALLATION 641
LIFT CYLINDER 642
REMOVAL 642
INSTALLATION 643
HYDRAULIC CYLINDER 644
DISASSEMBLY 644
ASSEMBLY 646
BOOM AND PARALLEL TOOL LINKAGE 648
REMOVAL 648
INSTALLATION 656
COUNTERWEIGHT 659
REMOVAL 659
INSTALLATION 659
FUEL TANK 660
REMOVAL 660
INSTALLATION 661
CAB (ROPS) 662
REMOVAL 662
INSTALLATION 663
MAIN MONITOR 664
REMOVAL 664
INSTALLATION 665
MAINTENANCE MONITOR ASSEMBLY 666
REMOVAL 666
INSTALLATION 666
40 MAINTENANCE STANDARD 668
ENGINE MOUNT, TRANSMISSION MOUNT 670
TORQUE CONVERTER, CHARGING PUMP 671
TORQUE CONVERTER 672
TRANSMISSION 674
TRANSMISSION CONTROL VALVE 683
ACCUMULATOR VALVE 687
DRIVE SHAFT 688
DIFFERENTIAL 689
FINAL DRIVE 693
AXLE MOUNT 695
CENTER HINGE PIN 697
STEERING COLUMN 699
PRIORITY VALVE 700
MASTER CYLINDER 701
BRAKE 702
PARKING BRAKE 703
HYDRAULIC PUMP 704
MAIN CONTROL VALVE 705
HYDRAULIC CYLINDER 710
STEERING CYLINDER MOUNT 711
WORK EQUIPMENT LINKAGE 712
BUCKET POSTIONER AND BOOM KICK-OUT 715
S.V 13/12/24
