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Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair Manual SN A75001 And Up – DOWNLOAD
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Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair Manual
Book Code: CEBM001801
MACHINE MODEL SERIAL NUMBERS
WA250-3 A75001 and up
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Description
Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair Manual
FILE DETAILS:
Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-3, WA250-3PTC Parallel Tool Carrier
Serial Number: A75001 and up
Book Code: CEBM001801
Language: English
Pages: 716
File Format: Portable Document Format (PDF)
KOMATSU WA250-3 PARALLEL TOOL CARRIER WHEEL LOADER SERVICE REPAIR MANUAL SN A75001 AND UP – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair 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 sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING 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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA250-3 Parallel Tool Carrier Wheel Loader Service Repair Manual
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
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