Komatsu WA250-3L Wheel Loader Shop Manual CEBM001301 PDF
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Komatsu WA250-3L Wheel Loader Shop Manual CEBM001301 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA250-3L A70001 and up
Description
Komatsu WA250-3L Wheel Loader Shop Manual CEBM001301 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA250-3L Wheel Loader Shop Manual CEBM001301 – PDF DOWNLOAD
Language : English
Pages : 653
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-3L Wheel Loader Shop Manual CEBM001301 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA250-3L A70001 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 WA250-3L Wheel Loader Shop Manual CEBM001301 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA250-3L A70001 and up
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 9
FOREWARD 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
COATING MATERIALS 14
STANDARD TORQUE REQUIREMENTS 15
ELECTRIC WIRE CODE 17
CONVERSION TABLES 18
01 GENERAL 24
SPECIFICATION DRAWINGS 25
SPECIFICATIONS 26
WEIGHT TABLE 29
FUEL, COOLANT AND LUBRICANTS 30
ENGINE OIL SPECIFICATIONS 31
DIESEL FUEL SPECIFICATIONS 32
COOLANT SPECIFICATIONS 33
10 STRUCTURE AND FUNCTION 38
POWER TRAIN 40
PATH OF POWER TRANSMISSION 41
TORQUE CONVERTER, TRANSMISSION PIPING 43
TORQUE CONVERTER, TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 45
TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 46
TORQUE CONVERTER 47
TORQUE CONVERTER OIL FILTER 49
TRANSMISSION 50
1ST, 3RD CLUTCH 54
2ND, 4TH CLUTCH 54
FORWARD 1ST 56
FORWARD 2ND 57
FORWARD 3RD 58
FORWARD 4TH 59
REVERSE 1ST 60
TRANSMISSION CONTROL VALVE 62
UPPER VALVE 63
LOWER VALVE 64
TRANSMISSION SOLENOID VALVE 65
TORQUE CONVERTER OUTLET PORT VALVE 66
PILOT REDUCING VALVE 67
MAIN REGULATOR VALVE 70
QUICK RETURN VALVE 71
MODULATION FILL VALVE 75
DIRECTIONAL SELECTOR SPOOL 77
EMERGENCY MANUAL SPOOL 78
ACCUMULATOR VALVE 81
DRIVE SHAFT 83
AXLE 84
FRONT AXLE 84
FRONT DIFFERENTIAL 85
REAR AXLE 86
REAR DIFFERENTIAL 87
TORQUE PROPORTIONING DIFFERENTIAL 89
FINAL DRIVE 90
AXLE MOUNT 91
CENTER HINGE PIN 93
STEERING PIPING 94
STEERING COLUMN 95
PRIORITY VALVE 97
STEERING VALVE (ORBIT-ROLL) 99
STEERING VALVE 101
CONNECTION BETWEEN HAND PUMP AND SLEEVE 105
2-WAY RESTRICTOR VALVE 107
BRAKE PIPING 108
POWER MASTER CYLINDER 109
BRAKE OFF 110
OIL PRESSURE STARTING TO RISE 110
PRESSURE RISING 111
RELIEF VALVE 111
ONE BRAKE LINE ACTUATED 112
BRAKE 113
PARKING BRAKE CONTROL 115
PARKING BRAKE 116
HYDRAULIC PIPING 117
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM 119
STEERING, HYDRAULIC PUMP HYDRAULIC CIRCUIT DIAGRAM 120
WORK EQUIPMENT LEVER LINKAGE 121
HYDRAULIC TANK 122
OIL FILTER BYPASS 123
BREATHER 124
MAIN CONTROL VALVE 125
2-SPOOL VALVE 126
3-SPOOL VALVE 127
RELIEF VALVE 129
SAFETY VALVE (WITH SUCTION) 130
WORK EQUIPMENT LINKAGE 139
BUCKET 141
BUCKET POSITIONER AND BOOM KICK-OUT 142
ROPS CAB 146
AIR CONDITIONER PIPING 148
AIR CONDITIONSER/HEATER WIRING DIAGRAM (EAGLE) 149
MACHINE MONITOR SYSTEM 150
MAIN MONITOR 151
MAIN MONITOR DISPLAY FUNCTION 152
PREHEATING OUTPUT FUNCTION 154
MAINTENANCE MONITOR DISPLAY FUNCTION 156
SENSORS AND SWITCHES 159
BRAKE OIL LEVEL SENSOR 159
RADIATOR WATER LEVEL 160
ENGINE OIL LEVEL SENSOR 160
FUEL LEVEL SENSOR 161
ENGINE WATER TEMPERATURE SENSOR 162
ENGINE SPEED SENSOR 163
ELECTRICAL WIRING DIAGRAM (1/2) 165
ELECTRICAL WIRING DIAGRAM (2/2) 166
ENGINE STARTING CIRCUIT 168
ENGINE STOP CIRCUIT 169
AUTOMATIC PREHEATING CIRCUIT (Q H S CIRCUIT) 170
ELECTRICAL TRANSMISSION CONTROL 172
RIBBON HEATER 172
Q H S WATER TEMPERATURE SENSOR 172
HEATER RELAY 172
ELECTRICAL TRANSMISSION CONTROL 173
COMBINATION SWITCH 174
TRANSMISSION CUT-OFF FUNCTION 175
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 177
KICK DOWN SWITCH 178
KICK DOWN ELECTRIC CIRCUIT DIAGRAM 179
KICK-DOWN SWITCH OPERATED 180
20 TESTING AND ADJUSTING 184
STANDARD VALUE TABLE FOR ENGINE 186
STANDARD VALUE TABLE FOR CHASSIS 187
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 191
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING 193
MEASURING ENGINE SPEEDS 195
MEASURING ENGINE LUBRICATING OIL PRESSURE 196
MEASURING FUEL FILTER INLET RESTRICTION 196
MEASURING BLOW-BY PRESSURE 196
MEASURING COMPRESSION PRESSURE 197
MEASURING EXHAUST COLOR 198
MEASURING COOLANT TEMPERATURE 199
MEASURING AND ADJUSTING VALVE CLEARANCE 199
MEASURING ACCELERATOR PEDAL 200
MEASURING SHIFT LEVER 202
MEASURING STALL SPEEDS 203
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE 205
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 207
TESTING AND ADJUSTING STEERING WHEEL 209
MEASURING STEERING OIL PRESSURE 212
MEASURING BRAKE PEDAL 214
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 215
MEASURING BRAKE PERFORMANCE 217
MEASURING BRAKE OIL PRESSURE 218
MEASURING WEAR OF BRAKE DISC 219
BLEEDING AIR FROM BRAKE SYSTEM 220
MEASURING PARKING BRAKE PERFORMANCE 221
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 222
TESTING PARKING BRAKE PISTON STROKE 223
MEASURING WEAR OF PARKING BRAKE DISC 224
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER 225
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 228
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 229
MEASURING WORK EQUIPMENT 231
TESTING AND ADJUSTING BUCKET POSITIONER 233
TESTING AND ADJUSTING BOOM KICK-OUT 234
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 236
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR 237
TROUBLESHOOTING 238
POINTS TO REMEMBER WHEN TROUBLESHOOTING 240
SEQUENCE OF EVENTS IN TROUBLESHOOTING 241
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 242
1 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 242
2 HANDLING CONTROL BOX 247
3 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 248
CHECKS BEFORE TROUBLESHOOTING 250
JUDGEMENT OF POWER TRAIN 251
PRECAUTIONS WHEN TROUBLESHOOTING 252
PREVENTING RECURRENCE OF TROUBLE 254
METHOD OF USING TROUBLESHOOTING CHARTS 255
CONNECTOR TYPES AND MOUNTING LOCATIONS 263
CONNECTOR PIN ARRANGEMENT DIAGRAM 264
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 266
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 274
ENGINE START, STOP SYSTEM 274
PREHEATING SYSTEM 275
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 276
TROUBLESHOOTING OF ENGINE SYSTEM TABLE OF CONTENTS (S MODE) 278
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 279
S-2 ENGINE DOES NOT START 280
(1) ENGINE DOES NOT TURN 280
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 281
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING EJECTED) 282
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR) 283
S-4 ENGINE STOPS DURING OPERATIONS 284
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 285
S-6 ENGINE LACKS OUTPUT (NO POWER) 286
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 287
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 288
S-9 OIL BECOMES CONTAMINATED QUICKLY 289
S-10 FUEL CONSUMPTION IS EXCESSIVE 290
S-11 OIL IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 291
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 292
S-13 OIL LEVEL RISES 293
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 294
S-15 ABNORMAL NOISE IS MADE 295
S-16 VIBRATION IS EXCESSIVE 296
TROUBLESHOOTING SYSTEMS OF HYD AND MECHANICAL (T-MODE) 298
POWER TRAIN 299
T-1 MACHINE DOES NOT START 298
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 301
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 303
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 304
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 305
STEERING SYSTEM 306
T-6 STEERING WHEEL DOES NOT TURN 306
T-7 STEERING IS HEAVY 307
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 308
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 308
BRAKE SYSTEM 309
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 309
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS 310
WORK EQUIPMENT 311
T-12 BOOM DOES NOT RISE 311
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 312
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 313
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 313
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 313
T-17 BOOM SHAKES DURING OPERATION 314
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 314
T-19 BUCKET DOES NOT TILT BACK 315
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 316
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 317
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 317
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 317
T-24 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 318
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 318
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 319
TROUBLESHOOTING OF ELECTRICAL EQUIPMENT FOR ENGINE, TRANSMISSION (E-MODE) 320
E-1 ENGINE DOES NOT START (1/2) 321
(A) CHECK STARTING CIRCUIT 321
E-1 ENGINE DOES NOT START (2/2) 323
(B) CHECK FUEL SHUT-OFF SOLENOID 323
E-2 ENGINE DOES NOT STOP 324
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIES (TRANSMISSION CUT-OFF IS NORMAL) 325
E-5 TRANSMISSION DOES NOT WORK NORMALLY 326
(A) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRALIZER RELAY CIRCUIT 327
(B) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUIT 329
(C) DEFECTIVE CONTINUIT IN REVERSE SOLENOID CIRCUIT 331
(D) CONTACT IN DIRECTIONAL CIRCUIT 333
1) FORWARD IS CONTINUOUS 333
2) REVERSE IS CONTINUOUS 335
(E) PROBLEM WITH SPEED SOLENOID OR ALWAYS STAYS IN 2ND 337
(F) CONTACT IN SPEED CIRCUIT 339
1) BATTERY VOLTAGE FORMED IN 1ST (SPEED) SOLENOID 339
2) BATTERY VOLTAGE 341
E-6 KICK-DOWN SWITCH DOES NOT WORK (USUAL F1 – F4 SHIFTS NORMALLY) 343
E-7 KICK-DOWN IS ACTUATED ONLY WHEN KICK-DOWN SWITCH IS ON (SELF-HOLD FUNCTION OF KICK-DOWN SWITCH RELAY DOES NOT WORK) 345
E-8 KICK-DOWN IS NOT CANCELED 346
(A) KICK-DOWN IS NOT CANCELEL WHEN DIRECTIONAL LEVER IS MOVED FROM FORWARD TO NEUTRAL OR REVERSE 346
(B) KICK-DOWN IS NOT CANCELLED WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER SPEED RANGE 347
E-9 KICK-DOWN SWITCH IS WRONGLY ACTUATED WHEN TRAVELING IN F2 349
E-10 PREHEATING IS NOT CARRIED OUT 350
E-11 PREHEATING REMAINS ACTUATED 352
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 354
TROUBLESHOOTING DATA DISPLAY 356
TABLE OF ACTION CODES AND FAILURE CODES 357
M-1 MAIN MONITOR DOES NOT WORK 358
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT 359
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 360
M-4 ABNORMALITY IN SHIFT INDICATOR 361
(A) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 361
(B) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 361
(C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F 361
(D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAY E WHEN DIRECTIONAL LEVER IS AT R 362
(E) DOES NOT DISPLY 1ST, 4TH 362
(F) DOES NOT DISPLAY 3RD, 4TH 362
(G) DOES NOT DISPLAY 2ND, 3RD 363
(H) DOES NOT DISPLAY 1ST, 2ND 363
M-5 HIGH BEAM DOES NOT LIGHT UP 364
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 365
(A) L H TURN SIGNAL DOES NOT LIGHT UP 365
(B) R H TURN SIGNAL DOES NOT LIGHT UP 365
M-7 ABNORMALITY IN PARKING DISPLAY 366
(A) PARKING LAMP DOES NOT LIGHT UP 366
(B) PARKING LAMP STAY LIGHTED UP 366
M-8 ABNORMALITY IN PREHEATING SYSTEM 367
(A) DOES NOT CARRY OUT PREHEATING 367
(1) MONITOR DISPLAY ALSO DOES NOT LIGHT UP 367
(2) ONLY MONITOR DISPLAY LIGHTS UP 367
(B) ONLY MONITOR DISPLAY DOES NOT LIGHT UP 368
(C) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE 368
(D) PREHEATING STAYS ON 368
(E) PREHEATING TIME BECOMES SHORTER, OR IS UNSTABLE 369
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 371
M-10 ABNORMALITY IN FRONT WORKING LAMP 372
(A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 372
(B) WORKING LAMP LIGHT UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 372
(C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 372
M-11 ABNORMALITY IN REAR WORKING LAMP 373
(A) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 373
(B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 373
(C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 373
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 375
(A) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 375
(B) MONITOR DISPLAY GOES OUT BUT OUT-OFF FUCTION STAYS ON 375
(C) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 376
M-13 ABNORMALITY IN PARKING DRAGGING WARNING 377
(A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTION LEVER IS AT N AND CAUTION LAMP FLASHES 377
(B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT 377
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATE 378
(A) ACTUATED CONTINUOUSLY 378
(B) NOT ACTUATED 378
M-15 ABNORMALITY IN BUZZER 379
(A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 379
(B) BUZZER ALWAYS SOUNDS 379
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 380
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 381
(A) DOES NOT ENTER FAILURE DISPLAY MODE 381
(B) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 381
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 382
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 383
(A) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 383
(B) SOME LAMPS DO NOT LIGHT UP 383
K-2 WHEN STARTING SWICH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT 384
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR D 385
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH 386
(A) ENGINE OIL LEVEL DISPLAY FLASHES 386
(B) ENGINE WATER LEVEL DISPLAY FLASHES 387
(C) BRAKE OIL LEVEL DISPLAY FLASHES 388
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED) CAUTION ITEMS FLASH 389
(A) ENGINE OIL PRESSURE DISPLAY FLASHES 389
(B) BATTERY CHARGE LEVEL DISPLAY FLASHES 390
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 391
K-7 THERE IS NOT ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 392
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP 393
(A) CHECK LAMP 393
(B) CAUTION LAMP 393
K-9 THERE IS NOT ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP 394
(A) CHECK LAMP 394
(B) CAUTION LAMP 394
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 395
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP 396
K-12 SERVICE METER DOES NOT WORK 397
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 397
K-14 ABNORMALITY IN GAUGE ITEMS 398
(A) ABNORMALITY IN FUEL GAUGE 398
(B) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 399
(C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 400
TROUBLESHOOTING EAGLE AIR CONDITIONER 402
30 DISASSEMBLY AND ASSEMBLY 408
METHOD OF USING MANUAL 412
PRECAUTIONS WHEN CARRYING OUT OPERATION 413
1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 413
2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 414
3 PRECAUTIONS WHEN COMPLETING THE OPERATIONS 415
SPECIAL TOOL LIST 416
STARTING MOTOR 418
REMOVAL 418
INSTALLATION 418
ALTERNATOR 419
REMOVAL 419
INSTALLATION 419
FUEL INJECTION PUMP 420
REMOVAL 420
INSTALLATION 420
ENGINE OIL COOLER 421
REMOVAL 421
INSTALLATION 421
WATER PUMP 422
REMOVAL 422
INSTALLATION 422
NOZZLE HOLDER 423
REMOVAL 423
INSTALLATION 423
THERMOSTAT 424
REMOVAL 424
INSTALLATION 424
TURBOCHARGER 425
REMOVAL 425
INSTALLATION 425
CYLINDER HEAD 426
REMOVAL 426
INSTALLATION 426
RADIATOR 427
REMOVAL 427
INSTALLATION 429
ENGINE 430
REMOVAL 430
INSTALLATION 433
ENGINE HOOD 434
REMOVAL 434
INSTALLATION 434
MUFFLER AND AIR CLEANER 435
REMOVAL 435
INSTALLATION 435
TORQUE CONVERTER CHARGING PUMP 436
REMOVAL 436
INSTALLATION 436
TORQUE CONVERTER, TRANSMISSION 437
REMOVAL 437
INSTALLATION 446
TORQUE CONVERTER 448
DISASSEMBLY 448
ASSEMBLY 450
TRANSMISSION 452
DISASSEMBLY 452
ASSEMBLY 461
TRANSMISSION CLUTCH PACK 474
DISASSEMBLY 474
DISASSEMBLY OF FR CLUTCH PACK 474
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK 476
DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK 478
ASSEMBLY 480
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK 480
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK 484
ASSEMBLY OF 2ND AND 4TH CLUTCH PACK 488
PARKING BRAKE ASSEMBLY 492
DISASSEMBLY 492
ASSEMBLY 494
TRANSMISSION CONTROL VALVE 497
REMOVAL 497
INSTALLATION 498
DISASSEMBLY 499
ASSEMBLY 501
TRANSMISSION SOLENOID VALVE 503
DISASSEMBLY 503
ASSEMBLY 503
ACCUMULATOR VALVE 504
DISASSEMBLY 504
ASSEMBLY 505
DRIVE SHAFT 506
DISASSEMBLY 506
ASSEMBLY 508
FRONT AXLE 506
REMOVAL 510
INSTALLATION 512
REAR AXLE 513
REMOVAL 513
INSTALLATION 517
DIFFERENTIAL 520
DISASSEMBLY 520
ASSEMBLY 524
AXLE HOUSING 533
DISASSEMBLY 533
ASSEMBLY 538
CENTER HINGE PIN 544
REMOVAL 544
INSTALLATION 551
STEERING VALVE 555
REMOVAL 555
INSTALLATION 557
DISASSEMBLY 558
ASSEMBLY 561
PRIORITY VALVE 566
REMOVAL 566
INSTALLATION 567
MAIN CONTROL VALVE 568
REMOVAL 568
INSTALLATION 569
DISASSEMBLY 571
ASSEMBLY 571
STEERING CYLINDER 572
REMOVAL 572
INSTALLATION 572
POWER MASTER CYLINDER 573
REMOVAL 573
INSTALLATION 574
DISASSEMBLY 575
ASSEMBLY 578
PARKING BRAKE DISC 583
REMOVAL 583
INSTALLATION 584
HYDRAULIC TANK 585
REMOVAL 585
INSTALLATION 586
HYDRAULIC FILTER 587
REMOVAL 587
INSTALLATION 587
WORK EQUIPMENT, STEERING PUMP 588
REMOVAL 588
INSTALLATION 588
BUCKET CYLINDER 589
REMOVAL 589
INSTALLATION 590
BOOM CYLINDER 591
REMOVAL 591
INSTALLATION 592
HYDRAULIC CYLINDER 593
DISASSEMBLY 593
ASSEMBLY 595
WORK EQUIPMENT 597
REMOVAL 597
INSTALLATION 600
COUNTERWEIGHT 602
REMOVAL 602
INSTALLATION 602
FUEL TANK 603
REMOVAL 603
INSTALLATION 604
CAB (ROPS) 605
REMOVAL 605
INSTALLATION 606
MAIN MONITOR 607
REMOVAL 607
INSTALLATION 608
MAINTENANCE MONITOR ASSEMBLY 609
REMOVAL 609
INSTALLATION 609
40 MAINTENANCE STANDARD 610
ENGINE MOUNT, TRANSMISSION MOUNT 611
TORQUE CONVERTER CHARGING PUMP 612
TORQUE CONVERTER 613
TRANSMISSION 614
TRANSMISSION CONTROL VALVE 622
ACCUMULATOR VALVE 626
DRIVE SHAFT 627
DIFFERENTIAL 628
FINAL DRIVE 632
AXLE MOUNT 633
CENTER HINGE PIN 635
STEERING COLUMN 637
PRIORITY VALVE 638
MASTER CYLINDER 639
BRAKE 640
PARKING BRAKE 641
HYDRAULIC PUMP 642
MAIN CONTROL VALVE 643
HYDRAULIC CYLINDER 647
STEERING CYLINDER MOUNT 648
WORK EQUIPMENT LINKAGE 649
BUCKET 651
BUCKET POSITIONER AND BOOM KICK-OUT 652
S.V 14/12/24
