Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu WA250-3L Wheel Loader Shop Manual SN A70001 and up – PDF DOWNLOAD
Original price was: $52.95.$32.95Current price is: $32.95.
Komatsu WA250-3L Wheel Loader Shop Manual
Book Code: CEBM001301
MACHINE MODEL SERIAL NUMBERS
WA250-3L A70001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu WA250-3L Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA250-3L Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-3L
Serial Number: A70001 and up
Book Code: CEBM001301
Language: English
Pages: 653
File Format: Portable Document Format (PDF)
KOMATSU WA250-3L WHEEL LOADER SHOP MANUAL SN A70001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-3L Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following 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 WA250-3L Wheel Loader Shop Manual
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
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
