Komatsu WA320PT-5L Parallel Tool Carrier Shop Manual CEBM013602 PDF

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Komatsu WA320PT-5L Parallel Tool Carrier Shop Manual CEBM013602 – PDF DOWNLOAD

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Komatsu WA320PT-5L Parallel Tool Carrier Shop Manual CEBM013602 – PDF DOWNLOAD 

Language : English
Pages : 1215
Downloadable : Yes
File Type : PDF

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Komatsu WA320PT-5L Parallel Tool Carrier Shop Manual CEBM013602 – PDF DOWNLOAD 

SERIAL NUMBERS WA320PT-5L A39001 and UP

CEBM013602 – WA320PT-5L S/N A39001 and up 1
CONTENTS 2
REVISION PAGES 3
01 GENERAL 33
GENERAL INFORMATION 34
Machine Specifications 35
Weight Table 41
LUBRICANTS 42
Ambient Temperature Range 42
Recommended Lubricants 43
Addtional Lubricant Information 44
10 STRUCTURE AND FUNCTION 45
ENGINE AND DRIVE SYSTEM 50
Mounting 50
Drive Dampener 51
Outline 51
Cooling System 52
Specification 52
Drive Line Componants 53
Drive Line Flow 54
Power Flow Outline 55
Drive Shaft System 56
Drive Shaft Outline 56
HST HYDRAULIC SYSTEM 57
Piping Diagram 57
HST Pump (Hydro-static Transmission) 58
Specifications 58
Flow of Power 59
Flow of Oil 59
High Pressure Relief Valve 60
Function 60
Valve Operation 61
Low Pressure Relief Valve 62
Function 62
Valve Operation 62
HST Charge Pump 63
Specifications 63
Pump Outline 63
Function 63
Speed Related Valve (DA Valve) 64
Function 64
Valve Operation 64
High Pressure Cut-off Valve 65
Function 65
Valve Operation 65
HST MOTOR (HYDRO-STATIC TRANSMISSION) 66
Motor 1 66
Motor 1 Specifications 66
Motor 2 67
Motor 2 Specifications 67
Principle 68
Structure 68
Operation 68
PUMP VALVES 69
EP Servo Valve 69
Function 69
Operation 69
HA Servo Valve 70
Function 70
Operation 70
Forward-Reverse Shuttle Valve 71
Function 71
Operation 71
TRANSFER 72
Outline 73
Input Shaft 75
Output Shaft 77
Clutch Operation 80
Low-Speed Mode 81
Operation 81
High-Speed Mode 82
Operation 82
CLUTCH SOLENOID VALVE 83
Operation 83
DRIVE AXLES 84
Front Axle 84
Front Differential 85
Rear Axle 88
Rear Differential 89
Outline 92
Torque Proportioning Differential 93
Outline 93
LIMITED-SLIP DIFFERENTIALS 94
Front Differential 94
Operation of Limited-Slip Differential 95
Final Drive 98
Outline 99
AXLE MOUNTING AND CENTER HINGE 100
Outline 101
Center Hinge 102
Axle Mount 104
STEERING SYSTEM 105
Steering Piping 105
Steering Column 106
Priority Valve 107
Outline 108
Operation 108
Orbit-Roll Valve 110
Outline 111
Structure 111
Cushion Valve 117
Outline 117
Function 117
Steering Cylinder 118
EMERGENCY STEERING 120
Steering Piping 120
Steering Valve 121
BRAKING SYSTEM 125
Brake Piping 125
Brake Valve 126
Outline 127
Inching Valve 130
Outline 130
Charge Valve 131
Function 132
Operation 133
Braking System Accumulator 135
Function 135
Specifications 135
Slack Adjuster 136
Function 137
Operation 137
Braking Unit 138
Outline 139
PARKING BRAKE 140
Control 140
Outline 140
Parking Brake Unit 141
Outline 141
WORK EQUIPMENT 142
Hydraulic Piping Layout WA320-5L 142
Outline 143
Hydraulic Piping Layout WA320PT-5L 144
Outline 145
Control Lever Linkage 146
WA320-5L 2-Lever Type 146
WA320PT-5L 3-Lever Type 147
Multi-Function Joystick Type (WA320-5L) 148
BASIC HYDRAULIC SYSTEM 150
Hydraulic Tank 150
Specifications 151
Vent 151
4-gear Pump Unit 152
Outline 152
Accumulator PPC Circuit 154
Outline 154
Specifications 154
Lock Valve 155
Outline 155
Bypass Valve 156
System Operation 157
Quick Coupler Solenoid Valve 159
Outline 159
E C S S Valve 160
ECSS Accumulator 162
Function 162
Specifications 162
HYDRAULIC COOLING SYSTEM 163
Piping Layout 163
Outline 163
Cooling Fan Motor 164
Specifications 164
Function 165
Principle of Operation 165
WORK EQUIPMENT CONTROL VALVE 166
2-Spool Valve 166
3-Spool Valve 169
Relief Valve 172
Function 172
Operation 172
Safety-suction Valve 173
Function 173
Operation as Safety Valve 173
Suction Valve 174
Function 174
Operation 174
Cut-Off Valve 175
Function 176
Operating Condition of Cut-Off Valve 176
Work Equipment Controll Valve Operation 179
WORK EQUIPMENT PPC VALVES 185
2-Lever Type Valve 185
Operation 187
Attachment Lever Valve 190
Operation 191
Joystick Lever Type 194
Operation 196
WA320-5L MECHANICAL AND WORK EQUIPMENT 200
Standard Work Equipment Bucket 202
WA320PT-5L MECHANICAL AND WORK EQUIPMENT 204
Optional Bucket 206
Optional 1524 mm (60 inch) Construction Forks 208
Optional 1371 6 mm (54 inch) Utility Forks 209
Optional Extendable Boom 210
Hydraulic Quick Coupler Group 211
BUCKET POSITIONER, BOOM KICK-OUT AND DUMP SPEED 212
WA320-5L Related System 212
Outline 213
Operation of Proximity Switch 214
Function of Proximity Switch 216
Function of Proximity Switch 219
WA320PT-5L Related System 220
Outline 221
Operation of Proximity Switch 221
WORK EQUIPMENT CYLINDERS 230
WA320-5L 230
Lift Cylinder 230
Bucket Cylinder 230
WA320PT-5L 231
Lift Cylinder 231
Bucket Cylinder 231
Coupler Plunger 231
HEATING AND AIR CONDITIONER PIPING 233
MACHINE MONITERING SYSTEM 234
Starting and Lighting Power Supply 236
Speedometer Power Supply 238
Load Meter Power Supply 239
Sensor System Power Supply 240
HST Safety Control Power Supply 241
Preheat System Power Supply 242
Load Meter Power Supply 243
MACHINE MONITOR 244
Standard Speedometer Display 244
Optional Load Meter 245
LIST OF ITEMS DISPLAYED ON MONITOR 246
Service Mode Functions 252
Outline 252
Operating Method 254
Spedometer Specifications 254
Load Meter Specifications 255
Items Related to the Fault History of Electrical System 256
Items Related to the Fault History of Machine System 259
Real-Time Monitor Function Speedometer Specification 261
Real-Time Monitor Function Load Meter Specification 264
Real-Time Monitoring Items 268
Tuning Function 272
Maintenance Functions 274
Setting Required When Optional Device is Installed 278
Function of Selecting Optional Device 278
Function of Selecting Optional Device 280
Load Meter Function 284
Outline 284
Operating Method 284
Input/Ouput Signal 294
Speedometer Specification 294
HST SYSTEM ELECTRICAL CONTROLLER 301
System Diagram 301
Control Function 302
HST Controller 305
Input and Output Signals 305
Selecting Directional Selector Switch (If Equipped) 306
Outline 306
Function 306
Operation 307
Engine Starting Circuit 308
Function 308
Operation 308
Engine Stop Circuit 310
Operation 310
Automatic Preheating System 311
Outline 311
Operation 311
Parking Brake Circuit 312
Operation 313
Electronically Controlled Suspension System 315
Function 315
Sensors 316
Engine Speed Sensor 316
Speed Sensor 316
Engine Oil Pressure Sensor 317
Fuel Level Sensor 317
Coolant Temperature Sensor (For Monitor) 318
Coolant Temperature Sensor (For Preheating) 318
Axle Oil Temperature Sensor 319
HST Sensor for Load Meter (Load Meter Specification) 319
Emergency Steering Oil Pressure Sensor (If Equipped) 320
HST Oil Filter Clogging Sensor 320
Coolant Level Sensor 321
Engine Oil Level Sensor 322
Air Cleaner Clogging Sensor 323
Lift Arm Angle Sensor (Load Meter Specification) (If Equipped) 324
KOMTRAX SYSTEM 326
KOMTRAX Terminal System 326
KOMTRAX Terminal 327
Input and Output Signals 328
20 TESTING, ADJUSTING AND TROUBLESHOOTING 329
STANDARD VALUE TABLE 331
Engine 331
Chassis 332
SPECIAL TOOLS 337
ENGINE COMPONENTS 340
Measuring Exhaust Smoke 340
Measuring Exhaust Temperature 340
Adjusting Valve Clearance 340
Measuring Compression Pressure 340
Measuring Crankcase Pressure 340
Measuring Engine Oil Pressure 340
Measuring Boost Pressure 340
Measuring Fuel Pressure 340
Adjusting Engine Speed Sensor 340
Bleeding Air From Fuel System 340
Adjusting Engine Stop Solenoid 340
Measuring Engine Speed 341
Measuring Low And High Idle 341
Measuring HST Stall Speed 342
Measuring Hydraulic Stall 342
Measuring Full Stall Speed 342
ACCELERATOR PEDAL 343
Testing Pedal Force 343
Operating Angle of Pedal 344
ADJUSTING ENGINE STOP SOLENOID 345
ADJUSTING ENGINE SPEED SENSOR 346
REFRIGERENT COMPRESSOR BELT 347
DIRECTIONAL LEVER 348
HST OIL PRESSURE 349
Measuring 349
Adjusting 352
CLUTCH CONTROL PRESSURE 354
STEERING WHEEL 355
Measuring Steering Wheel End Play 355
Measuring Operating Force on Steering Wheel 355
Measuring Operating Time for Steering Wheel 356
STEERING OIL PRESSURE 357
Measuring Main Relief Pressure 357
Adjusting Main Relief Pressure 357
Bleeding Air From Steering Circuit 358
HYDRAULIC FAN 359
Measuring Fan Speed 359
Measuring Oil Pressure 359
MEASURING BRAKE PEDAL 360
BRAKE PEDAL LINKAGE 361
Testing 361
Adjusting 361
MEASURING BRAKE PERFORMANCE 362
ACCUMULATOR CHARGE PRESSURE 363
Measuring 363
Adjusting 363
BRAKE OIL PRESSURE 364
MEASURING WEAR OF BRAKE DISC 366
BLEEDING AIR FROM BRAKE CIRCUIT 367
PARKING BRAKE PERFORMANCE 368
PARKING BRAKE LINKAGE 369
Testing 369
Adjusting 370
WORK EQUIPMENT CONTROL LEVER 371
WORK EQUIPMENT PRESSURE 372
Measuring 372
Adjusting 372
WORK EQUIPMENT PPC OIL PRESSURE 374
Testing and Adjusting 374
Bleeding Air 376
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 377
BUCKET POSITIONER 378
Testing 378
Adjusting 378
BOOM KICK-OUT 379
PROXIMITY SWITCH ACTUATION DISPLAY LAMP 380
PROCEDURE FOR CHECKING DIODE 382
SPECIAL FUNCTIONS OF MACHINE MONITOR 383
FLOW OF MODES AND FUNCTIONS 384
SETTING MACHINE MONITOR (EMMS) 400
REAL-TIME MONITORING ITEMS 409
PM CLINIC INSPECTION CHART 415
TROUBLESHOOTING (GENERAL) 417
POINTS TO REMEMBER WHEN TROUBLESHOOTING 418
SEQUENCE OF EVENTS IN TROUBLESHOOTING 420
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 421
Precautions When Handling Electric Equipment 421
Handling Control Box 426
Points To Remember When Troubleshooting Electric Circuits 427
Points To Remember When Handling Hydraulic Equipment 428
CHECKS BEFORE TROUBLESHOOTING 430
Using Troubleshooting Charts 431
Phenomena Considered To Be Failures And Troubleshooting 432
TABLE FOR CONNECTOR PIN NUMBERS 435
T-ADAPTER TABLE 458
CONNECTOR TYPES AND MOUNTING LOCATIONS 461
CONNECTOR LAYOUT DRAWING 467
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 473
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 474
Points To Remember If A Problem Returns To Normal 474
User Code Memory Retention Function 474
ERROR CODE AND POSSIBLE CAUSE TABLE 475
FUSE SYSTEM CHECK 477
Fuse Pannel Connection Table 477
INFORMATION CONTAINED IN TESTING PROCEDURES 478
Code Key Table 479
[989F00] 480
Transmission Protection Alert (00) 480
[DHH1KX] 482
HST Oil Pressure Signal Out Of Range 482
[DLE2LC] 484
Engine Speed Sensor Out Of Range 484
[DW26KZ] 486
Motor 2 Solenoid System Open Or Shorted 486
[DX19KZ] 490
Motor 1 Solenoid System Open Or Shorted 490
Load Meter Specifications (If Equipped) 492
[DX20KZ] 495
Clutch Solenoid System Open Or Shorted 495
Load Meter Specifications (If Equipped) 498
[HST-1] 502
Defective HST Power Controller Source 502
[HST-2] 506
Travel Speed Ranges Do Not Change 506
[HST-3] 510
Traction Control Inoperable 510
[HST-4] 512
Travel Speed Cannot Be Changed When Gear Selector Is In 1st 512
[HST-5] 515
Travel Speed Cannot Be Increased 515
TROUBLESHOOTING OF TRAVEL DAMPENER SYSTEM (ECSS MODE) 517
POINTS TO REMEMBER WHEN TROUBLESHOOTING 518
Points To Remember If A Problem Returns To Normal 518
User Code Memory Retention Function 518
ECSS-1 519
Travel Damper Dose Not Operate 519
Travel Damper Does Not Reset 522
TROUBLESHOOTING OF HST MONITOR SYSTEM (MON MODE) 525
POINTS TO REMEMBER WHEN TROUBLESHOOTING 529
Points To Remember If A Problem Returns To Normal 529
User Code Memory Retention Function 529
ERROR CODE AND POSSIBLE CAUSE TABLE 530
FUSE SYSTEM CHECK 532
Fuse Pannel Connection Table 532
INFORMATION CONTAINED IN TESTING PROCEDURES 533
Code Key Table 534
[15B0NX] 535
HST Oil Filter Showing Clogged Condition 535
HST Load Meter Specifications (If Equipped) 537
[2G42ZG] 539
Low Accumulator Oil Pressure Indicated 539
Load Meter Specifications (If Equipped) 541
[989F00] 543
Transmission Protection Caution Indicated 543
[989FN1] 544
HST Over-speed Condition 544
[AA1ANX] 545
Clogged Air Cleaner Indicated (Standard) 545
Load Meter Specifications (If Equipped) 547
[AB00L6] 549
Defective Battery Charging Circuit 549
Load Meter Specifications (If Equipped) 551
[AB00MA] 553
Defective Battery Charging Circuit 553
Load Meter Specifications (If Equipped) 555
[B@BAZG] 557
Abnormal Engine Oil Pressure Indicated 557
Load Meter Specifications (If Equipped) 559
[B@BAZK] 561
Abnormal Engine Oil Level Indication 561
Load Meter Specifications (If Equipped) 563
[B@BCNS] 564
Engine Coolant Indicating Overheat Condition 564
Load Meter Specifications (If Equipped) 567
[B@BCZK] 569
Abnormal Coolant Level Indication 569
Load Meter Specifications (If Equipped) 571
[B@C7NS] 573
Brake Cooling Oil Indicating Overheating Condition 573
Load Meter Specifications (If Equipped) 575
[B@CRNS] 577
HST Oil Showing Overheating Condition 577
Load Meter Specifications (If Equipped) 579
[D5ZHL6] 581
Ignition Switch “C” (Ign) Input Failure Indicated 581
Load Meter Specifications (If Equipped) 583
[DAF3KK] 586
With Ignition Switch On, Power Supply For Memory Is Off 586
[DAF5KP] 588
Defective 5-V Power Supply Output (KP) 588
[DAF6KP] 590
Defective 24-V Power Supply Output (KP) 590
[DAF0KT] 592
Controller Internal Failure 592
[DAJ0KR] 594
HST Controller Communication Failure 594
Load Meter Specifications (If Equipped) 596
[D182KZ] 599
The Pre-heater Relay Coil Is Open Or Shorted 599
[D1B0KB] 601
HST Safety (Transmission Cut-off) Relay Open Or Shorted (KB) 601
[DD1CLD] 603
Defective Subtotal Switch 603
[DD15LD] 605
Monitor Panel Mode Selector Switch Will Not Set 605
Load Meter Specifications (If Equipped) 607
[DD16LD] 609
Monitor Panel Mode Selector Switch Will Not Set 609
Load Meter Specifications (If Equipped) 611
[DD17LD] 613
Monitor Panel Mode Selector Switch Will Not Set 613
Load Meter Specifications (If Equipped) 615
[DD18LD] 617
Monitor Panel Mode Selector Switch Will Not Set 617
Load Meter Specifications (If Equipped) 619
[DDK3KB] 621
Improper Input For Multiple Shift (FNR) Lever 621
Load Meter Specifications (If Equipped) 624
[DDS5L6] 628
Decreased Steering Oil Pressure 628
Load Meter Specifications (If Equipped) 630
[DDY0LD] 632
Defective Cancel Switch 632
[DGE2KX] 634
Engine Coolant Temperature Sensor Out Of Range 634
Load Meter Specifications (If Equipped) 636
[DGE3L6] 638
Engine Coolant Temperature Sensor Out Of Range 638
Load Meter Specifications (If Equipped) 640
[DGH1KX] 642
HST Oil Showing Overheating Condition 642
load Meter Specifications (If Equipped) 644
[DGR4KA] 646
Axle Oil Indicating Short Circuit 646
Load Meter Specifications (If Equipped) 648
[DGR4KX] 650
Brake Cooling Oil Indicating Open Circuit 650
Load Meter Specifications (If Equipped) 652
[DHE4L6] 654
Engine Oil Pressure Indicating A Short Or Open In The System 654
Load Meter Specifications (If Equipped) 656
[DHPCKX] 658
Possible Defective Bottom Pressure Sensor 658
[DHPDKX] 660
Possible Defective Rod Pressure Sensor 660
[DKA0KX] 662
Possible Defective Boom Angle Sensor 662
[DV00KB] 664
Possible Short Or Open In Alarm Buzzer 664
[MON-1] 666
Parking Brake Indicator Lamp Does Not Work 666
Load Meter Specifications (If Equipped) 670
[MON-2] 675
Brake Oil Pressure Not Indicating Correctly 675
Load Meter Specifications (If Equipped) 677
[MON-3] 679
Engine Coolant Sensor Not Indicating Correctly 679
Load Meter Specifications (If Equipped) 681
[MON-4] 683
HST Oil Temperature Not Indicating Correctly 683
[MON-5] 687
Fuel Level Gauge Does Not Indicate Properly 687
Load Meter Specifications (If Equipped) 689
[MON-6] 691
Abnormal Coolant Level Indication 691
Load Meter Specifications (If Equipped) 693
[MON-7] 695
Steering Oil Pressure Not Reading Correctly 695
Load Meter Specifications (If Equipped) 697
[MON-8] 699
Emergency Steering Oil Pressure Not Reading Correctly 699
Load Meter Specifications (If Equipped) 701
[MON-9] 703
Monitor Panel Mode Selector Switch Will Not Set Correctly 703
Load Meter Specifications (If Equipped) 705
[MON-10] 707
Monitor Panel Mode Selector Switch Will Not Set Correctly 707
Load Meter Specifications (If Equipped) 709
[MON-11] 711
Monitor Panel Mode Selector Switch Will Not Set Correctly 711
Load Meter Specifications (If Equipped) 713
[MON-12] 715
Monitor Panel Mode Selector Switch Will Not Set Correctly 715
Load Meter Specifications (If Equipped) 717
[MON-13] 719
Alarm Buzzer Does Not Stop Or Remains ON 719
Load Meter Specifications (If Equipped) 721
[MON-14] 723
Abnormal Engine Oil Level Indication 723
Load Meter Specifications (If Equipped) 725
[MON-15] 727
Clogged Air Cleaner Indicated 727
Load Meter Specifications (If Equipped) 729
[MON-16] 731
Defective Cancel Switch 731
[MON-17] 733
Defective Subtotal Switch 733
[MON-18] 735
Possible Defective Bottom Pressure Sensor 735
[MON-19] 737
Possible Defective Rod Pressure Sensor 737
[MON-20] 739
Front Windshield Wiper Does Not Work 739
Rear Windshield Wiper Does Not Work 741
[MON-21] 743
Headlamps (Lo And High Beam) Does Not Function 743
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 747
POINTS TO REMEMBER WHEN TROUBLESHOOTING 749
Points To Remember If Abnormality Returns To Normal 749
User Code Memory Retention Function 749
FUSE SYSTEM CHECK 750
Fuse Panel Connection Table 750
INFORMATION CONTAINED IN TESTING PROCEDURES 751
(E-1) 753
Engine Will Not Crank 753
When Directional Selector Actuation Switch Is Turned OFF 753
When Directional Selector Actuation Switch Is Turned ON 757
Defective Fuel Cut Solenoid System 758
When Directional Selector Actuation Switch Is Turned ON (Load Meter Specification) 765
Defective Fuel Cut Solenoid System (Load Meter Specification) 766
(E-2) 770
The Engine Does Not Shut Down 770
(E-3) 773
Cold Start Pre-heater Does Not Work Properly 773
Preheating Does Not Work At All 773
Preheat Is Constant 775
Preheating Does Not Work At All (Load Meter Specification) 778
Preheat Is Constant (Load Meter Specification 780
(E-4) 782
Parking Brake Does Not Function Properly 782
Parking Brake Dragging (Prevention Does Not Function) 782
(E-5) 792
Boom Kick-out Function Not Working Properly 792
(E-6) 795
Bucket Lever Function Not Working Properly 795
(E-7) 798
Float Hold Function Not Working Properly 798
(E-8) 801
Travel Direction Does Not Change (“F” Machine Does Not Travel Forward) 801
Travel Direction Does Not Change (“R” Machine Does Not Travel Reverse) 803
(E-9) 807
Front Windshield Wiper Does Not Work 807
Rear Windshield Wiper Does Not Work 811
(E-10) 813
The Window Washer Does Not Work 813
(E-11) 815
Headlamps (Lo And High Beam) Does Not Function 815
Headlamps (Lo Beam) Do Not Function 820
Headlamps (Hi Beam) Do Not Function 824
Clearance Lamps Do Not Function 828
Turn Signals Do Not Function 832
Work Lamps Do Not Function 836
(E-12) 840
Horn Does Not Sound 840
(E-13) 843
Air Conditioner System Does Not Work 843
Air Does Not Flow From System And Cannot Be Adjusted 846
Air Does Not Cool Or Temperature Cannot Be Adjusted 850
Cannot Switch Between Circulated And Vent Functions 854
Cannot Switch Vent Functions 856
DEFECTIVE COOLING (MECHANICAL) 859
DEFECTIVE HEATING (MECHANICAL) 860
ABNORMAL NOISE IS HEARD FROM SYSTEM (MECHANICAL) 861
WATER LEAKS FROM SYSTEM (MECHANICAL) 862
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE) 863
METHOD OF USING TROUBLESHOOTING CHART 865
FAILURE CODE AND CAUSE TABLE 868
(H-1) 870
The Machine Does Not Start 870
(H-2) 871
The Travel Speed Is Slow 871
(H-3) 872
The Thrust Force Is Weak 872
(H-4) 873
Engine Stalls Or Engine Speed Drops Excessively 873
(H-5) 874
The Gears Do Not Change Speed Range 874
(H-6) 875
The Steering Wheel Does Not Turn 875
(H-7) 876
Steering Wheel Movement Is Heavy 876
(H-8) 877
Steering Wheel Shakes Or Has Jerky Movement 877
(H-10) 878
Brakes Do Not Work Or Works Poorly 878
(H-11) 879
Brakes Is Not Releasing Or Dragged 879
(H-12) 880
The Lift Arm Does Not Rise Or Lower 880
(H-13) 881
Lift Arm Moves Slow Or Rising Force Is Poor 881
(H-14) 882
When Rising Lift Arm, Arm Moves Slowly At Specific Heights 882
(H-15) 882
The Lift Arm Cylinder Will Not Hold Down The Bucket (The Bucket Rises) 882
(H-16) 882
Hydraulic Drift On The Lift Arm Occurs Often 882
(H-17) 882
The Lift Arm Wobbles During Operation 882
(H-18) 883
When The Control Lever Is Switched From “Hold” To “Raise,” The Lift Arm Falls Temporarily 883
(H-19) 884
The Bucket Does Not Tilt Back 884
(H-20) 885
Bucket Moves Slow Or The Tilting-back Force Is Insufficient 885
(H-21) 886
The Bucket Operates Slowly In Tilting-back 886
(H-22) 886
Bucket Cylinder Cannot Hold Down The Bucket 886
(H-23) 886
Hydraulic Drifts Of The Bucket Occurs Often 886
(H-24) 887
The Bucket Wobbles During Travel With Cargo (The Work Equipment Valve Is Set To “Hold”) 887
(H-25) 887
When The Control Lever Is Switched From “Hold” To “Tilt,” The Bucket Falls Temporarily 887
(H-26) 888
Control Levers For The Lift Arm And Bucket Do Not Move Smoothly 888
(H-27) 889
Travel Damper Does Not Operate And Machine Pitches And Bounces 889
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 891
METHOD OF USING TROUBLESHOOTING CHARTS 892
(S-1) ENGINE STARTING PERFORMANCE IS POOR 896
(S-2) ENGINE HAS STARTING PROBLEMS 898
Engine Does Not Crank 898
Engine Cranks But No Exhaust Smoke Comes Out Of Stack 899
Smoke Comes Out Of Stack But Engine Does Not Start 900
(S-3) ENGINE DOES NOT RUN SMOOTHLY 901
(S-4) ENGINE STOPS DURING OPERATIONS 902
(S-5) ENGINE SPEED HUNTS 903
(S-6) ENGINE LACKS POWER 904
(S-7) EXHAUST SMOKE IS BLACK 905
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 906
(S-9) OIL BECOMES CONTAMINATED QUICKLY 907
(S-10) FUEL CONSUMPTION IS EXCESSIVE 908
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR 909
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP 910
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) 911
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) 912
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG 913
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING 914
30 DISASSEMBLY AND ASSEMBLY 915
HOW TO USE THIS MANUAL 918
Removal And Installation Of Componants 918
Special Tools 918
Overhaul Of Componants 919
Special Tools 919
Disassembly 919
Assembly 919
PRECAUTIONS WHEN CARRYING OUT AN OPERATION 920
SPECIAL TOOL LIST 922
Sketch Of Special Tools 926
CONNECTOR REPAIR PROCEDURES 931
Contact Terminal Removal (HD30 Type) 931
Striping Insulation 932
Crimping Contact Terminal (HD30 Type) 933
Insertion Of Contact Terminal (HD30 Type) 934
Contact Terminal Removal (DT Type) 935
Striping Insulation 936
Crimping Contact Terminal (DT Type) 937
Insertion Of Contact Terminal (DT Type) 938
ENGINE ASSEMBLY 939
Removal Procedures 939
Engine Installation 946
RADIATOR AND AFTER-COOLER 948
Radiator Removal Procedures 948
Radiator Installation Procedures 949
Aftercooler Removal Procedures 950
Aftercooler Installation Procedures 951
Hydraulic Oil Cooler Removal Procedures 952
COOLING FAN AND FAN MOTOR ASSEMBLY 954
Removal Procedures 954
Installation Procedures 955
FUEL TANK ASSEMBLY 956
Removal Procedures 956
Installation Procedures 958
TRANSFER ASSEMBLY 959
Removal Procedures 959
Installation Procedures 961
TRANSFER ASSEMBLY OVERHAUL PROCEDURES 962
Special Tools 962
Disassembly Procedures 962
Assembly Procedures 973
PARKING BRAKE ASSEMBLY 988
Removal Procedures 988
Installation Procedures 989
PARKING BRAKE ASSEMBLY OVERHAUL PROCEDURES 990
Special Tools 990
Disassembly Procedures 990
Assembly Procedures 992
FRONT AXLE ASSEMBLY 996
Removal Procedures 996
Installation Procedures 998
REAR AXLE ASSEMBLY 1000
Removal Procedures 1000
Installation Procedures 1002
FRONT AND REAR AXLE HOUSING OVERHAUL PROCEDURES 1004
Special Tools 1004
Disassembly Procedures 1004
Assembly Procedures 1010
DIFFERENTIAL CARRIER OVERHAUL PROCEDURES 1018
Special Tools 1018
Dissembly Procedures 1018
DISASSEMBLY OF STANDARD CARRIER 1024
Disassembly Of Anti-slip Differential 1026
Assembly Procedures 1030
Assembly Of Anti-slip Differential 1030
Assembly of Standard Differential Carrier 1035
HST AND 4-GEAR PUMP ASSEMBLY 1046
Removal Procedures 1046
Installation Procedures 1048
HST MOTOR 1 ASSEMBLY 1050
Removal Procedures 1050
Installation Procedures 1051
HST MOTOR 2 ASSEMBLY 1052
Removal Procedures 1052
Installation Procedures 1053
WORK EQUIPMENT CONTROL VALVE ASSEMBLY 1054
Removal Procedures 1054
Installation Procedures 1055
TRAVEL DAMPER VALVE ASSEMBLY 1058
Removal Procedures 1058
Installation Procedures 1059
HYDRAULIC TANK ASSEMBLY 1060
Removal Procedures 1060
Installation Procedures 1062
HST PUMP OVERHAUL PROCEDURES 1064
Special Tools List 1064
Disassembly Procedures 1064
Assembly Procedures 1077
HST MOTOR OVERHAUL PROCEDURES 1096
Special Tools List 1096
Disassembly Procedures 1096
Assembly Procedures 1107
CYLINDERS 1116
Bucket (Tilt) Cylinder 1116
Removal 1116
Installation 1117
Boom (Lift) Cylinder 1118
Removal 1118
Installation 1119
CYLINDER OVERHAUL PROCEDURES 1120
Special Tools List 1120
Disassembly Procedures 1120
Assembly Procedures 1123
WORK EQUIPMENT ASSEMBLY 1128
Removal Procedures 1128
Installation Procedure 1132
Procedure For Installing Bucket Link Pin 1132
Procedure For Installing Bucket Hinge Pin 1133
Procedure For Installing Bucket Cylinder Pin (On Rod Side) 1133
Procedure For Installing Boom Cylinder Pin (On Rod Side) 1134
Procedure For Installing Boom Pin (On Frame Side) 1134
Procedure For Installing Bucket Link Pin 1135
Procedure For Installing Bell Crank Center Pin 1136
OPERATOR’S CAB ASSEMBLY 1138
Special Tools 1138
Removal Procedures 1138
Installation Procedures 1143
OPERATOR’S CAB GLASS 1144
Special Tools 1144
Removal Procedures 1144
Installation Procedures 1146
Coating Materials 1154
CENTER HINGE PIN 1155
Special Tools 1155
Removal Procedures 1155
Installation Procedures 1162
REAR COUNTERWEIGHT 1168
Removal Procedures 1168
Installation Procedures 1169
AIR CONDITIONER UNIT 1170
Special Tools 1170
Removal Procedures 1170
Load Meter Specification 1171
Installation Procedures 1173
REFRIGERENT COMPRESSOR ASSEMBLY 1174
Special Tools 1174
Removal Procedures 1174
Installation Procedures 1175
MONITOR PANEL 1176
Removal Procedures 1176
Installation Procedures 1181
HST CONTROLLER 1182
Removal Procedures 1182
Installation Procedures 1183
KOMTRAX TERMINAL ASSEMBLY 1184
Removal 1184
Installation 1185
90 OTHER 1187
HYDRAULIC CIRCUIT DIAGRAM 1188
ELECTRICAL CIRCUIT DIAGRAM 1190
STANDARD FLOOR HARNESS 1190
LIGHT SWITCH AND FRONT WIPER 1190
MONITOR CONTROLLER 1191
TO CAB HARNESS 1192
TO REAR AND BULKHEAD HARNESS 1193
TO HST HARNESS 1194
TO SHORT CONNECTOR 1195
TO HST CONTROLLER 1196
AIR CONDITIONER RELAY HARNESS 1197
JOINT CONNECTOR 1198
FLOOR HARNESS FOR LOAD METER 1199
LIGHT SWITCH AND FRONT WIPER 1199
MONITOR CONTROLLER 1200
TO CAB HARNESS 1201
TO REAR AND BULKHEAD HARNESS 1202
TO HST HARNESS 1203
TO KOMTRAX 1204
HST CONTROLLER 1205
AIR CONDITIONER RELAY HARNESS 1206
JOINT CONNECTOR 1207
HST AND BULK HEAD HARNESS 1208
GRILL HARNESS 1209
ENGINE AND POWER SUPPLY HARNESS 1210
CAB HARNESS 1211
EMERGENCY STEERING AND MULTI-FUNCTION HARNESS 1212
LOAD METER AND PRINTER HARNESS 1213
FRONT HARNESS 1214

S.V 15/12/24