Komatsu WA350-1 Wheel Loader Service Repair Manual – PDF Download

Description

Komatsu WA350-1 Wheel Loader Service Repair Manual

Description:

Komatsu WA350-1 Wheel Loader Service Repair Manual

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 chapters for each main ‘group of components; these chapters are further divided into the following sections.
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 thejudgement standards when inspecting disassembled parts.

Table of Contents:

Komatsu WA350-1 Wheel Loader Service Repair Manual

MAIN MENU......................................................................................................................................  0
COVER..........................................................................................................................................  1
CONTENTS.......................................................................................................................................  2
10 ENGINE...................................................................................................................................... 17
	11 STRUCTURE AND FUNCTION.................................................................................................................. 17
		ENGINE MOUNT........................................................................................................................... 18
		RADIATOR............................................................................................................................... 19
		FUEL TANK AND PIPING................................................................................................................... 20
		ENGINE CONTROL......................................................................................................................... 21
	12 TESTING AND ADJUSTING................................................................................................................... 22
		STANDARD VALUE TABLE................................................................................................................... 23
		TOOL LIST FOR TESTING AND ADJUSTING.................................................................................................... 24
		ADJUSTING VALVE CLEARANCE.............................................................................................................. 25
		MEASURING COMPRESSION PRESSURE......................................................................................................... 26
		TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................ 27
		MEASURING ENGINE OIL PRESSURE AND TEMPERATURE.......................................................................................... 29
		MEASURING BLOW-BY PRESSURE............................................................................................................. 30
		TESTING AND ADJUSTING FAN BELT TENSION................................................................................................. 31
		MEASURING EXHAUST GAS COLOR............................................................................................................ 32
		MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE........................................................................ 33
		ADJUSTING FUEL CUT SOLENOID............................................................................................................ 35
	13 DISASSEMBLY AND ASSEMBLY................................................................................................................ 36
		STARTING MOTOR ASSEMBLY................................................................................................................ 37
			REMOVAL............................................................................................................................ 37
			INSTALLATION....................................................................................................................... 37
		ALTERNATOR ASSEMBLY.................................................................................................................... 38
			REMOVAL............................................................................................................................ 38
			INSTALLATION....................................................................................................................... 38
		FUEL INJECTION PUMP ASSEMBLY........................................................................................................... 39
			REMOVAL............................................................................................................................ 39
			INSTALLATION....................................................................................................................... 39
		WATER PUMP ASSEMBLY.................................................................................................................... 40
			REMOVAL............................................................................................................................ 40
			INSTALLATION....................................................................................................................... 40
		NOZZLE HOLDER ASSEMBLY................................................................................................................. 41
			REMOVAL............................................................................................................................ 41
			INSTALLATION....................................................................................................................... 41
		CYLINDER HEAD ASSEMBLY................................................................................................................. 42
			REMOVAL............................................................................................................................ 42
			INSTALLATION....................................................................................................................... 48
		TURBOCHARGER ASSEMBLY.................................................................................................................. 56
			REMOVAL............................................................................................................................ 56
			INSTALLATION....................................................................................................................... 56
		COMPRESSOR ASSEMBLY.................................................................................................................... 57
			REMOVAL............................................................................................................................ 57
			INSTALLATION....................................................................................................................... 57
		RADIATOR ASSEMBLY...................................................................................................................... 58
			REMOVAL ........................................................................................................................... 58
			INSTALLATION....................................................................................................................... 61
		OIL COOLER ASSEMBLY.................................................................................................................... 63
			REMOVAL............................................................................................................................ 63
			INSTALLATION....................................................................................................................... 63
		ENGINE ASSEMBLY........................................................................................................................ 64
			REMOVAL............................................................................................................................ 64
			INSTALLATION....................................................................................................................... 71
		FUEL TANK.............................................................................................................................. 78
			REMOVAL............................................................................................................................ 78
			INSTALLATION....................................................................................................................... 80
20 POWER TRAIN................................................................................................................................. 82
	21 STRUCTURE AND FUNCTION.................................................................................................................. 82
		GENERAL................................................................................................................................ 83
			HYDRAULIC CIRCUIT FOR POWER TRAIN.................................................................................................. 85
			HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.......................................................................................... 86
		TORQUE CONVERTER AND TRANSMISSION PIPING............................................................................................... 87
		TORQUE CONVERTER CHARGING PUMP......................................................................................................... 88
		TORQUE CONVERTER....................................................................................................................... 89
		TORQUE CONVERTER OIL FILTER............................................................................................................ 92
		TORQUE CONVERTER OIL COOLER............................................................................................................ 93
		TORQUE CONVERTER RELIEF VALVE.......................................................................................................... 94
		TRANSMISSION........................................................................................................................... 95
		TRANSMISSION CONTROL VALVE.............................................................................................................103
			UPPER VALVE........................................................................................................................105
			LOWER VALVE........................................................................................................................106
			TRANSMISSION SOLENOID VALVE........................................................................................................107
			EMERGENCY MANUAL SPOOL.............................................................................................................108
			PRIORITY VALVE.....................................................................................................................111
			MODULATING VALVE AND QUICK RETURN VALVE............................................................................................112
			ACCUMULATOR VALVE..................................................................................................................115
			PILOT REDUCING VALVE...............................................................................................................117
		TRANSMISSION PILOT FILTER..............................................................................................................118
		TRANSFER...............................................................................................................................119
		DRIVE SHAFT............................................................................................................................120
		AXLE MOUNT.............................................................................................................................121
		AXLE AND DIFFERENTIAL..................................................................................................................123
			TORQUE PROPORTIONING DIFFERENTIAL..................................................................................................128
		FINAL DRIVE............................................................................................................................129
		TIRE AND WHEEL.........................................................................................................................130
	22 TESTING AND ADJUSTING...................................................................................................................131
		STANDARD VALUE TABLE...................................................................................................................132
		TOOL LIST FOR TESTING AND ADJUSTING....................................................................................................133
		MEASURING ENGINE STALL SPEED...........................................................................................................134
		MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION............................................................................136
		MEASURING SHIFT LEVER..................................................................................................................138
		METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.........................................................................................139
		TIRE AND WHEEL.........................................................................................................................141
		TROUBLESHOOTING........................................................................................................................142
			PRECAUTIONS WHEN TROUBLESHOOTING...................................................................................................143
			METHOD OF READING TROUBLESHOOTING TABLE............................................................................................145
			PREVENTING RECURRENCE OF TROUBLE...................................................................................................147
			METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYTEM.....................................................148
			TROUBLESHOOTING TABLE..............................................................................................................149
				1. MACHINE DOES NOT MOVE.......................................................................................................149
				2. MACHINE LACKS POWER OR SPEED................................................................................................151
				3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...................................................................152
				4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH...................................................................................153
	23 DISASSEMBLY AND ASSEMBLY................................................................................................................154
		TORQUE CONVERTER CHARGING PUMP.........................................................................................................155
			REMOVAL............................................................................................................................155
			INSTALLATION.......................................................................................................................156
		TORQUE CONVERTER, TRANSMISSION, TRANSFER ASSEMBLY......................................................................................157
			REMOVAL............................................................................................................................157
			INSTALLATION.......................................................................................................................166
		TORQUE CONVERTER ASSEMBLY..............................................................................................................174
			DISASSEMBLY........................................................................................................................174
			ASSEMBLY...........................................................................................................................179
		TRANSMISSION ASSEMBLY..................................................................................................................185
			DISASSEMBLY........................................................................................................................185
			ASSEMBLY...........................................................................................................................198
		TRANSFER ASSEMBLY......................................................................................................................213
			DISASSEBLY.........................................................................................................................213
			ASSEMBLY...........................................................................................................................216
		TRANSMISSION CONTROL VALVE.............................................................................................................223
			REMOVAL............................................................................................................................223
			INSTALLATION.......................................................................................................................224
			LOWER VALVE........................................................................................................................225
				DISASSEMBLY....................................................................................................................225
				ASSEMBLY.......................................................................................................................225
			UPPER VALVE........................................................................................................................227
				DISASSEMBLY....................................................................................................................227
				ASSEMBLY.......................................................................................................................227
		FRONT DIFFERENTIAL.....................................................................................................................229
			REMOVAL............................................................................................................................229
			INSTALLATION.......................................................................................................................232
		REAR DIFFERENTIAL......................................................................................................................235
			REMOVAL............................................................................................................................235
			INSTALLATION.......................................................................................................................236
		DIFFERENTIAL...........................................................................................................................237
			DISASSEMBLY........................................................................................................................237
			ASSEMBLY...........................................................................................................................240
		FRONT AXLE.............................................................................................................................248
			REMOVAL............................................................................................................................248
			INSTALLATION.......................................................................................................................250
		REAR AXLE..............................................................................................................................252
			REMOVAL............................................................................................................................252
			INSTALLATION.......................................................................................................................256
		DRIVE SHAFT............................................................................................................................260
			DISASSEMBLY........................................................................................................................260
			ASSEMBLY...........................................................................................................................262
		FINAL DRIVE............................................................................................................................264
			DISASSEMBLY........................................................................................................................264
			ASSEMBLY ..........................................................................................................................267
	24 MAINTENANCE STANDARD....................................................................................................................271
		TRANSMISSION AND ENGINE MOUNT..........................................................................................................272
		TORQUE CONVERTER CHARGING PUMP.........................................................................................................273
		TORQUE CONVERTER.......................................................................................................................274
		TORQFLOW TRANSMISSION..................................................................................................................276
			1. TRANSMISSION....................................................................................................................276
			2. TRANSMISSION CONTROL VALVE......................................................................................................278
			3. SOLENOID VALVE..................................................................................................................282
		TRANSFER...............................................................................................................................283
		DIFFERENTIAL...........................................................................................................................285
		FINAL DRIVE............................................................................................................................287
		DRIVE SHAFT............................................................................................................................288
		AXLE MOUNT.............................................................................................................................289
40 STEERING SYSTEM.............................................................................................................................291
	41 STRUCTURE AND FUNCTION..................................................................................................................291
		GENERAL................................................................................................................................292
		HYDRAULIC CIRCUIT FOR STEERING.........................................................................................................294
			HYDRAULIC CIRCUIT DIAGRAM FOR STEERING.............................................................................................295
			OPERATIONS OF STEERING VALVE.......................................................................................................296
		STEERING CONTROL SYSTEM................................................................................................................298
			STEERING VALVE.....................................................................................................................298
			STEERING RELIEF VALVE..............................................................................................................300
			SAFETY VALVE (DIFFERENTIAL TYPE)...................................................................................................301
			OPERATION OF DEMAND POOL...........................................................................................................302
			TWO-WAY RESTICTOR VALVE............................................................................................................304
		STEERING CYLINDER......................................................................................................................305
		STEERING COLUMN AND GEAR BOX...........................................................................................................306
		CENTER HINGE PIN.......................................................................................................................307
		STEERING LINKAGE.......................................................................................................................308
		EMERGENCY STEERING PUMP (IF EQUIPPED)..................................................................................................309
		DIVERTER VALVE (IF EQUIPPED)...........................................................................................................310
		SECURITY VALVE (IF EQUIPPED)...........................................................................................................313
	42 TESTING AND ADJUSTING...................................................................................................................316
		STANDARD VALUE TABLE...................................................................................................................317
		TOOL LIST FOR TESTING AND ADJUSTING....................................................................................................317
		MEASURING STEERING WHEEL PLAY..........................................................................................................318
		MEASURING OPERATING FORCE OF STEERING WHEEL............................................................................................319
		OPERATING TIME OF STEERING WHEEL LOCK TO LOCK..........................................................................................320
		TESTING STEERING LINKAGE...............................................................................................................321
		ADJUSTING STEERING LINKAGE.............................................................................................................322
		STEERING OIL PRESSURE..................................................................................................................323
		TROUBLESHOOTING........................................................................................................................324
			TROUBLESHOOTING TABLE..............................................................................................................325
				1. STEERING WHEEL DOES NOT TURN................................................................................................325
				2. STEERING WHEEL IS SLUGGISH..................................................................................................326
				3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK..............................................................327
				4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING..................................................327
				5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT..................................................................................327
	43 DISASSEMBLY AND ASSEMBLY................................................................................................................328
		STEERING GEAR..........................................................................................................................329
			REMOVAL............................................................................................................................329
			INSTALLATION.......................................................................................................................330
			DISASSEMBLY........................................................................................................................331
			ASSEMBLY...........................................................................................................................332
		STEERING VALVE.........................................................................................................................335
			REMOVAL............................................................................................................................335
			INSTALLATION.......................................................................................................................337
			DISASSEMBLY........................................................................................................................339
			ASSEMBLY...........................................................................................................................339
		STEERING CYLINDER......................................................................................................................341
			REMOVAL............................................................................................................................341
			INSTALLATION.......................................................................................................................342
			DISASSEMBLY........................................................................................................................343
			ASSEMBLY...........................................................................................................................345
		CENTER HINGE PIN.......................................................................................................................348
			REMOVAL............................................................................................................................348
			INSTALLATION.......................................................................................................................356
	44 MAINTENANCE STANDARD....................................................................................................................365
		STEERING LINKAGE.......................................................................................................................366
		STEERING COLUMN AND GEAR BOX...........................................................................................................368
		STEERING VALVE.........................................................................................................................369
		STEERING CYLINDER MOUNT................................................................................................................371
		STEERING CYLINDER......................................................................................................................372
		CENTER HINGE PIN.......................................................................................................................373
		DIVERTER VALVE (IF EQUIPPED)...........................................................................................................375
		EMERGENCY STEERING PUMP (IF EQUIPPED)..................................................................................................377
		SECURITY VALVE (IF EQUIPPED)...........................................................................................................378
50 BRAKE AND AIR SYSTEM........................................................................................................................379
	51 STRUCTURE...............................................................................................................................379
		GENERAL................................................................................................................................380
		AIR TANK...............................................................................................................................383
		SAFETY VALVE...........................................................................................................................383
		BRAKE VALVE............................................................................................................................384
			BRAKE ACTUATED.....................................................................................................................385
			OPERATING IN BALANCE...............................................................................................................386
			BRAKE RELEASED.....................................................................................................................387
		AIR GOVERNOR...........................................................................................................................388
		TWO-WAY VALVE..........................................................................................................................390
		BRAKE CHAMBER..........................................................................................................................391
		SLACK ADJUSTER.........................................................................................................................393
		BRAKE..................................................................................................................................396
		PARKING BRAKE..........................................................................................................................398
		PARKING BRAKE SOLENOID VALVE...........................................................................................................400
		SPRING CYLINDER........................................................................................................................401
		BRAKE CALIPER..........................................................................................................................402
	52 TESTING AND ADJUSTING...................................................................................................................403
		STANDARD VALUE TABLE...................................................................................................................404
		TOOL LIST FOR TESTING AND ADJUSTING....................................................................................................405
		MEASURING BRAKE PEDAL..................................................................................................................406
		MEASURING AIR..........................................................................................................................407
		BRAKE PERFORMANCE......................................................................................................................410
		CHECKING BRAKE PISTON LEAKAGE..........................................................................................................411
		MEASURING WEAR OF BRAKE DISC...........................................................................................................412
		AIR BLEEDING FROM BRAKE LINE...........................................................................................................413
		PARKING BRAKE PERFORMANCE..............................................................................................................414
		CHECKING AND ADJUSTING PARKING BRAKE...................................................................................................415
		TROUBLESHOOTING........................................................................................................................417
			TROUBLESHOOTING....................................................................................................................418
			1. AIR PRESSURE DOES NOT RISE AT ALL...............................................................................................418
			2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE...............................................................................419
			3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE......................................................................................420
			4. BRAKE DOES NOT RELEASE, OR DRAGS................................................................................................421
			5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS .......................................................................................422
	53 DISASSEMBLY AND ASSEMBLY................................................................................................................423
		AIR GOVERNOR...........................................................................................................................424
			DISASSEMBLY........................................................................................................................424
			ASSEMBLY...........................................................................................................................425
		BRAKE VALVE............................................................................................................................426
			REMOVAL............................................................................................................................426
			INSTALLATION.......................................................................................................................427
			DISASSEMBLY........................................................................................................................428
			ASSEMBLY...........................................................................................................................430
		BRAKE CHAMBER..........................................................................................................................432
			REMOVAL............................................................................................................................432
			INSTALLATION.......................................................................................................................434
			DISASSEMBLY........................................................................................................................435
			ASSEMBLY...........................................................................................................................438
		SLACK ADJUSTER.........................................................................................................................441
			REMOVAL............................................................................................................................441
			INSTALLATION.......................................................................................................................441
			DISASSASSEMBLY.....................................................................................................................442
			ASSEMBLY...........................................................................................................................443
		BRAKE ASSEMBLY.........................................................................................................................444
			DISASSEMBLY........................................................................................................................444
			ASSEMBLY...........................................................................................................................451
		SPRING CYLINDER........................................................................................................................459
			REMOVAL............................................................................................................................459
			INSTALLATION.......................................................................................................................460
			DISASSEMBLY........................................................................................................................461
			ASSEMBLY...........................................................................................................................463
		PARKING BRAKE..........................................................................................................................465
			REMOVAL............................................................................................................................465
			INSTALLATION.......................................................................................................................467
		PARKING BRAKE PAD......................................................................................................................469
			REMOVAL............................................................................................................................469
			INSTALLATION.......................................................................................................................470
	54 MAINTENANCE STANDARD....................................................................................................................471
		BRAKE VALVE............................................................................................................................472
		BRAKE CHAMBER..........................................................................................................................474
		SLACK ADJUSTER.........................................................................................................................475
		BRAKE..................................................................................................................................476
		PARKING BRAKE..........................................................................................................................478
		SPRING CYLINDER........................................................................................................................479
60 WORK EQUIPMENT SYSTEM.......................................................................................................................480
	61 STRUCTURE AND FUNCTION..................................................................................................................480
		GENERAL................................................................................................................................481
		HYDRAULIC CIRCUIT SYSTEM ..............................................................................................................483
		HYDRAULIC CIRCUIT DIAGRAM (FOR 2-SPOOL)................................................................................................484
		HYDRAULIC CIRCUIT DIAGRAM (FOR 3-SPOOL, WITH EMERGENCY STEERING (IF EQUIPPED)).........................................................485
		BUCKET LINKAGE.........................................................................................................................486
		BUCKET POSITIONER AND BOOM KICK-OUT....................................................................................................489
		HYDRAULIC TANK.........................................................................................................................491
			OIL FILTER BYPASS VALVE............................................................................................................492
			BREATHER...........................................................................................................................492
		HYDRAULIC AND STEERING PUMPS...........................................................................................................493
		MAIN CONTROL VALVE  (FOR 2-SPOOL)......................................................................................................494
		MAIN CONTROL VALVE (FOR 3-SPOOL (IF EQUIPPED)).........................................................................................496
			RELIEF VALVE.......................................................................................................................504
			SAFETY VALVE.......................................................................................................................505
			SUCTION VALVE......................................................................................................................506
		HYDRAULIC CYLINDER.....................................................................................................................507
	62 TESTING AND ADJUSTING...................................................................................................................509
		STANDARD VALUE TEST....................................................................................................................510
		TOOL LIST FOR TESTING AND ADJUSTING....................................................................................................511
		MEASURING DUMP AND LIFT CONTROL LEVERS.................................................................................................512
		ADJUSTING DUMP AND LIFT CONTROL LEVERS.................................................................................................513
		MEASURING HYDRAULIC PRESSURE...........................................................................................................514
		MEASURING LIFT ARM AND BUCKET..........................................................................................................516
		MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET.......................................................................................517
		ADJUSTING BUCKET POSITIONER............................................................................................................518
		ADJUSTING BOOM KICK-OUT................................................................................................................519
		TROUBLESHOOTING........................................................................................................................520
			TROUBLESHOOTING TABLE..............................................................................................................521
			1. LIFT ARM DOES NOT RISE..........................................................................................................521
			2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.................................................................522
			3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT................................................................523
			4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER...............................................................................523
			5. LIFT ARM HAS LARGE HYDRAULIC DRIFT..............................................................................................523
			6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK.......................................................................................523
			7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"..............................................523
			8. BUCKET DOES NOT TILT BACK.......................................................................................................524
			9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER.........................................................................525
			10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK..................................................................................526
			11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER..............................................................................526
			12.  BUCKET HAS LARGE HYDRAULIC DRIFT..............................................................................................526
			13.BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVEL UNDER LOAD (MAIN CONTROL VALVE IN "HOLD")...........................................526
			14. BUCKET DUMPS MOMENTARILY WHEN CONTROL..........................................................................................526
			15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY................................................................527
	63 DISASSEMBLY AND ASSEMBLY................................................................................................................528
		HYDRAULIC TANK.........................................................................................................................529
			REMOVAL............................................................................................................................529
			INSTALLATION.......................................................................................................................531
		HYDRAULIC FILTER.......................................................................................................................533
			REMOVAL ...........................................................................................................................533
			INSTALLATION.......................................................................................................................533
		HYDRAULIC, STEERING PUMP...............................................................................................................534
			REMOVAL............................................................................................................................534
			INSTALLATION.......................................................................................................................537
		MAIN CONTROL VALVE.....................................................................................................................540
			REMOVAL............................................................................................................................540
			INSTALLATION.......................................................................................................................543
			DISASSEMBLY........................................................................................................................545
			ASSEMBLY...........................................................................................................................547
		DUMP CYLINDER..........................................................................................................................549
			REMOVAL............................................................................................................................549
			INSTALLATION.......................................................................................................................551
		LIFT CYLINDER..........................................................................................................................552
			REMOVAL............................................................................................................................552
			INSTALLATION.......................................................................................................................553
		HYDRAULIC CYLINDER ASSEMBLY............................................................................................................554
			DISASSEMBLY........................................................................................................................554
			ASSEMBLY...........................................................................................................................556
		WORK EQUIPMENT.........................................................................................................................559
			REMOVAL............................................................................................................................559
			INSTALLATION.......................................................................................................................562
		COUNTERWEIGHT..........................................................................................................................565
			REMOVAL............................................................................................................................565
			INSTALLATION.......................................................................................................................565
	64 MAINTENANCE STANDARD....................................................................................................................566
		MAIN CONTROL VALVE (FOR 2-SPOOL).......................................................................................................567
		MAIN CONTROL VALVE (FOR 3-SPOOL)(IF EQUIPPED)..........................................................................................569
		DUMP CYLINDER..........................................................................................................................571
		LIFT CYLINDER..........................................................................................................................572
		BUCKET LINKAGE.........................................................................................................................573
		BUCKET POSITIONER AND BOOM KICK-OUT....................................................................................................575
		BUCKET.................................................................................................................................576
		HYDRAULIC AND STEERING PUMP............................................................................................................577
80 ELECTRIC AND ELECTRONIC SYSTEM..............................................................................................................578
	81 STRUCTURE AND FUNCTION..................................................................................................................578
		ELECTRIC AND ELECTRONIC SYSTEM.........................................................................................................579
		ELECTRICAL WIRING DIAGRAM..............................................................................................................  0
		ELECTRICAL WIRING DIAGRAM CIRCUIT......................................................................................................582
		ENGINE STARTING CIRCUIT................................................................................................................592
		ENGINE STOP CIRCUIT....................................................................................................................593
		PREHEATING CIRCUIT.....................................................................................................................594
			PREHEATING WITH HEATER CIRCUIT.....................................................................................................594
			PREHEATING WITH STARTING SWITCH....................................................................................................595
			AUTOMATIC PREHEATING...............................................................................................................596
		COMBINATION SWITCH.....................................................................................................................597
		ELECTRICAL TRANSMISSION CONTROL........................................................................................................598
			ELECTRICAL TRANSMISSION CONTROL DIAGRAM............................................................................................599
			TRANSMISSION CUT-OFF SWITCH........................................................................................................600
			TRANSMISSION CUT-OFF SELECTOR SWITCH...............................................................................................601
			NEUTRALIZER  RELAY.................................................................................................................602
		ELECTRICAL PARKING BRAKE CONTROL.......................................................................................................603
		ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)............................................................................................612
			MONITOR PANEL......................................................................................................................612
			INDICATION ON MONITOR PANEL........................................................................................................614
			CONTROLLER.........................................................................................................................616
			SENSOR.............................................................................................................................617
			WIRING HARNESS.....................................................................................................................623
			OPERATION OF PROXIMITY SWITCH......................................................................................................624
	82 TESTING AND ADJUSTING...................................................................................................................628
		ADJUSTING SPEEDOMETER MODULE IN THE VEHICLE MONITOR....................................................................................629
		TROUBLESHOOTING........................................................................................................................630
			BEFORE TROUBLESHOOTING.............................................................................................................631
			METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART..................................................................................632
			CONNECTOR TERMINAL NUMBERS.........................................................................................................634
			PRECAUTION WHEN HANDLING CONNECTOR.................................................................................................639
			ELECTRICAL WIRING DIAGRAM..........................................................................................................  0
			ELECTRICAL CIRCUIT SYSTEM..........................................................................................................  0
			TROUBLESHOOTING CHART FOR ELECTRIC DIAGRAM.........................................................................................647
				E-1 ENGINE DOES NOT START......................................................................................................648
				E-2 ENGINE DOES NOT STOP.......................................................................................................651
				E-3 ENGINE STOPS WHEN TRAVELING................................................................................................651
				E-4 PARKING BRAKE DOES NOT WORK................................................................................................652
				E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING....................................................................................654
				E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON.............................................................658
				E-7 TRANSMISSION IS NOT RETURENED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.....................................................658
				E-8 MACHINE DOES NOT TRAVEL FORWARD............................................................................................660
				E-9 MACHINE DOES NOT TRAVEL REVERSE............................................................................................664
				E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL)......................................................................668
				E-11 MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SWITCH IS ON............................................................670
				E-12 TRANSMISSION CANNOT BE CUT-OFF............................................................................................670
				E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL...................................................................................672
				E-14 PREHEATING DISPLAY DOES NOT GO OUT........................................................................................675
				E-15 PREHEATING DOES NOT WORK..................................................................................................675
			ELECTRONIC VEHICLE MONITORING SYSTEM...............................................................................................677
			TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM).......................................................................  0
			TROUBLESHOOTING CHART FOR ELECTRIC VEHICLE MONITORING SYSTEM (M-1 TO M-33).........................................................680
				M-1 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNORMALITY IN MACHINE, BRAKE OIL LEVEL DISPLAY FLASHES......................681
				M-2 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNORMALITY IN MACHINE, ENGINE OIL LEVEL DISPLAY FLASHES.....................681
				M-3 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNOMALITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES.........................683
				M-4 BATTERY CHARGE DISPLAY FLASHES.............................................................................................683
				M-5 FUEL LEVEL DISPLAY FLASHES.................................................................................................685
				M-6 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NO ABNORMLITY IN MACHINE FAILURE IN BRAKE LINE DISPLAY FLASHES...................685
				M-7 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNORMALITY IN MACHINE, ENGINE OIL PRESSURE DISPLAY FLASHES..................687
				M-8 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNORMLITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES.........................687
				M-9 EVEN WHEN ENGINE IS STOPPED AND THERE IS NOT ABNORMALITY IN MACHINE, DROP IN AIR PRESSURE DISPLAY FLASHES..................689
				M-10 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NO ABNORMALITY IN MACHINE, COOLANT TEMPERATURE DISPLAY FLASHES..................689
				M-11 EVEN WHEN ENGINE IS STOPPED, AND THERE IS NOT ABNORMALITY IN MACHINE, TORQUE CONVERTER OIL TEMPERATUER DISPLAY FLASHES....690
				M-12 PARKING BRAKE DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP..........................................................691
				M-13 WORKING LAMP DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP...........................................................693
				M-14 PREHEAT DISPLAY LIGHTS UP ABNORMALLY......................................................................................695
				M-15 FAILURE IN MAIN STEERING DISPLAY LIGHT UP ABNORMALLY, OR DOES NOT LIGHT UP (IF EQUIPPED)..................................697
				M-16 EMERGENCY STEERING  NORMAL DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT  LIGHT UP (IF EQUIPPED)..............................699
				M-17 TRANSMISSION CUT-OFF DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT  LIGHT UP..................................................701
				M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DOES NOT LIGHT UP....................................................703
				M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY................................................................................707
				M-20 SERVICEMETER DISPLAY DOES NOT WORK NORMALLY...............................................................................709
				M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK NORMALLY, IF ANY FUSE IS BROKEN, REPLACE AFTER CHECKING........................711
				M-22 EVEN WHEN ENGINE STOPPED, ENGINE OIL PRESSURE DISPLAY FLASHES, OR BATTERY CHARGE DISPLAY FLASHES..........................713
				M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)............................714
				M-24 CENTRAL WARNING LAMP DOES NOT GO OUT......................................................................................715
				M-25 CENTRAL WARNING BUZZER DOES NOT STOP......................................................................................717
				M-26 NONE OF PANEL LAMPS ON MONITOR LIGHT UP...................................................................................719
				M-27 SOME OF PANEL LAMPS ON MONITOR DO NOT LIGHT UP............................................................................722
				M-28 EMERGENGY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND...............................................................724
				M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH.........................................726
				M-30 ABNORMALITY IN FUEL GAUGE.................................................................................................728
				M-30-1 ABNORMALTIY IN FUEL GAUGE SENSOR........................................................................................729
				M-31 ABNORMALITY IN AIR PRESSURE GAUGE.........................................................................................730
				M-32 ABNORMALITY IN COOLANT TEMPERATUERE GAUGE.................................................................................732
				M-33 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....................................................................734
	83 DISASSEMBLY AND ASSEMBLY................................................................................................................736
		MACHINE MONITOR........................................................................................................................737
			REMOVAL............................................................................................................................737
			INSTALLATION.......................................................................................................................737
90 OTHERS......................................................................................................................................738
	91 OTHERS..................................................................................................................................738
		CAB....................................................................................................................................739
		AIR CONDITIONER (IF EQUIPPED)..........................................................................................................740
			PIPING.............................................................................................................................740
			AIR CONDITIONER WIRING DIAGRAM.....................................................................................................741
			AIR CONDITIONER ELECTRIC CIRCUIT...................................................................................................741
			AIR CONDITIONER UNIT...............................................................................................................742
	93 DISASSEMBLY AND ASSEMBLY................................................................................................................745
		CAB....................................................................................................................................746
			REMOVAL............................................................................................................................746
			INSTALLATION.......................................................................................................................747
		AIR CONDITIONER UNIT...................................................................................................................748
			REMOVAL............................................................................................................................748
			INSTALLATION.......................................................................................................................750
		CONDENSER FOR AIR CONDITIONER..........................................................................................................752
			REMOVAL............................................................................................................................752
			INSTALLATION.......................................................................................................................752
		DRY RECEIVER...........................................................................................................................753
			REMOVAL ...........................................................................................................................753
			INSTALLATION.......................................................................................................................753
		COMPRESSOR FOR AIR CONDITIONER.........................................................................................................754
			REMOVAL ...........................................................................................................................754
			INSTALLATION.......................................................................................................................754
	97 GEAR PUMP...............................................................................................................................755
		97 GENERAL.............................................................................................................................756
			GENERAL............................................................................................................................757
			PRINCIPLE OF OPERATION.............................................................................................................758
			PRESSURE LOADED TYPE GEAR PUMP.....................................................................................................761
			FIXED SIDE PLATE TYPE GEAR PUMP....................................................................................................763
		97 SA SERIES...........................................................................................................................764
			STRUCTURE..........................................................................................................................765
			TESTING AND ADJUSTING..............................................................................................................768
			DISASSEMBLY........................................................................................................................771
			ASSEMBLY...........................................................................................................................775
			MAINTENANCE STANDARD...............................................................................................................780

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