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KOMATSU WA450-1 SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU WA450-1 SERVICE REPAIR MANUAL
- SERIAL No: 10001 and up
- PUBLICATION NUMBER:SEBMA4210108
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Description
KOMATSU WA450-1 SERVICE REPAIR MANUAL
KOMATSU WA450-1 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU WA450-1 SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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 gr0up of compenents; 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 ‘eference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. ‘ Troubleshooting charts correlating “Problems” to “Causes” are also included in this section - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing. disassembling or assembling each component. as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU WA450-1 SERVICE REPAIR MANUAL
COVER................................................................................................................................................ 1 CONTENTS............................................................................................................................................. 2 01 GENERAL........................................................................................................................................... 18 WEIGHT TABLE..................................................................................................................................... 19 TABLE OF OIL AND COOLANT QUANTITIES.............................................................................................................. 21 10 ENGINE............................................................................................................................................ 22 11 STRUCTURE AND FUNCTION........................................................................................................................ 22 ENGINE MOUNT................................................................................................................................. 23 RADIATOR..................................................................................................................................... 24 FUEL TANK AND PIPING......................................................................................................................... 25 ENGINE CONTROL............................................................................................................................... 26 12 TESTING AND ADJUSTING......................................................................................................................... 27 STANDARD VALUE TABLE......................................................................................................................... 28 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................... 30 ADJUSTING VALVE CLEARANCE.................................................................................................................... 31 MEASURING COMPRESSION PRESSURE............................................................................................................... 32 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................................. 33 MEASURING BLOW-BY PRESSURE................................................................................................................... 35 TESTING AND ADJUSTING FAN BELT TENSION....................................................................................................... 36 MEASURING EXHAUST COLOR...................................................................................................................... 37 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE.............................................................................. 38 TESTING AND ADJUSTING FUEL CUT SOLENOID...................................................................................................... 42 13 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 43 STARTING MOTOR............................................................................................................................... 44 REMOVAL.................................................................................................................................. 44 INSTALLATION............................................................................................................................. 44 ALTERNATOR ASSEMBLY.......................................................................................................................... 45 REMOVAL ................................................................................................................................. 45 INSTALLATION............................................................................................................................. 45 FUEL INJECTION PUMP ASSEMBLY................................................................................................................. 46 REMOVAL ................................................................................................................................. 46 INSTALLATION............................................................................................................................. 46 WATER PUMP ASSEMBLY.......................................................................................................................... 47 REMOVAL.................................................................................................................................. 47 INSTALLATION............................................................................................................................. 47 NOZZLE HOLDER ASSEMBLY....................................................................................................................... 48 REMOVAL ................................................................................................................................. 48 INSTALLATION............................................................................................................................. 49 TURBOCHARGER................................................................................................................................. 50 REMOVAL.................................................................................................................................. 50 INSTALLATION............................................................................................................................. 50 CYLINDER HEAD ASSEMBLY....................................................................................................................... 51 REMOVAL.................................................................................................................................. 51 INSTALLATION............................................................................................................................. 57 RADIATOR ASSEMBLY............................................................................................................................ 64 REMOVAL.................................................................................................................................. 64 INSTALLATION............................................................................................................................. 67 OIL COOLER ASSEMBLY.......................................................................................................................... 69 REMOVAL.................................................................................................................................. 69 INSTALLATION............................................................................................................................. 69 ENGINE ASSEMBLY.............................................................................................................................. 70 REMOVAL.................................................................................................................................. 70 INSTALLATION............................................................................................................................. 76 FUEL TANK ASSEMBLY........................................................................................................................... 82 REMOVAL.................................................................................................................................. 82 INSTALLATION............................................................................................................................. 83 14 MAINTENANCE STANDARD.......................................................................................................................... 84 ENGINE MOUNT................................................................................................................................. 85 20 POWER TRAIN....................................................................................................................................... 86 21 STRUCTURE AND FUNCTION........................................................................................................................ 86 GENERAL...................................................................................................................................... 87 HYDRAULIC CIRCUIT FOR POWER TRAIN........................................................................................................ 89 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN................................................................................................ 90 TRANSMISSION MOUNT........................................................................................................................... 92 DAMPER....................................................................................................................................... 93 TORQUE CONVERTER AND TRANSMISSION PIPING..................................................................................................... 95 TORQUE CONVERTER CHARGING PUMP............................................................................................................... 96 TORQUE CONVERTER............................................................................................................................. 97 TORQUE CONVERTER OIL FILTER.................................................................................................................. 100 TORQUE CONVERTER OIL COOLER.................................................................................................................. 101 TORQUE CONVERTER RELIEF VALVE................................................................................................................ 102 TRANSMISSION................................................................................................................................. 103 TRANSMISSION CONTROL VALVE................................................................................................................... 111 UPPER VALVE.............................................................................................................................. 115 LOWER VALVE.............................................................................................................................. 116 TRANSMISSION SOLENOID VALVE.............................................................................................................. 119 EMERGENCY MANUAL SPOOL................................................................................................................... 120 PRIORITY VALVE........................................................................................................................... 123 MODULATING VALVE AND QUICK RETURN VALVE.................................................................................................. 124 ACCUMULATOR VALVE........................................................................................................................ 127 PILOT REDUCING VALVE..................................................................................................................... 129 TRANSMISSION PILOT FILTER.................................................................................................................... 132 TRANSFER..................................................................................................................................... 133 DRIVE SHAFT.................................................................................................................................. 134 AXLE MOUNT................................................................................................................................... 135 AXLE AND DIFFERENTIAL........................................................................................................................ 139 TORQUE PROPORTIONING DIFFERENTIAL........................................................................................................ 144 FINAL DRIVE.................................................................................................................................. 145 TIRE AND WHEEL............................................................................................................................... 147 22 TESTING AND ADJUSTING......................................................................................................................... 148 STANDARD VALUE TABLE......................................................................................................................... 149 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................... 150 MEASURING ENGINE STALL SPEED................................................................................................................. 151 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.................................................................................. 153 MEASURING SHIFT LEVER........................................................................................................................ 155 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL............................................................................................... 156 TIRE AND WHEEL .............................................................................................................................. 158 TROUBLESHOOTING.............................................................................................................................. 159 PRECAUTIONS WHEN TROUBLESHOOTING......................................................................................................... 160 METHOD OF READING TROUBLESHOOTING TABLE.................................................................................................. 162 PREVENTING RECURRENCE OF TROUBLE......................................................................................................... 164 JUDGEMENT ON POWER TRAIN................................................................................................................. 165 TROUBLESHOOTING TABLE.................................................................................................................... 168 1. MACHINE DOES NOT MOVE............................................................................................................. 168 2. MACHINE LACKS POWER OR SPEED (ALL SPEED RANGE).................................................................................... 170 3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR......................................................................... 171 4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH......................................................................................... 172 23 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 173 DAMPER....................................................................................................................................... 174 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999)........................................................................................ 174 REMOVAL AND INSTALLATION (20001-UP)...................................................................................................... 175 DISASSEMBLY (SERIAL NO. 10001-19999)..................................................................................................... 176 DISASSEMBLY (SERIAL NO. 20001 AND UP).................................................................................................... 180 ASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................ 178 ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................................... 182 TORQUE CONVERTER CHARGING PUMP............................................................................................................... 186 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999......................................................................................... 186 REMOVAL (SERIAL NO. 20001 AND UP......................................................................................................... 187 INSTALLATION (SERIAL NO. 20001 AND UP).................................................................................................. 188 TORQUE CONVERTER AND TRANSMISSION............................................................................................................ 189 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 189 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 197 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 207 INSTALLATION (SERIAL NO. 20001AND UP..................................................................................................... 215 TORQUE CONVERTER ASSEMBLY.................................................................................................................... 224 DISASSEMBLY.............................................................................................................................. 224 ASSEMBLY................................................................................................................................. 228 TRANSMISSION ASSEMBLY........................................................................................................................ 234 DISASSEMBLY.............................................................................................................................. 234 ASSEMBLY................................................................................................................................. 249 TRANSFER ASSEMBLY............................................................................................................................ 264 DISASSEMBLY.............................................................................................................................. 264 ASSEMBLY................................................................................................................................. 268 TRANSMISSION CONTROL VALVE................................................................................................................... 275 REMOVAL.................................................................................................................................. 275 INSTALLATION............................................................................................................................. 278 DISASSEMBLY AND ASSEMBLEY................................................................................................................ 281 FRONT DIFFERENTIAL........................................................................................................................... 285 REMOVAL.................................................................................................................................. 285 INSTALLATION............................................................................................................................. 289 REAR DIFFERENTIAL............................................................................................................................ 293 REMOVAL.................................................................................................................................. 293 INSTALLATION............................................................................................................................. 297 DIFFERENTIAL................................................................................................................................. 304 DISASSEMBLY.............................................................................................................................. 301 ASSEMBLY................................................................................................................................. 304 FRONT AXLE................................................................................................................................... 312 REMOVAL.................................................................................................................................. 312 INSTALLATION............................................................................................................................. 315 REAR AXLE.................................................................................................................................... 318 REMOVAL.................................................................................................................................. 318 INSTALLATION............................................................................................................................. 323 DRIVE SHAFT.................................................................................................................................. 328 DISASSEMBLY.............................................................................................................................. 328 ASSEMBLY................................................................................................................................. 330 FINAL DRIVE.................................................................................................................................. 332 DISASSEMBLY.............................................................................................................................. 332 ASSEMBLY................................................................................................................................. 336 24 MAINTENANCE STANDARD.......................................................................................................................... 341 TRANSMISSION MOUNT........................................................................................................................... 342 TORQUE CONVERTER CHARGING PUMP............................................................................................................... 343 DAMPER....................................................................................................................................... 344 TORQUE CONVERER.............................................................................................................................. 347 TORQFLOW TRANSMISSION........................................................................................................................ 349 1. TRANSMISSION.......................................................................................................................... 349 2. TRANSMISSION CONTROL VALVE............................................................................................................ 352 3. SOLENOID VALVE........................................................................................................................ 362 TRANSFER..................................................................................................................................... 363 DIFFERENTIAL................................................................................................................................. 365 FINAL DRIVE.................................................................................................................................. 369 DRIVE SHAFT.................................................................................................................................. 371 AXLE MOUNT................................................................................................................................... 372 40 STEERING SYSTEM................................................................................................................................... 374 41 STRUCTURE AND FUNCTION........................................................................................................................ 374 GENERAL...................................................................................................................................... 375 HYDRAULIC CIRCUIT FOR STEERING............................................................................................................... 377 STEERING VALVE............................................................................................................................... 383 TWO-WAY RESTRICTOR VALVE..................................................................................................................... 404 ORBIT-ROLL VALVE............................................................................................................................. 405 STOP VALVE................................................................................................................................... 409 STEERING PUMP................................................................................................................................ 410 STEERING CYLINDER............................................................................................................................ 411 STEERING COLUMN AND GEAR BOX................................................................................................................. 412 STEERING LINKAGE............................................................................................................................. 413 STEERING COLUMN AND ORBIT-ROLL............................................................................................................... 414 CENTER HINGE PIN............................................................................................................................. 415 42 TESTING AND ADJUSTING......................................................................................................................... 417 STANDARD VALUE TABLE......................................................................................................................... 418 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................... 418 MEASURING STEERING WHEEL PLAY................................................................................................................ 419 MEASURING OPERATING FORCE OF STEERING WHEEL.................................................................................................. 420 OPERATING TIME OF STEERING WHEEL............................................................................................................. 421 TESTING STEERING LINKAGE..................................................................................................................... 422 ADJUSTING STEERING LINKAGE................................................................................................................... 423 STEERING OIL PRESSURE........................................................................................................................ 424 TROUBLESHOOTING.............................................................................................................................. 426 TROUBLESHOOTING TABLE (SERIAL NO. 10001 - 20000)......................................................................................... 427 1. STEERING WHEEL DOES NOT TURN...................................................................................................... 427 2. STEERING WHEEL IS SLUGGISH........................................................................................................ 428 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.................................................................... 429 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING........................................................ 429 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT........................................................................................ 429 TROUBLESHOOTING TABLE (SERIAL NO. 20001 AND UP)......................................................................................... 430 1. STEERING WHEEL DOES NOT TURN...................................................................................................... 430 2. STEERING WHEEL IS SLUGGISH........................................................................................................ 431 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.................................................................... 432 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELLING....................................................... 432 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT........................................................................................ 432 6. WHEN STEERING WHEEL IS TURNED FULLY TO THE LEFT OR RIGHT, CHASSIS IS SUBJECTED TO LARGE SHOCK..................................... 432 43 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 433 STEERING GEAR ............................................................................................................................... 434 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 434 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 435 DISASSEMBLY (SERIAL NO. 10001-19999)..................................................................................................... 436 ASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................ 437 STEERING VALVE............................................................................................................................... 440 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 440 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 442 DISASSEMBLY (SERIAL NO. 20001 AND UP).................................................................................................... 445 ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................................... 448 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 453 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 455 DISASSEMBLY (SERIAL NO. 10001-19999)..................................................................................................... 457 ASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................ 459 STEERING DEMAND VALVE........................................................................................................................ 461 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 461 INSTALLATION (SERIAL NO. 20001 AND UP).................................................................................................. 463 DISASSEMBLY (SERIAL NO. 20001 AND UP).................................................................................................... 466 ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................................... 470 STEERING PUMP................................................................................................................................ 474 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 474 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 475 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 476 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 477 STEERING CYLINDER............................................................................................................................ 478 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 478 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 479 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 480 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 481 DISASSEMBLY ............................................................................................................................. 482 ASSEMBLY................................................................................................................................. 484 CENTER HINGE PIN............................................................................................................................. 487 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 487 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 496 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 507 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 516 44 MAINTENANCE STANDARD.......................................................................................................................... 527 STEERING LINKAGE............................................................................................................................. 528 STEERING COLUMN AND GEAR BOX................................................................................................................. 530 STEERING COLUMN AND ORBIT-ROLL............................................................................................................... 531 STEERING VALVE............................................................................................................................... 532 STEERING PUMP................................................................................................................................ 535 STEERING CYLINDER MOUNT...................................................................................................................... 536 STEERING CYLINDER............................................................................................................................ 538 CENTER HINGE PIN............................................................................................................................. 539 50 BRAKE AND AIR SYSTEM.............................................................................................................................. 541 51 STRUCTURE AND FUNCTION........................................................................................................................ 541 GENERAL...................................................................................................................................... 542 BRAKING AND AIR PIPING....................................................................................................................... 543 BRAKE AND AIR CIRCUIT SYSTEM................................................................................................................. 545 AIR TANK..................................................................................................................................... 547 SAFETY VALVE................................................................................................................................. 549 BRAKE VALVE.................................................................................................................................. 550 BRAKE ACTUATED........................................................................................................................... 551 OPERATING IN BALANCE..................................................................................................................... 552 BRAKE RELEASED........................................................................................................................... 553 AIR GOVERNOR................................................................................................................................. 554 TWO-WAY VALVE................................................................................................................................ 556 BRAKE CHAMBER................................................................................................................................ 557 SLACK ADJUSTER............................................................................................................................... 559 BRAKE........................................................................................................................................ 562 PARKING BRAKE................................................................................................................................ 565 PARKING BRAKE SOLENOID VALVE................................................................................................................. 567 SPRING CYLINDER.............................................................................................................................. 568 BRAKE CALIPER................................................................................................................................ 569 52 TESTING AND ADJUSTING......................................................................................................................... 570 STANDARD VALUE TABLE......................................................................................................................... 571 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................... 572 MEASURING BRAKE PEDAL........................................................................................................................ 573 MEASURING AIR................................................................................................................................ 574 BRAKE PERFORMANCE............................................................................................................................ 577 CHECKING BRAKE OIL PRESSURE.................................................................................................................. 578 MEASURING WEAR OF BRAKE DISC................................................................................................................. 579 AIR BLEEDING FROM BRAKE LINE................................................................................................................. 581 PARKING BRAKE PERFORMANCE.................................................................................................................... 582 CHECKING AND ADJUSTING PARKING BRAKE......................................................................................................... 583 TROUBLESHOOTING.............................................................................................................................. 585 TROUBLESHOOTING TABLE.................................................................................................................... 586 1. AIR PRESSURE DOES NOT RISE AT ALL................................................................................................. 586 2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE................................................................................. 587 3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE........................................................................................ 588 4. BRAKE DOES NOT RELEASE, OR DRAGS.................................................................................................. 589 5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS. ........................................................................................ 590 53 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 591 AIR GOVERNOR................................................................................................................................. 592 DISASSEMBLY.............................................................................................................................. 592 ASSEMBLY................................................................................................................................. 593 BRAKE VALVE.................................................................................................................................. 594 REMOVAL (SERIAL NO. 10001-19999)........................................................................................................ 594 INSTALLATION (SERIAL NO. 10001-19999..................................................................................................... 595 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 596 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 597 DISASSEMBLY.............................................................................................................................. 598 ASSEMBLY................................................................................................................................. 600 BRAKE CHAMBER................................................................................................................................ 602 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 602 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 603 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 604 INSTALLATION (SERIAL NO. 20001 AND UP.................................................................................................... 606 DISASSEMBLY.............................................................................................................................. 608 ASSEMBLY................................................................................................................................. 611 SLACK ADJUSTER............................................................................................................................... 614 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999)........................................................................................ 614 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 615 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 617 DISASSEMBLY.............................................................................................................................. 619 ASSEMBLY................................................................................................................................. 620 BRAKE ASSEMBLY............................................................................................................................... 621 DISASSEMBLY.............................................................................................................................. 621 ASSEMBLY................................................................................................................................. 628 DISASSEMBLY (SERIAL NO. 20001 AND UP).................................................................................................... 636 ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................................... 642 SPRING CYLINDER.............................................................................................................................. 650 REMOVAL ................................................................................................................................. 650 INSTALLATION............................................................................................................................. 651 DISASSEMBLY.............................................................................................................................. 652 ASSEMBLY................................................................................................................................. 654 PARKING BRAKE................................................................................................................................ 656 REMOVAL.................................................................................................................................. 656 INSTALLATION............................................................................................................................. 658 PARKING BRAKE PAD............................................................................................................................ 661 REMOVAL AND INSTALLATION................................................................................................................. 661 54 MAINTENANCE STANDARD.......................................................................................................................... 662 BRAKE VALVE.................................................................................................................................. 663 BRAKE CHAMBER................................................................................................................................ 665 SLACK ADJUSTER............................................................................................................................... 666 BRAKE........................................................................................................................................ 667 PARKING BRAKE................................................................................................................................ 671 SPRING CYLINDER.............................................................................................................................. 672 60 WORK EQUIPMENT SYSTEM............................................................................................................................. 673 61 STRUCTURE AND FUNCTION ....................................................................................................................... 673 GENERAL...................................................................................................................................... 674 HYDRAULIC PIPING............................................................................................................................. 675 HYDRAULIC CIRCUIT SYSTEM..................................................................................................................... 677 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................... 678 HYDRAULIC TANK............................................................................................................................... 681 OIL FILTER BYPASS VALVE.................................................................................................................. 683 BREATHER................................................................................................................................. 684 HYDRAULIC PUMPS.............................................................................................................................. 685 HYDRAULIC PUMP........................................................................................................................... 685 SWITCH AND POC PUMP...................................................................................................................... 686 SWITCH AND PPC PUMP...................................................................................................................... 686 POC VALVE.................................................................................................................................... 687 PPC VALVE.................................................................................................................................... 689 MAIN CONTROL VALVE........................................................................................................................... 699 RELIEF VALVE............................................................................................................................. 705 SAFETY VALVE (WITH SUCTION VALVE)........................................................................................................ 706 SUCTION VALVE............................................................................................................................ 707 FLOAT SELECTOR VALVE AND UNLOADER VALVE.................................................................................................. 708 ACCUMULATOR.................................................................................................................................. 716 HYDRAULIC CYLINDER........................................................................................................................... 717 BUCKET LINKAGE............................................................................................................................... 719 BUCKET POSITIONER AND BOOM KICK OUT.......................................................................................................... 721 WORK EQUIPMENT LEVER LINKAGE................................................................................................................. 724 62 TESTING AND ADJUSTING......................................................................................................................... 726 STANDARD VALUE TABLE......................................................................................................................... 727 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................... 730 MEASURING DUMP AND LIFT CONTROL LEVERS....................................................................................................... 731 ADJUSTING DUMP AND LIFT CONTROL LEVERS....................................................................................................... 732 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT............................................................................................... 734 MEASURING WORK EQUIPMENT..................................................................................................................... 737 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT.................................................................................................. 738 ADJUSTING BUCKET POSITIONER.................................................................................................................. 739 ADJUSTING BOOM KICK-OUT...................................................................................................................... 740 TROUBLESHOOTING.............................................................................................................................. 741 TROUBLESHOOTING TABLE.................................................................................................................... 742 1. LIFT ARM DOES NOT RISE............................................................................................................ 742 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFIECIENT LIFTING POWER.................................................................. 743 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT.................................................................. 744 4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER................................................................................. 744 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT................................................................................................ 744 6. LIFT ARM HAS TOO LARGE HYDRAULIC DRIFT............................................................................................ 744 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"................................................ 744 8. BUCKET DOES NOT TILT BACK......................................................................................................... 745 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER........................................................................... 746 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK.................................................................................... 747 11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER................................................................................ 747 12. BUCKET HAS LARGE HYDRAULIC DRIFT................................................................................................. 747 13. BUCKET MOVED UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD. (MAIN CONTROL VALVE IN "HOLD"........................................... 747 14. BUCKET DUMP MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"................................................. 747 15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY.................................................................. 748 63 DISASSEMBLY AND ASSEMBLY...................................................................................................................... 749 HYDRAULIC TANK............................................................................................................................... 750 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 750 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 751 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 752 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 756 HYDRAULIC PUMP............................................................................................................................... 759 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 759 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 760 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 761 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 762 HYDRAULIC FILTER............................................................................................................................. 763 REMOVAL ................................................................................................................................. 763 INSTALLATION............................................................................................................................. 763 SWITCH, POC PUMP............................................................................................................................. 764 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999)........................................................................................ 764 SWITCH, PPC PUMP............................................................................................................................. 765 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 765 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 766 POC VALVE.................................................................................................................................... 767 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 767 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 769 DISASSEMBLY AND ASSEMBLY(SERIAL NO. 10001-19999)......................................................................................... 771 PPC VALVE.................................................................................................................................... 772 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 772 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 774 DISASSEMBLY AND ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................... 776 MAIN CONTROL VALVE........................................................................................................................... 777 REMOVAL (SERIAL NO. 10001-19999)......................................................................................................... 777 INSTALLATION (SERIAL NO. 10001-19999).................................................................................................... 779 DISASSEMBLY (SERIAL NO. 10001-19999)..................................................................................................... 781 ASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................ 783 REMOVAL (SERIAL NO. 20001 AND UP)........................................................................................................ 785 INSTALLATION (SERIAL NO. 20001 AND UP)................................................................................................... 788 DISASSEMBLY (SERIAL NO. 20001 AND UP)................................................................................................... 790 ASSEMBLY (SERIAL NO. 20001 AND UP)....................................................................................................... 792 DUMP CYLINDER................................................................................................................................ 794 REMOVAL ................................................................................................................................. 794 INSTALLATION............................................................................................................................. 796 LIFT CYLINDER................................................................................................................................ 798 REMOVAL ................................................................................................................................. 798 INSTALLATION............................................................................................................................. 799 LIFT AND DUMP CYLINDERS...................................................................................................................... 800 DISASSEMBLY.............................................................................................................................. 800 ASSEMBLY................................................................................................................................. 802 WORK EQUIPMENT............................................................................................................................... 805 REMOVAL.................................................................................................................................. 805 INSTALLATION............................................................................................................................ 808 COUNTERWEIGHT................................................................................................................................ 811 REMOVAL AND INSTALLATION................................................................................................................. 811 64 MAINTENANCE STANDARD.......................................................................................................................... 812 MAIN CONTROL VALVE........................................................................................................................... 813 SWITCH AND POC (PPC) PUMP.................................................................................................................... 821 HYDRAULIC PUMP............................................................................................................................... 823 POC VALVE.................................................................................................................................... 824 POC VALVE (RELIEF VALVE)..................................................................................................................... 825 PPC VALVE.................................................................................................................................... 826 DUMP CYLINDER................................................................................................................................ 828 LIFT CYLINDER................................................................................................................................ 829 BUCKET LINKAGE............................................................................................................................... 830 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................................................... 832 BUCKET....................................................................................................................................... 833 80 ELECTRIC AND ELECTRONIC SYSTEM.................................................................................................................... 834 81 STRUCTURE AND FUNCTION........................................................................................................................ 834 ELECTRICAL WIRING DIAGRAM.................................................................................................................... 835 ELECTRICAL WIRING DIAGRAM CIRCUIT............................................................................................................ 836 ENGINE STARTING CIRCUIT...................................................................................................................... 843 ENGINE STOP CIRCUIT.......................................................................................................................... 846 PREHEATING CIRCUIT........................................................................................................................... 849 PREHEATING AND AFTER-HEATING WITH HEATER SWITCH.......................................................................................... 849 PREHEATING WITH STARTING SWITCH.......................................................................................................... 850 AUTOMATIC PREHEATING..................................................................................................................... 851 COMBINATION SWITCH........................................................................................................................... 852 ELECTRICAL TRANSMISSION CONTROL.............................................................................................................. 853 TRANSMISSION CUT-OFF SWITCH.............................................................................................................. 855 TRANSMISSION CUT-OFF SELECTOR SWITCH..................................................................................................... 856 NEUTRALIZER RELAY........................................................................................................................ 858 KICK-DOWN SWITCH......................................................................................................................... 860 KICK-DOWN ELECTRIC SWITCH................................................................................................................ 861 ELECTRICAL PARKING BRAKE CONTROL............................................................................................................. 867 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).................................................................................................. 879 INDICATION ON MONITOR PANEL.............................................................................................................. 883 CONTROLLER............................................................................................................................... 885 SENSOR................................................................................................................................... 886 WIRING HARNESS........................................................................................................................... 892 OPERATION OF PROXIMITY SWITCH............................................................................................................ 894 82 TESTING AND ADJUSTING......................................................................................................................... 898 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM................................................................................................... 899 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)............................................................................................... 901 TROUBLESHOOTING.............................................................................................................................. 903 CHECKS BEFORE TROUBLESHOOTING............................................................................................................ 904 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART........................................................................................ 905 CONNECTOR TERMINAL NUMBERS............................................................................................................... 907 PRECAUTION WHEN HANDLING CONNECTOR....................................................................................................... 912 ELECTRICAL WIRING DIAGRAM................................................................................................................ 914 ELECTRICAL CIRCUIT DIAGRAM............................................................................................................... 916 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM ............................................................................................... 926 (SERIAL NO. 10001-20000)............................................................................................................. 926 E-1 ENGINE DOES NOT START........................................................................................................ 927 E-1A ENGINE DOES NOT START....................................................................................................... 929 E-2 ENGINE DOES NOT STOP......................................................................................................... 931 E-3 ENGINE STOPS WHEN TRAVELING.................................................................................................. 933 E-4 PARKING BRAKE DOES NOT WORK.................................................................................................. 935 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING...................................................................................... 937 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON............................................................... 939 E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................................................ 940 E-8 MACHINE DOES NOT TRAVEL FORWARD.............................................................................................. 941 E-9 MACHINE DOES NOT TRAVEL REVERSE.............................................................................................. 943 E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL)........................................................................ 945 E-11 MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON (MACHINE TRAVELS ONLY WHEN TRANSMISSION CUT-OFF .... 947 E-12 TRANSMISSION CANNOT BE CUT-OFF.............................................................................................. 948 E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL..................................................................................... 949 E-14 PREHEATING DISPLAY DOES NOT GO OUT.......................................................................................... 951 E-15 PREHEATING DOES NOT WORK.................................................................................................... 952 (SERIAL NO. 20001-UP)................................................................................................................ 953 POSITION OF CONNECTORS FOR TROUBLESHOOTING....................................................................................... 954 E-1 ENGINE DOES NOT START........................................................................................................ 960 E-2 ENGINE DOES NOT STOP......................................................................................................... 964 E-3 ENGINE STOPS WHEN TRAVELING.................................................................................................. 964 E-4 PARKING BRAKE DOES NOT WORK.................................................................................................. 965 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING ..................................................................................... 966 E-6 PARKING BRAKE IS RELEASED WHENT STARTING SWITCH IS TURNED ON................................................................. 968 E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL............................................................ 968 E-8 TRANSMISSION DOES NOT WORK NORMALLY.......................................................................................... 969 E-9 KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1 - F4 SWITCHES CORRECTLY........................................................... 990 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)............ 993 E-11 KICK-DOWN OPERATION IS NOT CANCELLED........................................................................................ 994 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2............................................................................. 996 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.................................................................... 996 E-14 PREHEAD DISPLAY STAYS ON.................................................................................................... 998 E-15 PREHEATING DOES NOT STOP.................................................................................................... 998 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (SERIAL NO. 10001-11147, SERIAL NO. 10001-11151 (D SPEC))................. 999 M-1 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE) CHECK BEFORE STARTING ITEMS FLASHES......................................1002 A) BRAKE OIL LEVEL...............................................................................................................1002 B) ENGINE OIL LEVEL..............................................................................................................1003 C) COOLANT LEVEL.................................................................................................................1004 M-2 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NOT ABNORMALITY IN MACHINE,M CAUTION ITEM FLASHES..........1005 A) BATTERY CHARGE................................................................................................................1005 B) FUEL LEVEL....................................................................................................................1006 M-3 WHEN STARTING SWITHC IS TURNED ON (ENGINE STARTED), AND THERE IS NOABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASHES...............1007 A) FAILURE IN BRAKE LINE.........................................................................................................1007 B) ENGINE OIL PRESSURE ..........................................................................................................1008 C) COOLANT LEVEL ................................................................................................................1009 D) DROP IN AIR PRESSURE .........................................................................................................1010 E) COOLANT TEMPERATURE...........................................................................................................1011 F) TORQUE CONVERTER OIL TEMPERATURE..............................................................................................1012 M-4 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP ABN........1013 A) PARKING BRAKE DISPLAY DOES NOT GO OUT.........................................................................................1013 B) PARKING BRAKE DISPLAY DOES NOT LIGHT UP.......................................................................................1014 C) WORKING LAMPL DISPLAY DOES NOT GO OUT.........................................................................................1015 D) WORKING LAMP DISPLAY DOES NOT LIGHT UP........................................................................................1016 E) PREHEAT DISPLAY LIGHTS UP.....................................................................................................1017 F) PREHEAT DISPLAY DOES NOT LIGHT UP.............................................................................................1018 G) FAILURE IN MAIN STEERING DISPLAY LIGHT UP (IF EQUIPPED).......................................................................1019 H) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)..............................................................1020 I) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED).....................................................................1021 J) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED).............................................................1022 K) TRANSMISSION CUT-OFF DISPLAY LIGHT UP........................................................................................1023 L) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP................................................................................1024 M-5 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT UP.............................................................1025 A) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHT UP............................................................................1025 B) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP............................................................................1025 C) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP...................................................................1026 D) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP....................................................................1027 E) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP........................................................................................1028 F) HIGH BEAM PILOT LAMP DOES NOT WORK NORMALLY...................................................................................1029 M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................................1030 M-7 ABNORMALITY IN MONITOR PANEL.....................................................................................................1031 M-8 ABNORMALITY IN MONITOR PANEL.....................................................................................................1033 A) NONE OF MONITOR PANEL WORKS...................................................................................................1033 B) PART OF MONITOR PANEL DOES NOT WORK...........................................................................................1035 C) EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE FLASHES, CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP...............1036 D) EVEN WHEN ENGINE IS STOPPED, BATTERY CHARGE FLASHES AND WARNING LAMP LIGHT UP.................................................1037 E) NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO "ON", ENGINE STOPPED...............................1037 F) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHT UP INTERMITTENTLY.............................................1038 G) CENTRAL WARNING LAMP LIGHT UP CONTINUOUSLY....................................................................................1039 H) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUND INTERMITTENTLY.............................................1040 I) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY....................................................................................1041 M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR............................................................................................1042 A) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED.................................................1042 B) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON......................................................................1044 C) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP...................................................................................1045 D) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP....................................................1046 E) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP..................................................................................1047 M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP.....................................................................................1048 A) EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND...................................................................1048 B) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING BUT WARNING LAMPS DOES NOT FLASH.............................................1050 M-11 ABNORMALITY IN GAUGE............................................................................................................1052 A) FUEL GAUGE....................................................................................................................1052 B) AIR PRESSURE GAUGE............................................................................................................1054 C) COOLANT TEMPERATURE GAUGE.....................................................................................................1056 D) TORQUE CONVERTER OIL TEMPERATURE GAUGE........................................................................................1058 TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM).............................................................................1001 TROUBLESHOOTING CHART FOR ELETRONIC VEHICLE MONITORING SYSTEM (SERIAL NO. 11148 AND UP, SERIAL NO. 11152 AND UP (D SPEC.))...............1060 POSITIONS FOR TROUBLESHOOTING .......................................................................................................1062 (SERIAL NO. 11148-20000, SERIAL NO. 11152-20000 (D SPEC.)).......................................................................1062 (SERIAL NO. 20001 AND UP)........................................................................................................1068 M-1. WHEN STARTING MOTOR SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LISTH UP FOR 3 SECONDS..............................1074 A) NONE OF MONITOR PANEL LIGHTS UP...............................................................................................1074 B) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP................................................................1074 C) NONE OF CAUTION ITEMS LIGHT UP................................................................................................1074 D) SOME OTHER PARTS DO NOT LIGHT UP..............................................................................................1074 M-2. WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT..................................1075 M-3. WHEN STARTING SWITCH IS TURNED TO ON POSTION (ENGINE STOPPED)), CHECK ITEMS FLASHES. (LEVELS OF CHECK ITEMS ARE CORRECT)........1076 A) (ENGINE OIL LEVEL)FLASHES.....................................................................................................1076 B) (RADIATOR WATER LEVEL) FLASHES................................................................................................1077 C) (BRAKE OIL LEVEL)FLASHES......................................................................................................1078 M-4. NO OPERATION IS BEING CARRIES OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY.......................................................1079 A) (PREHEAT) LIGHT UP............................................................................................................1079 B) (TRANSMISSION CUT-OFF LIGHTS UP)..............................................................................................1079 C) (PARKING BRAKE) LIGHTS UP....................................................................................................1080 D) (WORKING LAMP) LIGHT UP.......................................................................................................1080 M-5. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES..............................................1082 A) ENGINE OIL PRESSURE SYSTEM....................................................................................................1082 B) ALTERNATOR SYSTEM.............................................................................................................1082 M-6. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM FLASHES............................................1083 A) ENGINE OIL PRESSURE SYSTEM....................................................................................................1083 B) ALTERNATOR SYSTEM.............................................................................................................1083 M-7. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALU........1085 A) (CHARGE LEVEL) FLASHES........................................................................................................1085 B) (FUEL LEVEL) FLASHES..........................................................................................................1085 C) (BRAKE LINE FAILURE) FLASHES..................................................................................................1085 D) (ENGINE OIL PRESSURE) FLASHES.................................................................................................1085 E) (RADIATOR WATER LEVEL) FLASHES................................................................................................1085 F) (AIR PRESSURE) FLASHES........................................................................................................1086 G) (ENGINE WATER TEMPERATURE) FLASHES............................................................................................1086 H) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES....................................................................................1086 M-8. SPEED SENSOR DISPLAY STAYS AT '0'...............................................................................................1088 M-9. HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY............................................................................1089 A) IF HIGH BEAM DOES NOT LIGHT UP................................................................................................1089 B) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF ..........................................................................1089 C) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSTION...............................................1090 M-10. TURN SIGNAL LAMP DOES NOT FLASH; TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING...........................................1091 A) IF TURN SIGNAL LAM DOE NOT FLASH..............................................................................................1091 B) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING........................................................................1091 M-11. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEMS FLASHING........1092 M-12. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS............................................................1093 M-13. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM ........1094 M-14. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY BUT WARNING LAMP LIGHT UP...........................................................1094 M-15. WHEN STARTING SWITCH IS TURNED TO ON POSTION, LAMPS DO NOT LIGHT UP FOR 4 SEC. WHEN LAMP SWITCH IS ON, LAMPS DO NO LIGH........1095 A) NONE OF PANEL LIGHT UP........................................................................................................1095 B) SOME OM PANEL LAMPS DO NOT LIGHT UP...........................................................................................1095 M-16. LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON.......................................1096 M-17. SERVICE METER DOES NOT WORK....................................................................................................1097 M-18. SERVICE METER MOVES WHEN ENGINE IS STOPPED.....................................................................................1097 M-19. ABNORMALITY IN AIR PRESSURE GAUGE..............................................................................................1098 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA.......................................................................................1098 B) IF INDICATOR REMAINS AT MAXIMUM LEVEL.........................................................................................1098 M-20. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE..................................................................................1099 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA.......................................................................................1099 B) IF INDICATOR REMAINS AT MAXIMUM LEVEL.........................................................................................1099 M-21. ABNORMALITY IN TORQUE CONVERTER OIL TEMPRARTURE GAUGE..........................................................................1100 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA.......................................................................................1100 B) IF INDICATOR REMAINS AT MINIMUM LEVEL.........................................................................................1100 M-22. ABNORMALITY IN FUEL GAUGE......................................................................................................1101 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA.......................................................................................1101 B) IF INDICATOR REMAINS AT FULL..................................................................................................1101 83 DISASSEMBLY AND ASSEMBLY......................................................................................................................1102 MACHINE MONITOR .............................................................................................................................1103 REMOVAL AND INSTALLATION.................................................................................................................1103 90 OTHERS............................................................................................................................................1104 91 STRUCTURE AND FUNCTION........................................................................................................................1104 CAB..........................................................................................................................................1105 AIR CONDITIONER (IF EQUIPPED)................................................................................................................1106 PIPING...................................................................................................................................1106 AIR CONDITIONER WIRING DIAGRAM...........................................................................................................1107 AIR CONDITIONER ELECTRIC CIRCUIT.........................................................................................................1107 AIR CONDITIONER UNIT.....................................................................................................................1108 93 DISASSEMBLY AND ASSEMBLY......................................................................................................................1111 CAB..........................................................................................................................................1112 REMOVAL..................................................................................................................................1112 INSTALLATION.............................................................................................................................1113 AIR CONDITIONER UNIT (OPTION)................................................................................................................1114 REMOVAL..................................................................................................................................1114 INSTALLATION.............................................................................................................................1116 AIR CONDITIONER CONDENSER (OPTION)...........................................................................................................1118 REMOVAL AND INSTALLATION.................................................................................................................1118 DRY RECEIVER (OPTION)........................................................................................................................1119 REMOVAL AND INSTALLATION.................................................................................................................1119 COMPRESSOR OR AIR CONDITIONER................................................................................................................1120 REMOVAL AND INSTALLATION.................................................................................................................1120 97 GEAR PUMP.....................................................................................................................................1121 GENERAL......................................................................................................................................1121 GENERAL..................................................................................................................................1122 PRINCIPLE OF OPERATION...................................................................................................................1123 PRESSURE LOADED TYPE GEAR PUMP...........................................................................................................1126 FIXED SIDE PLATE TYPE GEAR PUMP..........................................................................................................1128 SA SERIES....................................................................................................................................1129 STRUCTURE................................................................................................................................1130 TESTING AND ADJUSTING....................................................................................................................1133 DISASSEMBLY..............................................................................................................................1136 ASSEMBLY.................................................................................................................................1140 MAINTENANCE STANDARD.....................................................................................................................1145
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