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Komatsu WA470-1 10001 and up Wheel Loader Shop Manual – PDF DOWNLOAD
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Komatsu WA470-1 10001 and up Wheel Loader Shop Manual
MACHINE MODEL SERIAL NO.
WA470-1 10001 and up
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Description
Komatsu WA470-1 10001 and up Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA470-1 10001 and up Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA470-1
Serial Number: 10001 and up
Book Code: SEBMU4210106
Language: English
Pages: 1120
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA470-1 10001 and up Wheel Loader Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA470-1 10001 and up Wheel Loader Shop Manual
COVER...................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................... 2 10 ENGINE.................................................................................................................................................................................. 20 12 TESTING AND ADJUSTING............................................................................................................................................................... 20 STANDARD VALUE TABLE............................................................................................................................................................... 21 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................................................... 23 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................... 24 MEASURING COMPRESSION PRESSURE..................................................................................................................................................... 25 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................................ 26 MEASURING BLOW-BY PRESSURE......................................................................................................................................................... 28 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................................................. 29 MEASURING EXHAUST GAS COLOR........................................................................................................................................................ 30 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE.................................................................................................................... 31 TESTING AND ADJUSTING FUEL CUT SOLENOID............................................................................................................................................ 35 13 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 36 STARTING MOTOR ASSEMBLY............................................................................................................................................................ 37 REMOVAL........................................................................................................................................................................ 37 INSTALLATION................................................................................................................................................................... 37 ALTERNATOR ASSEMBLY................................................................................................................................................................ 38 REMOVAL........................................................................................................................................................................ 38 INSTALLATION................................................................................................................................................................... 38 FUEL INJECTION PUMP ASSEMBLY....................................................................................................................................................... 39 REMOVAL........................................................................................................................................................................ 39 INSTALLATION................................................................................................................................................................... 39 WATER PUMP ASSEMBLY................................................................................................................................................................ 40 REMOVAL........................................................................................................................................................................ 40 INSTALLATION................................................................................................................................................................... 40 NOZZLE HOLDER ASSEMBLY............................................................................................................................................................. 41 REMOVAL........................................................................................................................................................................ 41 INSTALLATION................................................................................................................................................................... 42 TURBOCHARGER ASSEMBLY.............................................................................................................................................................. 43 REMOVAL........................................................................................................................................................................ 43 INSTALLATION................................................................................................................................................................... 43 CYLINDER HEAD ASSEMBLY............................................................................................................................................................. 44 REMOVAL........................................................................................................................................................................ 44 INSTALLATION................................................................................................................................................................... 50 RADIATOR ASSEMBLY.................................................................................................................................................................. 57 REMOVAL........................................................................................................................................................................ 57 INSTALLATION................................................................................................................................................................... 60 OIL COOLER ASSEMBLY................................................................................................................................................................ 62 REMOVAL........................................................................................................................................................................ 62 INSTALLATION................................................................................................................................................................... 62 ENGINE............................................................................................................................................................................. 63 REMOVAL........................................................................................................................................................................ 63 INSTALLATION................................................................................................................................................................... 69 FUEL TANK.......................................................................................................................................................................... 75 REMOVAL........................................................................................................................................................................ 75 INSTALLATION................................................................................................................................................................... 75 14 MAINTENANCE STANDARD................................................................................................................................................................ 76 ENGINE MOUNT....................................................................................................................................................................... 77 20 POWER TRAIN............................................................................................................................................................................. 78 21 STRUCTURE AND FUNCTION.............................................................................................................................................................. 78 GENERAL............................................................................................................................................................................ 79 ・HYDRAULIC CIRCUIT FOR POWER TRAIN............................................................................................................................................. 81 ・HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN..................................................................................................................................... 82 DAMPER............................................................................................................................................................................. 84 TORQUE CONVERTER AND TRANSMISSION PIPING........................................................................................................................................... 86 TORQUE CONVERTER CHARGING PUMP..................................................................................................................................................... 87 TORQUE CONVERTER................................................................................................................................................................... 88 TORQUE CONVERTER OIL FILTER........................................................................................................................................................ 91 TORQUE CONVERTER OIL COOLER........................................................................................................................................................ 92 TORQUE CONVERTER RELIEF VALVE...................................................................................................................................................... 93 TRANSMISSION....................................................................................................................................................................... 94 TRANSMISSION CONTROL VALVE......................................................................................................................................................... 102 UPPER VALVE.................................................................................................................................................................... 106 LOWER VALVE.................................................................................................................................................................... 107 TRANSMISSION SOLENOID VALVE.................................................................................................................................................... 110 EMERGENCY MANUAL SPOOL......................................................................................................................................................... 111 PRIORITY VALVE................................................................................................................................................................. 114 MODULATING VALVE AND QUICK RETURN VALVE........................................................................................................................................ 115 ACCUMULATOR VALVE.............................................................................................................................................................. 118 PILOT REDUCING VALVE........................................................................................................................................................... 120 TRANSMISSION PILOT FILTER.......................................................................................................................................................... 121 TRANSFER........................................................................................................................................................................... 122 DRIVE SHAFT........................................................................................................................................................................ 123 AXLE MOUNT......................................................................................................................................................................... 124 AXLE AND DIFFERENTIAL.............................................................................................................................................................. 128 TORQUE PROPORTIONING DIFFERENTIAL.............................................................................................................................................. 133 FINAL DRIVE........................................................................................................................................................................ 134 TIRE AND WHEEL..................................................................................................................................................................... 136 22 TESTING AND ADJUSTING............................................................................................................................................................... 137 STANDARD VALUE TABLE............................................................................................................................................................... 138 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 139 MEASURING ENGINE STALL SPEED....................................................................................................................................................... 140 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION........................................................................................................................ 142 MEASURING SHIFT LEVER.............................................................................................................................................................. 144 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL..................................................................................................................................... 145 TIRE AND WHEEL..................................................................................................................................................................... 147 TROUBLESHOOTING.................................................................................................................................................................... 148 PRECAUTIONS WHEN TROUBLESHOOTING............................................................................................................................................... 149 METHOD OF READING TROUBLESHOOTING TABLE........................................................................................................................................ 151 PREVENTING RECURRENCE OF TROUBLE............................................................................................................................................... 153 JUDGMENT ON POWER TRAIN........................................................................................................................................................ 154 TROUBLESHOOTING TABLE.......................................................................................................................................................... 157 1. MACHINE DOES NOT MOVE................................................................................................................................................... 157 2. MACHINE LACKS POWER OR SPEED............................................................................................................................................ 159 3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR............................................................................................................... 160 4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH............................................................................................................................... 161 23 DISASSEMBLY AND ASSEMBLY ........................................................................................................................................................... 162 DAMPER............................................................................................................................................................................. 163 REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)............................................................................................................................... 163 REMOVAL AND INSTALLATION (SERIAL NO.20001 AND UP).............................................................................................................................. 164 DISASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................ 165 ASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................... 167 DISASSEMBLY (SERIAL NO.20001 AND UP)........................................................................................................................................... 169 ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................................. 171 TORQUE CONVERTER CHARGING PUMP .................................................................................................................................................... 175 REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)............................................................................................................................... 175 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 176 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 177 TORQUE CONVERTER AND TRANSMISSION.................................................................................................................................................. 178 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 178 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 185 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 193 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 201 TORQUE CONVERTER ASSEMBLY.......................................................................................................................................................... 210 DISASSEMBLY.................................................................................................................................................................... 210 ASSEMBLY....................................................................................................................................................................... 214 TRANSMISSION ASSEMBLY.............................................................................................................................................................. 220 DISASSEMBLY.................................................................................................................................................................... 220 ASSEMBLY....................................................................................................................................................................... 233 TRANSFER ASSEMBLY.................................................................................................................................................................. 246 DISASSEMBLY.................................................................................................................................................................... 246 ASSEMBLY....................................................................................................................................................................... 249 TRANSMISSION CONTROL VALVE......................................................................................................................................................... 254 REMOVAL........................................................................................................................................................................ 254 INSTALLATION................................................................................................................................................................... 257 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................... 260 FRONT DIFFERENTIAL................................................................................................................................................................. 264 REMOVAL........................................................................................................................................................................ 264 INSTALLATION................................................................................................................................................................... 268 REAR DIFFERENTIAL.................................................................................................................................................................. 272 REMOVAL........................................................................................................................................................................ 272 INSTALLATION................................................................................................................................................................... 276 DIFFERENTIAL....................................................................................................................................................................... 280 DISASSEMBLY.................................................................................................................................................................... 280 ASSEMBLY....................................................................................................................................................................... 283 FRONT AXLE......................................................................................................................................................................... 291 REMOVAL........................................................................................................................................................................ 291 INSTALLATION................................................................................................................................................................... 294 REAR AXLE.......................................................................................................................................................................... 297 REMOVAL........................................................................................................................................................................ 297 INSTILLATION................................................................................................................................................................... 302 DRIVE SHAFT........................................................................................................................................................................ 307 DISASSEMBLY.................................................................................................................................................................... 307 ASSEMBLY....................................................................................................................................................................... 309 FINAL DRIVE........................................................................................................................................................................ 311 DISASSEMBLY.................................................................................................................................................................... 311 ASSEMBLY....................................................................................................................................................................... 315 24 MAINTENANCE STANDARD................................................................................................................................................................ 320 TRANSMISSION MOUNT................................................................................................................................................................. 321 TORQUE CONVERTER CHARGING PUMP..................................................................................................................................................... 322 DAMPER............................................................................................................................................................................. 323 TORQUE CONVERTER ................................................................................................................................................................. 326 TORQFLOW TRANSMISSION.............................................................................................................................................................. 328 1. TRANSMISSION................................................................................................................................................................ 328 2. TRANSMISSION CONTROL VALVE.................................................................................................................................................. 331 3. SOLENOID VALVE.............................................................................................................................................................. 339 TRANSFER........................................................................................................................................................................... 340 DIFFERENTIAL....................................................................................................................................................................... 342 FINAL DRIVE........................................................................................................................................................................ 346 DRIVE SHAFT........................................................................................................................................................................ 348 AXLE MOUNT......................................................................................................................................................................... 349 40 STEERING SYSTEM......................................................................................................................................................................... 351 41 STRUCTURE AND FUNCTION.............................................................................................................................................................. 351 GENERAL............................................................................................................................................................................ 352 HYDRAULIC CIRCUIT FOR STEERING..................................................................................................................................................... 354 STEERING VALVE (SERIAL NO.10001-20000)............................................................................................................................................. 361 STEERING VALVE (SERIAL NO.20001 AND UP)............................................................................................................................................ 368 TWO-WAY RESTRICTOR VALVE........................................................................................................................................................... 382 ORBIT-ROLL VALVE................................................................................................................................................................... 383 STOP VALVE......................................................................................................................................................................... 387 STEERING PUMP...................................................................................................................................................................... 388 STEERING CYLINDER.................................................................................................................................................................. 389 STEERING COLUMN AND GEAR BOX....................................................................................................................................................... 390 STEERING LINKAGE................................................................................................................................................................... 391 STEERING COLUMN AND ORBIT-ROLL..................................................................................................................................................... 392 CENTER HINGE PIN................................................................................................................................................................... 393 42 TESTING AND ADJUSTING............................................................................................................................................................... 395 STANDARD VALUE TABLE............................................................................................................................................................... 396 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 396 MEASURING STEERING WHEEL PLAY...................................................................................................................................................... 397 MEASURING OPERATING FORCE OF STEERING WHEEL ....................................................................................................................................... 398 OPERATING TIME OF STEERING WHEEL................................................................................................................................................... 399 TESTING STEERING LINKAGE........................................................................................................................................................... 400 ADJUSTING STEERING LINKAGE......................................................................................................................................................... 401 STEERING OIL PRESSURE.............................................................................................................................................................. 402 TROUBLESHOOTING.................................................................................................................................................................... 404 TROUBLESHOOTING TABLE (SERIAL NO.10001-20000).................................................................................................................................. 405 1. STEERING WHEEL DOES NOT TURN............................................................................................................................................ 405 2. STEERING WHEEL IS SLUGGISH.............................................................................................................................................. 406 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.......................................................................................................... 407 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING.............................................................................................. 407 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT.............................................................................................................................. 407 TROUBLESHOOTING TABLE (SERIAL NO.20001 AND UP)................................................................................................................................. 408 1. STEERING WHEEL DOES NOT TURN............................................................................................................................................ 408 2. STEERING WHEEL IS SLUGGISH.............................................................................................................................................. 409 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.......................................................................................................... 410 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING.............................................................................................. 410 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT.............................................................................................................................. 410 6. WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT,CHASSIS IS SUBJECTED TO LARGE SHOCK................................................................................ 410 43 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 411 STEERING GEAR...................................................................................................................................................................... 412 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 412 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 413 DISASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................ 414 ASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................... 415 STEERING VALVE..................................................................................................................................................................... 418 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 418 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 420 DISASSEMBLY (SERIAL NO.20001 AND UP)........................................................................................................................................... 423 ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................................. 426 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 431 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 433 DISASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................ 435 ASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................... 437 STEERING DEMAND VALVE.............................................................................................................................................................. 439 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 439 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 441 DISASSEMBLY (SERIAL NO.20001 AND UP)........................................................................................................................................... 444 ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................................. 448 STEERING PUMP...................................................................................................................................................................... 452 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 452 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 453 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 454 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 455 STEERING CYLINDER ................................................................................................................................................................. 456 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 456 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 457 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 458 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 459 DISASSEMBLY.................................................................................................................................................................... 460 ASSEMBLY....................................................................................................................................................................... 462 CENTER HINGE PIN................................................................................................................................................................... 465 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 465 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 472 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 481 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 490 44 MAINTENANCE STANDARD................................................................................................................................................................ 501 STEERING LINKAGE................................................................................................................................................................... 502 STEERING COLUMN AND GEAR BOX....................................................................................................................................................... 504 STEERING COLUMN AND ORBIT-ROLL..................................................................................................................................................... 505 STEERING VALVE..................................................................................................................................................................... 506 STEERING PUMP...................................................................................................................................................................... 509 STEERING CYLINDER MOUNT............................................................................................................................................................ 510 STEERING CYLINDER ................................................................................................................................................................. 512 CENTER HINGE PIN................................................................................................................................................................... 513 50 BRAKE AND AIR SYSTEM.................................................................................................................................................................... 515 51 STRUCTURE AND FUNCTION.............................................................................................................................................................. 515 GENERAL............................................................................................................................................................................ 516 BRAKE AND AIR PIPING............................................................................................................................................................... 517 BRAKE AND AIR CIRCUIT SYSTEM....................................................................................................................................................... 519 AIR TANK........................................................................................................................................................................... 521 SAFETY VALVE....................................................................................................................................................................... 523 BRAKE VALVE........................................................................................................................................................................ 524 BRAKE ACTUATED................................................................................................................................................................. 525 OPERATING IN BALANCE........................................................................................................................................................... 526 BRAKE RELEASED................................................................................................................................................................. 527 AIR GOVERNOR....................................................................................................................................................................... 528 TWO-WAY VALVE...................................................................................................................................................................... 530 BRAKE CHAMBER...................................................................................................................................................................... 531 SLACK ADJUSTER..................................................................................................................................................................... 533 BRAKE.............................................................................................................................................................................. 536 PARKING BRAKE...................................................................................................................................................................... 539 PARKING BRAKE SOLENOID VALVE....................................................................................................................................................... 541 SPRING CYLINDER.................................................................................................................................................................... 542 BRAKE CALIPER...................................................................................................................................................................... 543 52 TESTING AND ADJUSTING............................................................................................................................................................... 544 STANDARD VALUE TABLE............................................................................................................................................................... 545 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 546 MEASURING BRAKE PEDAL.............................................................................................................................................................. 547 MEASURING AIR...................................................................................................................................................................... 548 BRAKE PERFORMANCE.................................................................................................................................................................. 551 CHECKING BRAKE OIL PRESSURE........................................................................................................................................................ 552 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................... 553 AIR BLEEDING FROM BRAKE LINE....................................................................................................................................................... 555 PARKING BRAKE PERFORMANCE.......................................................................................................................................................... 556 CHECKING AND ADJUSTING PARKING BRAKE............................................................................................................................................... 557 TROUBLESHOOTING.................................................................................................................................................................... 559 TROUBLESHOOTING TABLE.......................................................................................................................................................... 560 1. AIR PRESSURE DOES NOT RISES AT ALL...................................................................................................................................... 560 2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE....................................................................................................................... 561 3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE.............................................................................................................................. 562 4. BRAKE DOES NOT RELEASE,OR DRAGS......................................................................................................................................... 563 5. PARKING BRAKE DOES NOT RELEASE,OR DRAGS................................................................................................................................. 564 53 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 565 AIR GOVERNOR....................................................................................................................................................................... 566 DISASSEMBL..................................................................................................................................................................... 566 ASSEMBLY....................................................................................................................................................................... 567 BRAKE VALVE........................................................................................................................................................................ 568 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 568 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 569 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 570 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 571 DISASSEMBLY.................................................................................................................................................................... 572 ASSEMBLY....................................................................................................................................................................... 574 BRAKE CHAMBER...................................................................................................................................................................... 576 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 576 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 577 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 578 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 580 DISASSEMBLY.................................................................................................................................................................... 582 ASSEMBLY....................................................................................................................................................................... 585 SLACK ADJUSTER..................................................................................................................................................................... 588 REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)............................................................................................................................... 588 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 589 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 591 DISASSEMBLY.................................................................................................................................................................... 593 ASSEMBLY....................................................................................................................................................................... 594 BRAKE ASSEMBLY..................................................................................................................................................................... 595 DISASSEMBLY.................................................................................................................................................................... 595 ASSEMBLY....................................................................................................................................................................... 601 DISASSEMBLY (SERIAL NO.20001 AND UP)........................................................................................................................................... 608 ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................................. 614 SPRING CYLINDER ................................................................................................................................................................... 622 REMOVAL ....................................................................................................................................................................... 622 INSTALLATION................................................................................................................................................................... 623 DISASSEMBLY.................................................................................................................................................................... 624 ASSEMBLY....................................................................................................................................................................... 626 PARKING BRAKE...................................................................................................................................................................... 628 REMOVAL........................................................................................................................................................................ 628 INSTALLATION................................................................................................................................................................... 630 PARKING BRAKE PAD.................................................................................................................................................................. 633 REMOVAL AND INSTALLATION ...................................................................................................................................................... 633 54 MAINTENANCE STANDARD................................................................................................................................................................ 634 BRAKE VALVE........................................................................................................................................................................ 635 BRAKE CHAMBER...................................................................................................................................................................... 637 SLACK ADJUSTER..................................................................................................................................................................... 638 BRAKE.............................................................................................................................................................................. 639 PARKING BRAKE...................................................................................................................................................................... 643 SPRING CYLINDER.................................................................................................................................................................... 644 60 WORK EQUIPMENT SYSTEM................................................................................................................................................................... 645 61 STRUCTURE AND FUNCTION.............................................................................................................................................................. 645 GENERAL ........................................................................................................................................................................... 646 HYDRAULIC PIPING................................................................................................................................................................... 647 HYDRAULIC CIRCUIT SYSTEM........................................................................................................................................................... 649 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................................................... 650 HYDRAULIC TANK..................................................................................................................................................................... 654 OIL FILTER BYPASS VALVE........................................................................................................................................................ 656 HYDRAULIC PUMPS.................................................................................................................................................................... 658 HYDRAULIC PUMP ................................................................................................................................................................ 658 SWITCH AND POC (PPC) PUMP...................................................................................................................................................... 659 POC VALVE.......................................................................................................................................................................... 660 PPC VALVE.......................................................................................................................................................................... 662 POC (PPC) RELIEF VALVE......................................................................................................................................................... 664 FUNCTION OF POC VALVE.......................................................................................................................................................... 665 FUNCTION OF PPC VALVE.......................................................................................................................................................... 670 MAIN CONTROL VALVE................................................................................................................................................................. 672 RELIEF VALVE................................................................................................................................................................... 680 SAFETY VALVE (WITH SUCTION VALVE).............................................................................................................................................. 681 SUCTION VALVE.................................................................................................................................................................. 682 FLOAT SELECTOR VALVE AND UNLOADER VALVE........................................................................................................................................ 683 ACCUMULATOR........................................................................................................................................................................ 691 HYDRAULIC CYLINDER................................................................................................................................................................. 692 BUCKET LINKAGE..................................................................................................................................................................... 694 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................ 696 WORK EQUIPMENT LEVER LINKAGE....................................................................................................................................................... 699 62 TESTING AND ADJUSTING............................................................................................................................................................... 701 STANDARD VALUE TABLE............................................................................................................................................................... 702 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 705 MEASURING DUMP AND LIFT CONTROL LEVERS............................................................................................................................................. 706 ADJUSTING DUMP AND LIFT CONTROL LEVERS............................................................................................................................................. 707 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT..................................................................................................................................... 709 MEASURING WORK EQUIPMENT........................................................................................................................................................... 712 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT........................................................................................................................................ 713 ADJUSTING BUCKET POSITIONER........................................................................................................................................................ 714 ADJUSTING BOOM KICK-OUT............................................................................................................................................................ 715 TROUBLESHOOTING.................................................................................................................................................................... 716 TROUBLESHOOTING TABLE.......................................................................................................................................................... 717 1. LIFT ARM DOES NOT RISE.................................................................................................................................................. 717 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER......................................................................................................... 718 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT........................................................................................................ 719 4. RUCKET CANNOT BE HELD DOWN WITH LIFT CYLINDER........................................................................................................................... 719 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT...................................................................................................................................... 719 6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK............................................................................................................................... 719 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"...................................................................................... 719 8. BUCKET DOES NOT TILT BACK............................................................................................................................................... 720 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER................................................................................................................. 721 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK.......................................................................................................................... 722 11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER...................................................................................................................... 722 12. BUCKET HAS LARGE HYDRAULIC DRIFT....................................................................................................................................... 722 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN "HOLD")................................................................................. 722 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"...................................................................................... 722 15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY........................................................................................................ 723 63 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 724 HYDRAULIC TANK..................................................................................................................................................................... 725 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 725 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 726 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 727 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 731 HYDRAULIC PUMP..................................................................................................................................................................... 734 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 734 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 735 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 736 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 737 HYDRAULIC FILTER................................................................................................................................................................... 738 REMOVAL AND INSTALLATION....................................................................................................................................................... 738 SWITCH,POC PUMP.................................................................................................................................................................... 739 REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)............................................................................................................................... 739 SWITCH,PPC PUMP.................................................................................................................................................................... 740 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 740 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 741 POC VALVE.......................................................................................................................................................................... 742 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 742 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 744 DISASSEMBLY AND ASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................... 746 PPC VALVE.......................................................................................................................................................................... 747 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 747 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 749 DISASSEMBLY AND ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................. 751 MAIN CONTROL VALVE................................................................................................................................................................. 752 REMOVAL (SERIAL NO.10001-19999)................................................................................................................................................ 752 INSTALLATION (SERIAL NO.10001-19999)........................................................................................................................................... 754 DISASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................ 756 ASSEMBLY (SERIAL NO.10001-19999)............................................................................................................................................... 758 REMOVAL (SERIAL NO.20001 AND UP)............................................................................................................................................... 760 INSTALLATION (SERIAL NO.20001 AND UP).......................................................................................................................................... 763 DISASSEMBLY (SERIAL NO.20001 AND UP)........................................................................................................................................... 765 ASSEMBLY (SERIAL NO.20001 AND UP).............................................................................................................................................. 767 DUMP CYLINDER...................................................................................................................................................................... 769 REMOVAL........................................................................................................................................................................ 769 INSTALLATION................................................................................................................................................................... 771 LIFT CYLINDER...................................................................................................................................................................... 773 REMOVAL........................................................................................................................................................................ 773 INSTALLATION................................................................................................................................................................... 774 LIFT AND DUMP CYLINDERS............................................................................................................................................................ 775 DISASSEMBLY.................................................................................................................................................................... 775 ASSEMBLY....................................................................................................................................................................... 777 WORK EQUIPMENT..................................................................................................................................................................... 780 REMOVAL........................................................................................................................................................................ 780 INSTALLATION................................................................................................................................................................... 783 COUNTERWEIGHT...................................................................................................................................................................... 786 REMOVAL AND INSTALLATION....................................................................................................................................................... 786 64 MAINTENANCE STANDARD................................................................................................................................................................ 787 MAIN CONTROL VALVE................................................................................................................................................................. 788 SWITCH AND POC (PPC) PUMP.......................................................................................................................................................... 796 HYDRAULIC PUMP..................................................................................................................................................................... 798 POC VALVE.......................................................................................................................................................................... 799 POC VALVE (RELIEF VALVE)........................................................................................................................................................... 800 PPC VALVE.......................................................................................................................................................................... 801 DUMP CYLINDER...................................................................................................................................................................... 803 LIFT CYLINDER...................................................................................................................................................................... 804 BUCKET LINKAGE..................................................................................................................................................................... 805 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................ 807 BUCKET............................................................................................................................................................................. 808 80 ELECTRIC AND ELECTRONIC SYSTEM.......................................................................................................................................................... 809 81 STRUCTURE AND FUNCTION.............................................................................................................................................................. 809 ELECTRICAL WIRING DIAGRAM.......................................................................................................................................................... 810 ELECTRICAL WIRING DIAGRAM CIRCUIT.................................................................................................................................................. 811 ENGINE STARTING CIRCUIT............................................................................................................................................................ 818 ENGINE STOP CIRCUIT................................................................................................................................................................ 821 PREHEATING CIRCUIT................................................................................................................................................................. 824 PREHEATING AND AFTER-HEATING WITH HEATER SWITCH................................................................................................................................ 824 PREHEATING WITH STARTING SWITCH................................................................................................................................................ 825 AUTOMATIC PREHEATING........................................................................................................................................................... 826 COMBINATION SWITCH................................................................................................................................................................. 827 ELECTRICAL TRANSMISSION CONTROL.................................................................................................................................................... 828 TRANSMISSION CUT-OFF SWITCH.................................................................................................................................................... 830 TRANSMISSION CUT-OFF SELECTOR SWITCH........................................................................................................................................... 831 NEUTRALIZER RELAY.............................................................................................................................................................. 833 KICK-DOWN SWITCH............................................................................................................................................................... 835 KICK-DOWN ELECTRIC CIRCUIT..................................................................................................................................................... 836 ELECTRICAL PARKING BRAKE CONTROL .................................................................................................................................................. 842 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)........................................................................................................................................ 854 INDICATION ON MONITOR PANEL.................................................................................................................................................... 858 CONTROLLER..................................................................................................................................................................... 860 SENSORS............................................................................................................................................................................ 861 WIRING HARNESS................................................................................................................................................................. 867 OPERATION OF PROXIMITY SWITCH.................................................................................................................................................. 869 82 TESTING AND ADJUSTING............................................................................................................................................................... 873 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM......................................................................................................................................... 874 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)..................................................................................................................................... 876 TROUBLESHOOTING.................................................................................................................................................................... 878 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................................. 879 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.............................................................................................................................. 880 CONNECTOR TERMINAL NUMBERS..................................................................................................................................................... 882 PRECAUTION WHEN HANDLING CONNECTOR............................................................................................................................................. 887 ELECTRICAL WIRING DIAGRAM...................................................................................................................................................... 889 ELECTRICAL CIRCUIT SYSTEM...................................................................................................................................................... 891 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.10001-20000).............................................................................................................. 901 E-1. ENGINE DOES NOT START................................................................................................................................................. 902 E-1A. ENGINE DOES NOT START................................................................................................................................................ 904 E-2. ENGINE DOES NOT STOP.................................................................................................................................................. 906 E-3. ENGINE STOPS WHEN TRAVELING........................................................................................................................................... 908 E-4. PARKING BRAKE DOES NOT WORK........................................................................................................................................... 910 E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING............................................................................................................................... 912 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON ....................................................................................................... 914 E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED................................................................................................. 915 E-8. MACHINE DOES NOT TRAVEL FORWARD....................................................................................................................................... 916 E-9. MACHINE DOES NOT TRAVEL REVERSE....................................................................................................................................... 918 E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL)................................................................................................................. 920 E-11. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON (MACHINE TRAVELS ONLY WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS OFF)...................... 922 E-12. TRANSMISSION CANNOT BE CUT-OFF....................................................................................................................................... 923 E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL.............................................................................................................................. 924 E-14. PREHEATING DISPLAY DOES NOT GO OUT................................................................................................................................... 926 E-15. PREHEATING DOES NOT WORK............................................................................................................................................. 927 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.20001 AND UP)............................................................................................................. 928 POSITION OF CONNECTORS FOR TROUBLESHOOTING................................................................................................................................. 929 E-1. ENGINE DOES NOT START................................................................................................................................................. 935 E-2. ENGINE DOES NOT STOP.................................................................................................................................................. 939 E-3. ENGINE STOPS WHEN TRAVELING........................................................................................................................................... 939 E-4. PARKING BRAKE DOES NOT WORK........................................................................................................................................... 940 E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING............................................................................................................................... 941 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON .......................................................................................................... 943 E-7. WHEN PARKING BRAKE IS APPLIED,SHIFT LEVER DOES NOT ENTER NEUTRAL...................................................................................................... 943 E-8. TRANSMISSION DOES NOT WORK NORMALLY................................................................................................................................... 944 E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY)...................................................................................................... 964 E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)..................................................... 967 E-11. KICK-DOWN OPERATION IS NOT CANCELED.................................................................................................................................. 968 E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2...................................................................................................................... 970 E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED............................................................................................................. 970 E-14. PREHEAT DISPLAY STAYS ON............................................................................................................................................. 972 E-15. PREHEATING DOES NOT STOP............................................................................................................................................. 972 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10001-10080 (M SPEC.), SERIAL NO.10001-10118 (P SPEC.), SERIAL NO.10001-10125 (D SPEC.) ............ 973 M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),AND THERE IS NO ABNORMALITY IN MACHINE,CHECK BEFORE STARTING ITEM FLASHES..................................... 976 a) BRAKE OIL LEVEL..................................................................................................................................................... 976 b) ENGINE OIL LEVEL.................................................................................................................................................... 977 c) COOLANT LEVEL....................................................................................................................................................... 978 M-2. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASHES.............................................................................................. 979 a) BATTERY CHARGE...................................................................................................................................................... 979 b) FUEL LEVEL.......................................................................................................................................................... 980 M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),EMERGENCY ITEMS FLASHES............................................................................................ 981 a) FAILURE IN BRAKE LINE............................................................................................................................................... 981 b) ENGINE OIL PRESSURE................................................................................................................................................. 982 c) COOLANT LEVEL....................................................................................................................................................... 983 d) DROP IN AIR PRESSURE................................................................................................................................................ 984 e) COOLANT TEMPERATURE................................................................................................................................................. 985 f) TORQUE CONVERTER OIL TEMPERATURE.................................................................................................................................... 986 M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),PILOT ITEMS LIGHT UP ABNORMALLY,OR DOES NOT LIGHT UP.......................................................... 987 a) PARKING BRAKE DISPLAY DOES NOT GO OUT............................................................................................................................... 987 b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP............................................................................................................................. 988 c) WORKING LAMP DISPLAY DOES NOT GO OUT................................................................................................................................ 989 d) WORKING LAMP DISPLAY DOES NOT LIGHT UP.............................................................................................................................. 990 e) PREHEAT DISPLAY LIGHTS UP........................................................................................................................................... 991 f) PREHEAT DISPLAY DOES NOT LIGHT UP................................................................................................................................... 992 g) FAILURE IN MAIN STEERING DISPLAY LIGHT UP (IF EQUIPPED)............................................................................................................. 993 h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED).................................................................................................... 994 i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED)........................................................................................................... 995 j) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)................................................................................................... 996 k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP.............................................................................................................................. 997 l) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP...................................................................................................................... 998 M-5. TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP.................................................................................................... 999 a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP................................................................................................................. 999 b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP.................................................................................................................. 999 c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.........................................................................................................1000 d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP..........................................................................................................1001 e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP..............................................................................................................................1002 f) HIGE BEAM PILOT LAMP DOES NOT WORK NORMALLY.........................................................................................................................1003 M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY............................................................................................................................1004 M-7. SERVICEMETER DOES NOT WORK NORMALLY...................................................................................................................................1005 M-8. ABNORMALITY IN MONITOR PANEL..........................................................................................................................................1007 a) NONE OF MONITOR PANEL WORKS.........................................................................................................................................1007 b) PART OF MONITOR PANEL DOES NOT WORK.................................................................................................................................1009 c) EVEN WHEN ENGINE IS STOPPED,ENGINE OIL PRESSURE FLASHES,CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP.......................................................1010 d) EVEN WHEN ENGINE IS STOPPED,BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP ......................................................................................1011 e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO "ON",ENGINE STOPPED)....................................................................1011 f) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY...................................................................................1012 g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.........................................................................................................................1013 h) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY....................................................................................1014 i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..........................................................................................................................1015 M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR.................................................................................................................................1016 a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED.......................................................................................1016 b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON............................................................................................................1018 c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP.........................................................................................................................1019 d) PANEL LAMPS OF CHECKS,CAUTION 1 AND 2,SPEEDOMETER MODULE DO NOT LIGHT UP............................................................................................1020 e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP........................................................................................................................1021 M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP..........................................................................................................................1022 a) EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND..........................................................................................................1022 b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH...................................................................................1024 M-11. ABNORMALITY IN GAUGE.................................................................................................................................................1026 a) FUEL GAUGE..........................................................................................................................................................1026 b) AIR PRESSURE GAUGE..................................................................................................................................................1029 c) COOLANT TEMPERATURE GAUGE...........................................................................................................................................1031 d) TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................................................1033 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10081 AND UP (M SPEC.), SERIAL NO.10119 AND UP (P SPEC.), SERIAL NO.10126 AND UP (D SPEC.)]..........1035 POSITION OF CONNECTORS FOR TROUBLESHOOTING.................................................................................................................................1037 SERIAL NO.10081-20000 (M SPEC.)........................................................................................................................................1037 SERIAL NO.10119-20000 (P SPEC.)........................................................................................................................................1037 SERIAL NO.10126-20000 (D SPEC.)........................................................................................................................................1037 (SERIAL NO.20001 AND UP)...............................................................................................................................................1043 M-1. WHEN STARTING SWITCH IS TURNED TO ON POSITION,MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS...........................................................................1049 a) NONE OF MONITOR PANEL LIGHTS UP.....................................................................................................................................1049 b) EXCEPT FOR SPEEDOMETER MODULE,NONE OF MONITOR PANEL LIGHTS UP.......................................................................................................1049 c) NONE OF CAUTION ITEMS LIGHT UP......................................................................................................................................1049 d) SOME OTHER PARTS DO NOT LIGHT UP....................................................................................................................................1049 M-2. WHEN STARTING SWITCH IS TURNED TO ON POSITION,ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT.........................................................................1050 M-3. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CHECK ITEM FLASHES (LEVELS OF CHECK ITEMS ARE CORRECT).................................................1051 a) (ENGINE OIL LEVEL) FLASHES..........................................................................................................................................1051 b) (RADIATOR WATER LEVEL) FLASHES......................................................................................................................................1052 c) (BRAKE OIL LEVEL) FLASHES...........................................................................................................................................1052 M-4. NO OPERATION IS BEING CARRIED OUT,BUT PILOT DISPLAY LIGHTS UP ABNORMALLY..............................................................................................1054 a) (PREHEAT) LIGHT UP..................................................................................................................................................1054 b) (TRANSMISSION CUT-OFF) LIGHTS UP....................................................................................................................................1054 c) (PARKING BRAKE) LIGHTS UP...........................................................................................................................................1055 d) (WORKING LAMP) LIGHTS UP............................................................................................................................................1055 M-5. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CHECK ITEM FLASHES.....................................................................................1057 a) ENGINE OIL PRESSURE SYSTEM..........................................................................................................................................1057 b) ALTERNATOR SYSTEM...................................................................................................................................................1057 M-6. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CAUTION ITEM FLASHES...................................................................................1058 a) ENGINE OIL PRESSURE SYSTEM..........................................................................................................................................1058 b) ALTERNATOR SYSTEM...................................................................................................................................................1058 M-7. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE).............................................1060 a) (CHARGE LEVEL) FLASHES..............................................................................................................................................1060 b) (FUEL LEVEL) FLASHES................................................................................................................................................1060 c) (BRAKE LINE FAILURE) FLASHES........................................................................................................................................1060 d) (ENGINE OIL PRESSURE) FLASHES.......................................................................................................................................1060 e) (RADIATOR WATER LEVEL) FLASHES......................................................................................................................................1060 f) (AIR PRESSURE) FLASHES..............................................................................................................................................1061 g) (ENGINE WATER TEMPERATURE) FLASHES..................................................................................................................................1061 h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES..........................................................................................................................1061 M-8. SPEED SENSOR DISPLAY STAYS AT "O".....................................................................................................................................1063 M-9. HIGH BEAM DOES NOT LIGHT UP,OR LIGHTS UP ABNORMALLY...................................................................................................................1064 a) IF HIGH BEAM DOES NOT LIGHT UP......................................................................................................................................1064 b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF.................................................................................................................1064 c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION....................................................................................1065 M-10. TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING.................................................................................1066 a) IF TURN SIGNAL LAMP DOES NOT FLASH..................................................................................................................................1066 b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING..............................................................................................................1066 M-11. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND...................1067 M-12. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS...................................................................................................1068 M-13. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH....1069 M-14. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP................................................................................................1069 M-15. WHEN STARTING SWITCH IS TURNED TO ON POSITION,LAMPS DO NOT LIGHT UP FOR 4 SEC.WHEN LAMP SWITCH IS ON,LAMPS DO NOT LIGHT UP...........................................1070 a) NONE OF PANEL LIGHTS UP.............................................................................................................................................1070 b) SOME OF PANEL LAMPS DO NOT LIGHT UP.................................................................................................................................1070 M-16. LAMP SWITCH IS NOT BEING OPERATED,BUT NIGHT LIGHTING LIGHTS UP.NIGHT LIGHTING STAYS ON...............................................................................1071 M-17. SERVICE METER DOES NOT WORK..........................................................................................................................................1072 M-18. SERVICE METER MOVES WHEN ENGINE IS STOPPED...........................................................................................................................1072 M-19. ABNORMALITY IN AIR PRESSURE GAUGE....................................................................................................................................1073 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1073 b) IF INDICATOR REMAINS AT MAXIMUM LEVEL...............................................................................................................................1073 M-20. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE........................................................................................................................1074 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1074 b) IF INDICATOR REMAINS AT MINIMUM LEVEL...............................................................................................................................1074 M-21. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGA................................................................................................................1075 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1075 b) IF INDICATOR REMAINS AT MINIMUM LEVEL...............................................................................................................................1075 M-22. ABNORMALITY IN FUEL GAUGE............................................................................................................................................1076 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1076 b) IF INDICATOR REMAINS AT FULL........................................................................................................................................1076 83 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................1077 MACHINE MONITOR....................................................................................................................................................................1078 REMOVAL AND INSTALLATION.......................................................................................................................................................1078 90 OTHERS..................................................................................................................................................................................1079 91 LOGGING SPECIFICATIONS..............................................................................................................................................................1079 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................................................1080 MAIN CONTROL VALVE.................................................................................................................................................................1081 ARM CYLINDER.......................................................................................................................................................................1083 WORK EQUIPMENT.....................................................................................................................................................................1084 DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY.........................................................................................................................................1085 ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY............................................................................................................................................1087 MAIN CONTROL VALVE.................................................................................................................................................................1089 WORK EQUIPMENT.....................................................................................................................................................................1091 ARM CYLINDER.......................................................................................................................................................................1093 93 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................1094 CAB................................................................................................................................................................................1095 REMOVAL........................................................................................................................................................................1095 INSTALLATION...................................................................................................................................................................1095 97 GEAR PUMP...........................................................................................................................................................................1096 GENERAL............................................................................................................................................................................1096 GENERAL........................................................................................................................................................................1097 PRINCIPLE OF OPERATION.........................................................................................................................................................1098 PRESSURE LOADED TYPE GEAR PUMP.................................................................................................................................................1101 FIXED SIDE PLATE TYPE GEAR PUMP................................................................................................................................................1103 SA SERIES..........................................................................................................................................................................1104 STRUCTURE......................................................................................................................................................................1105 TESTING AND ADJUSTING..........................................................................................................................................................1108 DISASSEMBLY....................................................................................................................................................................1111 ASSEMBLY.......................................................................................................................................................................1115 MAINTENANCE STANDARD...........................................................................................................................................................1120
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