Komatsu WA470-1 Shop Manual SEBMU4210106 – PDF DOWNLOAD

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Komatsu WA470-1 Shop Manual SEBMU4210106 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA470-1 Shop Manual SEBMU4210106 – PDF DOWNLOAD

Language : English
Pages :1120
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA470-1 Shop Manual SEBMU4210106 – PDF DOWNLOAD

TABLE OF CONTENTS:

Komatsu WA470-1 Shop Manual SEBMU4210106 – PDF DOWNLOAD

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 NO10001-19999) 163
REMOVAL AND INSTALLATION (SERIAL NO20001 AND UP) 164
DISASSEMBLY (SERIAL NO10001-19999) 165
ASSEMBLY (SERIAL NO10001-19999) 167
DISASSEMBLY (SERIAL NO20001 AND UP) 169
ASSEMBLY (SERIAL NO20001 AND UP) 171
TORQUE CONVERTER CHARGING PUMP 175
REMOVAL AND INSTALLATION (SERIAL NO10001-19999) 175
REMOVAL (SERIAL NO20001 AND UP) 176
INSTALLATION (SERIAL NO20001 AND UP) 177
TORQUE CONVERTER AND TRANSMISSION 178
REMOVAL (SERIAL NO10001-19999) 178
INSTALLATION (SERIAL NO10001-19999) 185
REMOVAL (SERIAL NO20001 AND UP) 193
INSTALLATION (SERIAL NO20001 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 NO10001-20000) 361
STEERING VALVE (SERIAL NO20001 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 NO10001-20000) 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 NO20001 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 NO10001-19999) 412
INSTALLATION (SERIAL NO10001-19999) 413
DISASSEMBLY (SERIAL NO10001-19999) 414
ASSEMBLY (SERIAL NO10001-19999) 415
STEERING VALVE 418
REMOVAL (SERIAL NO20001 AND UP) 418
INSTALLATION (SERIAL NO20001 AND UP) 420
DISASSEMBLY (SERIAL NO20001 AND UP) 423
ASSEMBLY (SERIAL NO20001 AND UP) 426
REMOVAL (SERIAL NO10001-19999) 431
INSTALLATION (SERIAL NO10001-19999) 433
DISASSEMBLY (SERIAL NO10001-19999) 435
ASSEMBLY (SERIAL NO10001-19999) 437
STEERING DEMAND VALVE 439
REMOVAL (SERIAL NO20001 AND UP) 439
INSTALLATION (SERIAL NO20001 AND UP) 441
DISASSEMBLY (SERIAL NO20001 AND UP) 444
ASSEMBLY (SERIAL NO20001 AND UP) 448
STEERING PUMP 452
REMOVAL (SERIAL NO10001-19999) 452
INSTALLATION (SERIAL NO10001-19999) 453
REMOVAL (SERIAL NO20001 AND UP) 454
INSTALLATION (SERIAL NO20001 AND UP) 455
STEERING CYLINDER 456
REMOVAL (SERIAL NO10001-19999) 456
INSTALLATION (SERIAL NO10001-19999) 457
REMOVAL (SERIAL NO20001 AND UP) 458
INSTALLATION (SERIAL NO20001 AND UP) 459
DISASSEMBLY 460
ASSEMBLY 462
CENTER HINGE PIN 465
REMOVAL (SERIAL NO10001-19999) 465
INSTALLATION (SERIAL NO10001-19999) 472
REMOVAL (SERIAL NO20001 AND UP) 481
INSTALLATION (SERIAL NO20001 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 NO10001-19999) 568
INSTALLATION (SERIAL NO10001-19999) 569
REMOVAL (SERIAL NO20001 AND UP) 570
INSTALLATION (SERIAL NO20001 AND UP) 571
DISASSEMBLY 572
ASSEMBLY 574
BRAKE CHAMBER 576
REMOVAL (SERIAL NO10001-19999) 576
INSTALLATION (SERIAL NO10001-19999) 577
REMOVAL (SERIAL NO20001 AND UP) 578
INSTALLATION (SERIAL NO20001 AND UP) 580
DISASSEMBLY 582
ASSEMBLY 585
SLACK ADJUSTER 588
REMOVAL AND INSTALLATION (SERIAL NO10001-19999) 588
REMOVAL (SERIAL NO20001 AND UP) 589
INSTALLATION (SERIAL NO20001 AND UP) 591
DISASSEMBLY 593
ASSEMBLY 594
BRAKE ASSEMBLY 595
DISASSEMBLY 595
ASSEMBLY 601
DISASSEMBLY (SERIAL NO20001 AND UP) 608
ASSEMBLY (SERIAL NO20001 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 NO10001-19999) 725
INSTALLATION (SERIAL NO10001-19999) 726
REMOVAL (SERIAL NO20001 AND UP) 727
INSTALLATION (SERIAL NO20001 AND UP) 731
HYDRAULIC PUMP 734
REMOVAL (SERIAL NO10001-19999) 734
INSTALLATION (SERIAL NO10001-19999) 735
REMOVAL (SERIAL NO20001 AND UP) 736
INSTALLATION (SERIAL NO20001 AND UP) 737
HYDRAULIC FILTER 738
REMOVAL AND INSTALLATION 738
SWITCH,POC PUMP 739
REMOVAL AND INSTALLATION (SERIAL NO10001-19999) 739
SWITCH,PPC PUMP 740
REMOVAL (SERIAL NO20001 AND UP) 740
INSTALLATION (SERIAL NO20001 AND UP) 741
POC VALVE 742
REMOVAL (SERIAL NO10001-19999) 742
INSTALLATION (SERIAL NO10001-19999) 744
DISASSEMBLY AND ASSEMBLY (SERIAL NO10001-19999) 746
PPC VALVE 747
REMOVAL (SERIAL NO20001 AND UP) 747
INSTALLATION (SERIAL NO20001 AND UP) 749
DISASSEMBLY AND ASSEMBLY (SERIAL NO20001 AND UP) 751
MAIN CONTROL VALVE 752
REMOVAL (SERIAL NO10001-19999) 752
INSTALLATION (SERIAL NO10001-19999) 754
DISASSEMBLY (SERIAL NO10001-19999) 756
ASSEMBLY (SERIAL NO10001-19999) 758
REMOVAL (SERIAL NO20001 AND UP) 760
INSTALLATION (SERIAL NO20001 AND UP) 763
DISASSEMBLY (SERIAL NO20001 AND UP) 765
ASSEMBLY (SERIAL NO20001 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 NO10001-20000) 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 NO20001 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 NO10001-10080 (M SPEC), SERIAL NO10001-10118 (P SPEC), SERIAL NO10001-10125 (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 UP1000
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP1001
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP1002
f) HIGE BEAM PILOT LAMP DOES NOT WORK NORMALLY1003
M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY1004
M-7 SERVICEMETER DOES NOT WORK NORMALLY1005
M-8 ABNORMALITY IN MONITOR PANEL1007
a) NONE OF MONITOR PANEL WORKS1007
b) PART OF MONITOR PANEL DOES NOT WORK1009
c) EVEN WHEN ENGINE IS STOPPED,ENGINE OIL PRESSURE FLASHES,CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP1010
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 INTERMITTENTLY1012
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY1013
h) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY1014
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY1015
M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR1016
a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED1016
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON1018
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP1019
d) PANEL LAMPS OF CHECKS,CAUTION 1 AND 2,SPEEDOMETER MODULE DO NOT LIGHT UP1020
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP1021
M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP1022
a) EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND1022
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH1024
M-11 ABNORMALITY IN GAUGE1026
a) FUEL GAUGE1026
b) AIR PRESSURE GAUGE1029
c) COOLANT TEMPERATURE GAUGE1031
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE1033
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO10081 AND UP (M SPEC), SERIAL NO10119 AND UP (P SPEC), SERIAL NO10126 AND UP (D SPEC)]1035
POSITION OF CONNECTORS FOR TROUBLESHOOTING1037
SERIAL NO10081-20000 (M SPEC)1037
SERIAL NO10119-20000 (P SPEC)1037
SERIAL NO10126-20000 (D SPEC)1037
(SERIAL NO20001 AND UP)1043
M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION,MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS1049
a) NONE OF MONITOR PANEL LIGHTS UP1049
b) EXCEPT FOR SPEEDOMETER MODULE,NONE OF MONITOR PANEL LIGHTS UP1049
c) NONE OF CAUTION ITEMS LIGHT UP1049
d) SOME OTHER PARTS DO NOT LIGHT UP1049
M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION,ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT1050
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) FLASHES1051
b) (RADIATOR WATER LEVEL) FLASHES1052
c) (BRAKE OIL LEVEL) FLASHES1052
M-4 NO OPERATION IS BEING CARRIED OUT,BUT PILOT DISPLAY LIGHTS UP ABNORMALLY1054
a) (PREHEAT) LIGHT UP1054
b) (TRANSMISSION CUT-OFF) LIGHTS UP1054
c) (PARKING BRAKE) LIGHTS UP1055
d) (WORKING LAMP) LIGHTS UP1055
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CHECK ITEM FLASHES1057
a) ENGINE OIL PRESSURE SYSTEM1057
b) ALTERNATOR SYSTEM1057
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CAUTION ITEM FLASHES1058
a) ENGINE OIL PRESSURE SYSTEM1058
b) ALTERNATOR SYSTEM1058
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CAUTION ITEM FLASHES (FLASHING ITEMS ARE SPECIFIED VALUE)1060
a) (CHARGE LEVEL) FLASHES1060
b) (FUEL LEVEL) FLASHES1060
c) (BRAKE LINE FAILURE) FLASHES1060
d) (ENGINE OIL PRESSURE) FLASHES1060
e) (RADIATOR WATER LEVEL) FLASHES1060
f) (AIR PRESSURE) FLASHES1061
g) (ENGINE WATER TEMPERATURE) FLASHES1061
h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES1061
M-8 SPEED SENSOR DISPLAY STAYS AT “O”1063
M-9 HIGH BEAM DOES NOT LIGHT UP,OR LIGHTS UP ABNORMALLY1064
a) IF HIGH BEAM DOES NOT LIGHT UP1064
b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF1064
c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION1065
M-10 TURN SIGNAL LAMP DOES NOT FLASH TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING1066
a) IF TURN SIGNAL LAMP DOES NOT FLASH1066
b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING1066
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 SOUND1067
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS1068
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 FLASH1069
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP1069
M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION,LAMPS DO NOT LIGHT UP FOR 4 SECWHEN LAMP SWITCH IS ON,LAMPS DO NOT LIGHT UP1070
a) NONE OF PANEL LIGHTS UP1070
b) SOME OF PANEL LAMPS DO NOT LIGHT UP1070
M-16 LAMP SWITCH IS NOT BEING OPERATED,BUT NIGHT LIGHTING LIGHTS UPNIGHT LIGHTING STAYS ON1071
M-17 SERVICE METER DOES NOT WORK1072
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED1072
M-19 ABNORMALITY IN AIR PRESSURE GAUGE1073
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA1073
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL1073
M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE1074
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA1074
b) IF INDICATOR REMAINS AT MINIMUM LEVEL1074
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGA1075
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA1075
b) IF INDICATOR REMAINS AT MINIMUM LEVEL1075
M-22 ABNORMALITY IN FUEL GAUGE1076
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA1076
b) IF INDICATOR REMAINS AT FULL1076
83 DISASSEMBLY AND ASSEMBLY1077
MACHINE MONITOR1078
REMOVAL AND INSTALLATION1078
90 OTHERS1079
91 LOGGING SPECIFICATIONS1079
HYDRAULIC CIRCUIT DIAGRAM1080
MAIN CONTROL VALVE1081
ARM CYLINDER1083
WORK EQUIPMENT1084
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY1085
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY1087
MAIN CONTROL VALVE1089
WORK EQUIPMENT1091
ARM CYLINDER1093
93 DISASSEMBLY AND ASSEMBLY1094
CAB1095
REMOVAL1095
INSTALLATION1095
97 GEAR PUMP1096
GENERAL1096
GENERAL1097
PRINCIPLE OF OPERATION1098
PRESSURE LOADED TYPE GEAR PUMP1101
FIXED SIDE PLATE TYPE GEAR PUMP1103
SA SERIES1104
STRUCTURE1105
TESTING AND ADJUSTING1108
DISASSEMBLY1111
ASSEMBLY1115
MAINTENANCE STANDARD1120

IMAGES PREVIEW OF THE MANUAL:

S.M 13/12/24