Komatsu WA500-1 Shop Manual SEBM04250107 – PDF DOWNLOAD

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Komatsu WA500-1 Shop Manual SEBM04250107 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-1 Shop Manual SEBM04250107 – PDF DOWNLOAD

Language : English
Pages :933
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA500-1 Shop Manual SEBM04250107 – PDF DOWNLOAD

• 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 chaptors for each main group of components; these chapters are further divided into the following sections.
  STRUCTURE AND FUNCTION
  This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
  TESTING AND ADJUSTING
  This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
  Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
  DISASSEMBLY AND ASSEMBLY
  This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
  MAINTENANCE STANDARD
  This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu WA500-1 Shop Manual SEBM04250107 – PDF DOWNLOAD

MAIN MENU 0
CONTENTS 3
10 ENGINE 41
11 STRUCTURE AND FUNCTION 43
ENGINE MOUNT 44
RADIATOR 45
FUEL TANK AND PIPING 46
ENGINE CONTROL 47
12 TESTING AND ADJUSTING 49
STANDARD VALUE TABLE 50
TOOL LIST FOR TESTING AND ADJUSTING 51
ADJUSTING VALVE CLEARANCE 52
MEASURING COMPRESSION PRESSURE 53
TESTING AND ADJUSTING FUEL INJECTION TIMING 54
MEASURING BLOW-BY PRESSURE 56
TESTING AND ADJUSTING BELT TENSION 57
MEASURING EXHAUST GAS COLOR 58
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 59
ADJUSTING FUEL CUT SOLENOID 60
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE 61
13 DISASSEMBLY AND ASSEMBLY 63
STARTING MOTOR 64
REMOVAL 64
INSTALLATION 64
ALTERNATOR 65
REMOVAL 65
INSTALLATION 65
OIL COOLER 66
REMOVAL 66
INSTALLATION 66
FUEL INJECTION PUMP 67
REMOVAL 67
INSTALLATION 67
WATER PUMP 68
REMOVAL 68
INSTALLATION 68
NOZZLE HOLDER 69
REMOVAL 69
INSTALLATION 69
TURBOCHARGER 70
REMOVAL 70
INSTALLATION 70
AIR COMPRESSOR 71
REMOVAL 71
INSTALLATION 71
CYLINDER HEAD 72
REMOVAL 72
INSTALLATION 77
RADIATOR 83
REMOVAL 83
INSTALLATION 85
ENGINE 87
REMOVAL 87
INSTALLATION 93
FUEL TANK 99
REMOVAL 99
INSTALLATION100
14 MAINTENANCE STANDARD101
ENGINE MOUNT102
20 POWER TRAIN103
21 STRUCTURE AND FUNCTION105
GENERAL 106
HYDRAULIC CIRCUIT FOR POWER TRAIN108
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN109
DAMPER 112
TORQUE CONVERTER AND TRANSMISSION PIPING 116
TORQUE CONVERTER CHARGING PUMP 119
TORQUE CONVERTER OIL COOLER 120
TORQUE CONVERTER OIL FILTER 123
TORQUE CONVERTER 124
TRANSMISSION MOUNT 126
TORQUE CONVERTER RELIEF VALVE 127
TRANSMISSION128
TRANSMISSION CONTROL VALVE 136
UPPER VALVE138
LOWER VALVE139
TRANSMISSION SOLENOID VALVE140
EMERGENCY MANUAL SPOOL141
FORWARD IST142
PRIORITY VALVE144
MODULATING VALVE AND QUICK RETURN VALVE145
ACCUMULATOR VALVE148
PILOT REDUCING VALVE150
MAIN RELIEF VALVE151
REDUCING VALVE152
LUBRICATION BYPASS VALVE153
PILOT OIL FILTER 154
TRANSFER155
DRIVE SHAfT 156
CENTER SUPPORT 157
AXLE MOUNT158
AXLE AND DIFFERENTIAL 160
FINAL DRIVE 165
TIRE AND WHEEL166
22 TESTING AND ADJUSTING167
STANDARD VALUE TABLE 168
TOOL LIST FOR TESTING AND ADJUSTING 169
MEASURING ENGINE STALL SPEED 170
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION * 172
MEASURING SHIFT LEVER 174
METHOD FOR OPERATION OF SPOOL EMERGENCY MANUAL 175
TIRE AND WHEEL 176
TROUBLESHOOTING177
PRECAUTIONS WHEN TROUBLESHOOTING 178
METHOD OF READING TROUBLESHOOTING TABLE 180
PREVENTING RECURRENCE OF TROUBLE 182
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM 183
TROUBLESHOOTING TABLE 184
1 Machine does not move184
2 Machine lacks power or speed186
3 Excessive time lag when starting machine or shifting gear187
4 Torque converter oil temperature too high188
23 DISASSEMBLY AND ASSEMBLY189
DAMPER190
REMOVAL190
INSTALLATION 194
DISASSEMBLY 198
ASSEMBLY 200
TORQUE CONVERTER CHARGING PUMP202
REMOVAL 202
INSTALLATION 202
TORQUE CONVERTER AND TRANSMISSION203
REMOVAL 203
INSTALLATION 210
TORQUE CONVERTER217
DISASSEMBLY 217
ASSEMBLY 221
TRANSMISSION227
DISASSEMBLY 227
ASSEMBLY 237
TRANSFER249
DISASSEMBLY 249
ASSEMBLY 252
TRANSMISSION CONTROL VALVE256
REMOVAL 256
INSTALLATION 258
DISASSEMBLY AND ASSEMBLY 260
FRONT DIFFERENTIAL264
REMOVAL264
INSTALLATION267
REAR DIFFERENTIAL270
REMOVAL270
INSTALLATION 273
DIFFERENTIAL GEAR276
DISASSEMBLY 276
ASSEMBLY 280
FRONT AXLE286
REMOVAL286
INSTALLATION288
REAR AXLE290
REMOVAL290
INSTALLATION294
CENTER SUPPORT298
REMOVAL 298
INSTALLATION 299
DISASSEMBLY300
ASSEMBLY 302
DRIVE SHAFT Serial No 10001 – 10222304
DISASSEMBLY 304
ASSEMBLY 306
DRIVE SHAFT Serial No 10223 and up308
DISASSEMBLY 308
ASSEMBLY310
FINAL DRIVE312
DISASSEMBLY312
ASSEMBLY 315
24 MAINTENANCE STANDARD 319
TRANSMISSION MOUNT320
TORQUE CONVERTER CHARGING PUMP 321
DAMPER322
TORQUE CONVERTER 325
TRANSMISSION326
TRANSFER 334
DRIVE SHAFT336
CENTER SUPPORT 337
DIFFERENTIAL338
AXLE MOUNT342
FINAL DRIVE 344
40 STEERING SYSTEM345
41 STRUCTURE AND FUNCTION 347
GENERAL 348
HYDRAULIC CIRCUIT FOR STEERING 350
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING351
OPERATIONS OF STEERING VALVE 352
STEERING CONTROL SYSTEM 354
STEERING VALVE354
STEERING RELIEF VALVE356
SAFETY VALVE (with suction valve)357
OPERATION OF DEMAND SPOOL358
TWO-WAY RESTRICTOR VALVE361
ROTOR SEAL362
STEERING CYLINDER363
STEERING COLUMN AND GEAR BOX 364
STEERING LINKAGE 365
STEERING PUMP 366
CENTER HINGE PIN367
42 TESTING AND ADJUSTING 369
STANDARD VALUE TABLE 370
TOOL LIST FOR TESTING AND ADJUSTING 370
MEASURING STEERING WHEEL PLAY 371
MEASURING OPERATING FORCE OF STEERING WHEEL 372
OPERATING TIME OF STEERING WHEEL 373
TESTING STEERING LINKAGE 374
ADJUSTING STEERING LINKAGE 375
STEERING OIL PRESSURE 376
TROUBLESHOOTING377
TROUBLESHOOTING TABLE 378
1 Steering wheel does not turn378
2 Steering wheel is sluggish379
3 Steering wheel moves unsteadily or is subjected to large shock380
4 Machine tends to turn naturally in one particular direction when traveling380
5 Left and right turning radii are different380
42 DISASSEMBLY AND ASSEMBLY381
STEERING GEAR BOX382
REMOVAL 382
INSTALLATION 383
DISASSEMBLY 384
ASSEMBLY 385
STEERING VALVE387
REMOVAL 387
INSTALLATION 389
DISASSEMBLY AND ASSEMBLY 391
STEERING PUMP AND POC PUMP393
REMOVAL 393
INSTALLATION 394
STEERING CYLINDER395
REMOVAL 395
INSTALLATION 396
DISASSEMBLY 397
ASSEMBLY 399
CENTER HINGE PIN402
REMOVAL 402
INSTALLATION 408
44 MAINTENANCE STANDARD415
STEERING LINKAGE 416
STEERING COLUMN AND GEAR BOX 417
STEERING PUMP 418
STEERING VALVE 419
STEERING CYLINDER MOUNT 420
STEERING CYLINDER 421
CENTER HINGE PIN 422
50 BRAKE AND AIR SYSTEM425
51 STRUCTURE AND FUNCTION427
GENERAL 428
AIR TANK 431
SAFETY VALVE 431
BRAKE VALVE 432
BRAKE ACTUATED433
OPERATING IN BALANCE434
BRAKE RELEASED435
AIR GOVERNOR 436
TWO-WAY VALVE 438
BRAKE CHAMBER 439
SLACK ADJUSTER 441
BRAKE 444
PARKING BRAKE 446
PARKING BRAKE SOLENOID VALVE 448
SPRING CYLINDER 451
BRAKE CALIPER 452
52 TESTING AND ADJUSTING453
STANDARD VALUE TABLE 454
TOOL LIST FOR TESTING AND ADJUSTING 455
MEASURING BRAKE PEDAL 456
MEASURING AIR 457
BRAKE PERFORMANCE 460
CHECKING BRAKE PISTON LEAKAGE 461
MEASURING WEAR OF BRAKE DISC 462
AIR BLEEDING FROM BRAKE LINE 463
PARKING BRAKE PERFORMANCE 464
CHECKING AND ADJUSTING PARKING BRAKE 465
TROUBLESHOOTING467
TROUBLESHOOTING TABLE 468
1 Air pressure does not rise at all468
2 Air pressure does not rise to the specified range469
3 Brake is ineffective or not very effective470
4 Brake does not release, or drags471
5 Parking brake does not release, or drags (Applies to machine equiped with air parking brake)472
53 DISASSEMBLY AND ASSEMBLY473
AIR GOVERNOR474
DISASSEMBLY 474
ASSEMBLY 475
BRAKE VALVE476
REMOVAL 476
INSTALLATION477
DISASSEMBLY 478
ASSEMBLY 480
BRAKE CHAMBER482
REMOVAL 482
INSTALLATION 484
DISASSEMBLY 486
ASSEMBLY 489
SLACK ADJUSTER492
REMOVAL 492
INSTALLATION492
DISASSEMBLY 493
ASSEMBLY 494
BRAKE495
REMOVAL 495
INSTALLATION 497
DISASSEMBLY 500
ASSEMBLY 504
SPRING CYLINDER508
REMOVAL 508
INSTALLATION 509
DISASSMBLY510
ASSEMBLY510
PARKING BRAKE511
REMOVAL 511
INSTALLATION 514
PARKING BRAKE PAD517
REMOVAL517
INSTALLATION517
54 MAINTENANCE STANDARD519
BRAKE VALVE 520
BRAKE CHAMBER 522
SLACK ADJUSTER 523
BRAKE 524
PARKING BRAKE 526
SPRING CYLINDER 527
60 WORK EQUIPMENT SYSTEM529
61 STRUCTURE AND FUNCTION531
GENERAL 532
HYDRAULIC CIRCUIT SYSTEM 534
HYDRAULIC CIRCUIT DIAGRAM 535
WORK EQUIPMENT LEVER LINKAGE 536
HYDRAULK TANK538
OIL FILTER BYPASS VALVE539
BREATHER539
HYDRAULIC PUMPS540
HYDRAULtC PUMP540
SWtTCH PUMP540
POC PUMP541
POC VALVE 542
MAIN CONTROL VALVE 550
RELIEF VALVE552
SAFETY VALVE553
SUCTION VALVE554
FLOAT SELECTOR VALVE AND UNLOADER VALVE555
HYDRAULIC CYLINDER 562
BUCKET POSITIONER AND BOOM KICK-OUT 564
BUCKET LINKAGE 566
BUCKET 568
ACCUMULATOR 569
62 TESTING AND ADJUSTING571
STANDARD VALUE TABLE572
TOOL LIST FOR TESTING AND ADJUSTING 575
MEASURING DUMP AND LIFT CONTROL LEVERS 576
ADJUSTING DUMP AND LIFT CONTROL LEVERS 577
MEASURING HYDRAULIC PRESSURE OF WORK’EQUIPME,NT 578
MEASURING WORK EQUIPMENT 581
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT 582
ADJUSTING BUCKET POSITIONER 583
ADJUSTING BOOM KICK-OUT 584
TROUBLESHOOTING585
TROUBLESHOOTING TABLE 586
1 Lift arm does not rise586
*** MISSING 2-7 (PGS 62-15 THROUGH 62-22)555
8 Bucket does not tilt back587
9 Bucket moves slowly or has insufficient tilt back power588
10 Bucket movement becomes slow during tilt back589
11 Bucket cannot be held down by the bucket cylinder589
12 Bucket has large hydraulic drift589
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”)589
14 Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” 589
15 Control levers of lift arm and dump move stiffly and sluggishly590
63 DISASSEMBLY AND ASSEMBLY591
HYDRAULIC TANK592
REMOVAL 592
INSTALLATION 593
HYDRAULIC PUMP594
REMOVAL 594
INSTALLATION 594
HYDRAULIC FILTER595
REMOVAL 595
INSTALLATION595
SWITCH PUMP596
REMOVAL596
INSTALLATION 597
POC VALVE598
REMOVAL 598
INSTALLATION 600
DISASSEMBLY 602
ASSEMBLY 602
MAIN CONTROL VALVE603
REMOVAL 603
INSTALLATION 605
DISASSEMBLY AND ASSEMBLY 608
DUMP CYLINDER610
REMOVAL 610
INSTALLATION612
LIFT CYLINDER614
REMOVAL 614
INSTALLATION 615
LIFT AND DUMP CYLINDERS617
DISASSEMBLY 617
ASSEMBLY 619
WORK EQUIPMENT622
REMOVAL622
INSTALLATION626
COUNTERWEIGHT633
REMOVAL633
INSTALLATION633
64 MAINTENANCE STANDARD 635
MAIN CONTROL VALVE 636
DUMP CYLINDER 638
LIFT CYLINDER 639
BUCKET LINKAGE640
BUCKET POSITIONER AND BOOM KICK-OUT 642
BUCKET 643
HYDRAULIC AND SWlTCH PUMP 644
POC PUMP 645
POC VALVE 646
80 ELECTRIC AND ELECTRONIC SYSTEM 647
81 STRUCTURE AND FUNCTION647
ELECTRIC AND ELECTRONIC SYSTEM 0
ELECTRICAL WIRING DIAGRAM CIRCUIT648
ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER 653
ENGINE STARTING CIRCUIT 654
ENGINE STOP CIRCUIT 657
PREHEATING CIRCUIT659
PREHEATING WITH STARTING SWITCH659
AUTOMATIC PREHEATING660
COMBINATION SWITCH661
ELECTRICAL TRANSMISSION CONTROL 662
TRANSMISSION CUT-OFF SWITCH663
TRANSMISSION CUT-OFF SELECTOR SWITCH664
NEUTRALIZER RELAY665
ELECTRICAL PARKING BRAKE CONTROL 666
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)675
MONITOR PANEL675
INDICATION ON MONITOR PANEL679
CONTROLLER681
WIRING HARNESS682
SENSORS 684
CONTACT SWITCH689
OPERATION OF CONTACT SWITCH 690
82 TESTING AND ADJUSTING695
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 696
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR 699
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR 701
TROUBLESHOOTING703
CHECK BEFORE TROUBLESHOOTING 704
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 705
CONNECTOR TERMINAL NUMBERS 707
PRECAUTION WHEN HANDLING CONNECTOR 711
ELECTRICAL WIRING DIAGRAM713
ELETRICAL CIRCUIT SYSTEM714
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-15)723
E-1 ENGINE DOES NOT START724
E-1A ENGINE DOES NOT START (STARTING MOTOR ROTATES)726
E-2 ENGINE DOES NOT STOP729
E-3 ENGINE STOPS WHEN TRAVELING730
E-4 a)PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON)732
b)PARKlNG BRAKE DOES NOT WORK (AIR PRESSURE LESS THAN 20kg/cm2)732
E-5 PARKING BRAKE IS NOT RELEASED736
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON740
E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED740
E-8 MACHINE DOES NOT TRAVEL FORWARD744
E-9 MACHINE DOES NOT TRAVEL REVERSE748
E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL)752
E-11 MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON754
E-12 TRANSMISSION CANNOT BE CUT-OFF755
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL 756
E-14 PREHEATING DISPLAY DOES NOT GO OUT758
E-15 PREHATING DOES NOT WORK759
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 to M-11)(Serial No 10001-10662)760
M-1 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ITEM764
a) BRAKE OIL LEVEL FLASHES764
b) ENGINE OIL LEVEL FLASHES765
c) COOLANT LEVEL FLASHES766
M-2 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES767
a) BATTERY CHARGE FLASHES767
b) FUEL LEVEL FLASHES768
c) CLOGGING IN TRANsMlSSl0N OIL FILTER FLASHES769
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASHES770
a) FAILURE IN BRAKE LINE FLASHES770
b) ENGINE OIL PRESSURE FLASHES771
c) COOLANT LEVEL FLASHES772
d) DROP IN AIR PRESSURE FLASHES773
e) COOLANT TEMPERATURE FLASHES 774
f) TORQUE CONVERTER OIL TEMPERATURE FLASHES 775
M-4 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP ABNORM776
a) PARKING BRAKE DISPLAY DOES NOT GO OUT776
b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP777
c) WORKING LAMP DISPLAY DOES NOT GO OUT778
d) WORKING LAMP DISPLAY DOES NOT LIGHT UP779
e) PREHEAT DISPLAY LIGHTS UP780
f) PREHEAT DISPLAY DOES NOT LIGHT UP781
g) FAILURE IN MAIN STEERING DISPLAY LIGHTS UP (IF EQUIPPED)782
h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)783
i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED)784
i) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)785
k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP786
I) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP787
M-5 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT UP 788
a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP788
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP788
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP789
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP790
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP791
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT792
M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY793
M-7 SERVICE METER DOES NOT WORK NORMALLY794
M-8 ABNORMALITY IN MONITOR PANEL796
a) NONE OF MONITOR PANEL WORKS796
*** MISSING “b)” (PG 82-79 & 82-80)796
c) EVEN WHEN ENGINE IS STOPPED (ENGINE OIL PRESSURE) FLASHES, CAUTION BUZZER SOUNDS AND WARNING 797
d) EVEN WHEN ENGINE STOPPED, I- (BATTERY CHARGE) L-J FLASHES AND WARNING LAMP LIGHTS UP 798
e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARGING SWITCH TO “ON”, ENGINE STOPPED) 798
f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY799
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY800
h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY801
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY802
M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR 804
a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED804
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS 806
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP807
d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP808
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP809
M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP 810
a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND810
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH812
M-11 ABNORMALITY IN GAUGE 814
a) FUEL GAUGE 814
b) AIR PRESSURE GUAGE816
c) COOLANT TEMPERATURE GAUGE818
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE820
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (Electronic vehicle monitoring system)(Serial No 10663 and UP)823
CONNECTOR TYPES AND LOCATION OF COMPONENTS 825
M-1 BRAKE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED 838
M-2 ENGINE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED838
M-3 RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS STOPPED840
M-4 BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING840
M-5 TRANSMISSION OIL FILTER CLOGGING FLASHES WHEN ENGINE IS RUNNING 842
M-6 FUEL LEVEL FLASHES WHEN ENGINE IS RUNNING844
M-7 BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING 844
M-8 ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING846
M-9 RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS RUNNING846
M-10 DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING848
M-11 ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING848
M-12 TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING848
M-13 PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP850
a) If parking brake stays lighted up 852
b) If parking brake does not light up 852
M-14 WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP852
a) if working lamp stays lighted up852
b) If working lamp does not light up852
M-15 PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP854
a) Preheating lights up854
b) Preheating does not light up854
M-16 TRANSMISSION CUT-OFF LIGHTS UP, DOES NOT LIGHT UP856
a) Transmission cut-off lights up856
b) Transmission cut-off does not light up856
M-17 TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP858
a) Turn signal (right) pilot display lights up858
b) Turn signal (left) pilot display lights up859
c) Turn signal (right) pilot display does not light up860
d) Turn signal (left) pilot display does not light up860
e) Hi beam pilot does not light up861
f) Hi beam pilot stays lighted up861
M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON863
M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY 864
M-20 HOURMETER DOES NOT WORK NORMALLY 865
M-21 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS 866
a) None of monitor panel lights up866
b) Except for speedometer module, none of monitor panel lights up866
c) None of CAUTION items light up 867
d) Some other parts do not light up 867
M-22 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT 867
M-23 (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED 868
a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated868
b) (Battery charge) flashes, and warning lamp lights up868
M-24 NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP 870
a) Even when combination lamp is placed at SMALL, none of panel lighting lights up870
b) Even when working lamp is switched ON, none of monitor panel lights up 872
c) Even when starting switch is turned ON, none of monitor panel lights up 874
d) Part of panel does not light up 874
M-25 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 876
M-26 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS 876
M-27 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 878
M-28 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNIGN LAMP LIGHTS UP879
M-29 ABNORMALITY IN (FUEL GAUGE) SYSTEM 880
a) If nothing is displayed in display area 880
b) If indicator remains at FULL 880
M-30 ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM 882
a) If nothing is displayed in display area 882
b) If indicator remains at maximum level 882
M-31 ABNORMALITY IN ENGINE WATER TEMPERRATURE GUAGE SYSTEM884
a) If nothing is displayed in display area884
b) If indicator remains at minimum level884
M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM 886
a) If nothing is displayed in display area 886
b) If indicator remains at minimum level 886
83 DISASSEMBLY AND ASSEMBLY889
MONITOR MACHINE 890
Serial No 10001-10662890
REMOVAL890
INSTALLATION890
Serial No 10663 and up891
REMOVAL891
INSTALLATION892
90 OTHERS893
91 OTHERS893
CAB894
AIR CONDITIONER895
PIPING895
AIR CONDITIONER WIRING DIAGRAM896
AIR CONDITIONER ELECTRIC CIRCUIT897
AIR CONDITIONER UNIT898
COMPRESSOR900
CONDENSER901
DRY RESERVOIR902
93 DISASSEMBLY AND ASSEMBLY903
CAB904
REMOVAL904
INSTALLATION905
AIR CONDITIONER UNIT (If equipped)906
REMOVAL906
INSTALLATION908
AIR CONDITIONER CONDENSER910
REMOVAL910
INSTALLATION910
DRY RESERVOIR911
REMOVAL911
INSTALLATION911
COMPRESSOR FOR AIR CONDITIONER912
(For DAIKIN air conditioner)912
REMOVAL912
INSTALLATION912
(For DENS0 air conditioner)913
REMOVAL913
INSTALLATION914
97 GEAR PUMP SA SERIES915
STRUCTURE916
TESTING AND ADJUSTING919
DISASSEMBLY922
ASSEMBLY926
MAINTENANCE STANDARD931

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24