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Komatsu Wa500-1 Wheel Loader Service Repair Manual Download SN 10001 And Up
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Komatsu Wa500-1 Wheel Loader Service Repair Manual Download SN 10001 And Up
- MACHINE MODEL :WA5004
- SERIAL No.: 10001 and up
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Description
Komatsu Wa500-1 Wheel Loader Service Repair Manual Download SN 10001 And Up
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:933
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU WA500-1 WHEEL LOADER SERVICE REPAIR MANUAL DOWNLOAD SN 10001 AND UP:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Wa500-1 Wheel Loader Service Repair Manual Download SN 10001 And Up
GENERAL PRECAUTIONS:
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. . Always wear safety glasses when hitting parts with a hammer. l Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3 PRECAUTIONS DURING WORK
1 1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12 The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13 Before starting work, remove the leads from the battery. Always remove the lead from the negative .
14 When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
15 When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
TABLE OF CONTENTS:
Komatsu Wa500-1 Wheel Loader Service Repair Manual Download SN 10001 And Up
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
INSTALLATION.........................................................................................................................................................................100
14 MAINTENANCE STANDARD......................................................................................................................................................................101
ENGINE MOUNT.............................................................................................................................................................................102
20 POWER TRAIN...................................................................................................................................................................................103
21 STRUCTURE AND FUNCTION....................................................................................................................................................................105
GENERAL .................................................................................................................................................................................106
HYDRAULIC CIRCUIT FOR POWER TRAIN....................................................................................................................................................108
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN............................................................................................................................................109
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
TRANSMISSION.............................................................................................................................................................................128
TRANSMISSION CONTROL VALVE ..............................................................................................................................................................136
UPPER VALVE..........................................................................................................................................................................138
LOWER VALVE..........................................................................................................................................................................139
TRANSMISSION SOLENOID VALVE..........................................................................................................................................................140
EMERGENCY MANUAL SPOOL...............................................................................................................................................................141
FORWARD IST..........................................................................................................................................................................142
PRIORITY VALVE.......................................................................................................................................................................144
MODULATING VALVE AND QUICK RETURN VALVE..............................................................................................................................................145
ACCUMULATOR VALVE....................................................................................................................................................................148
PILOT REDUCING VALVE.................................................................................................................................................................150
MAIN RELIEF VALVE....................................................................................................................................................................151
REDUCING VALVE.......................................................................................................................................................................152
LUBRICATION BYPASS VALVE.............................................................................................................................................................153
PILOT OIL FILTER ........................................................................................................................................................................154
TRANSFER.................................................................................................................................................................................155
DRIVE SHAfT .............................................................................................................................................................................156
CENTER SUPPORT ..........................................................................................................................................................................157
AXLE MOUNT...............................................................................................................................................................................158
AXLE AND DIFFERENTIAL ...................................................................................................................................................................160
FINAL DRIVE .............................................................................................................................................................................165
TIRE AND WHEEL...........................................................................................................................................................................166
22 TESTING AND ADJUSTING.....................................................................................................................................................................167
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
TROUBLESHOOTING..........................................................................................................................................................................177
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 move.............................................................................................................................................................184
2. Machine lacks power or speed......................................................................................................................................................186
3. Excessive time lag when starting machine or shifting gear.........................................................................................................................187
4. Torque converter oil temperature too high.........................................................................................................................................188
23 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................189
DAMPER...................................................................................................................................................................................190
REMOVAL..............................................................................................................................................................................190
INSTALLATION ........................................................................................................................................................................194
DISASSEMBLY .........................................................................................................................................................................198
ASSEMBLY ............................................................................................................................................................................200
TORQUE CONVERTER CHARGING PUMP...........................................................................................................................................................202
REMOVAL .............................................................................................................................................................................202
INSTALLATION ........................................................................................................................................................................202
TORQUE CONVERTER AND TRANSMISSION........................................................................................................................................................203
REMOVAL .............................................................................................................................................................................203
INSTALLATION ........................................................................................................................................................................210
TORQUE CONVERTER.........................................................................................................................................................................217
DISASSEMBLY .........................................................................................................................................................................217
ASSEMBLY ............................................................................................................................................................................221
TRANSMISSION.............................................................................................................................................................................227
DISASSEMBLY .........................................................................................................................................................................227
ASSEMBLY ............................................................................................................................................................................237
TRANSFER.................................................................................................................................................................................249
DISASSEMBLY .........................................................................................................................................................................249
ASSEMBLY ............................................................................................................................................................................252
TRANSMISSION CONTROL VALVE...............................................................................................................................................................256
REMOVAL .............................................................................................................................................................................256
INSTALLATION ........................................................................................................................................................................258
DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................260
FRONT DIFFERENTIAL.......................................................................................................................................................................264
REMOVAL..............................................................................................................................................................................264
INSTALLATION.........................................................................................................................................................................267
REAR DIFFERENTIAL........................................................................................................................................................................270
REMOVAL..............................................................................................................................................................................270
INSTALLATION ........................................................................................................................................................................273
DIFFERENTIAL GEAR........................................................................................................................................................................276
DISASSEMBLY .........................................................................................................................................................................276
ASSEMBLY ............................................................................................................................................................................280
FRONT AXLE...............................................................................................................................................................................286
REMOVAL..............................................................................................................................................................................286
INSTALLATION.........................................................................................................................................................................288
REAR AXLE................................................................................................................................................................................290
REMOVAL..............................................................................................................................................................................290
INSTALLATION.........................................................................................................................................................................294
CENTER SUPPORT...........................................................................................................................................................................298
REMOVAL .............................................................................................................................................................................298
INSTALLATION ........................................................................................................................................................................299
DISASSEMBLY..........................................................................................................................................................................300
ASSEMBLY ............................................................................................................................................................................302
DRIVE SHAFT Serial No. 10001 - 10222.....................................................................................................................................................304
DISASSEMBLY .........................................................................................................................................................................304
ASSEMBLY ............................................................................................................................................................................306
DRIVE SHAFT Serial No. 10223 and up......................................................................................................................................................308
DISASSEMBLY .........................................................................................................................................................................308
ASSEMBLY.............................................................................................................................................................................310
FINAL DRIVE..............................................................................................................................................................................312
DISASSEMBLY..........................................................................................................................................................................312
ASSEMBLY ............................................................................................................................................................................315
24 MAINTENANCE STANDARD ....................................................................................................................................................................319
TRANSMISSION MOUNT.......................................................................................................................................................................320
TORQUE CONVERTER CHARGING PUMP ..........................................................................................................................................................321
DAMPER...................................................................................................................................................................................322
TORQUE CONVERTER ........................................................................................................................................................................325
TRANSMISSION.............................................................................................................................................................................326
TRANSFER ................................................................................................................................................................................334
DRIVE SHAFT..............................................................................................................................................................................336
CENTER SUPPORT ..........................................................................................................................................................................337
DIFFERENTIAL.............................................................................................................................................................................338
AXLE MOUNT...............................................................................................................................................................................342
FINAL DRIVE .............................................................................................................................................................................344
40 STEERING SYSTEM...............................................................................................................................................................................345
41 STRUCTURE AND FUNCTION ...................................................................................................................................................................347
GENERAL .................................................................................................................................................................................348
HYDRAULIC CIRCUIT FOR STEERING ..........................................................................................................................................................350
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...............................................................................................................................................351
OPERATIONS OF STEERING VALVE ........................................................................................................................................................352
STEERING CONTROL SYSTEM .................................................................................................................................................................354
STEERING VALVE.......................................................................................................................................................................354
STEERING RELIEF VALVE................................................................................................................................................................356
SAFETY VALVE (with suction valve)....................................................................................................................................................357
OPERATION OF DEMAND SPOOL............................................................................................................................................................358
TWO-WAY RESTRICTOR VALVE.............................................................................................................................................................361
ROTOR SEAL...........................................................................................................................................................................362
STEERING CYLINDER........................................................................................................................................................................363
STEERING COLUMN AND GEAR BOX ............................................................................................................................................................364
STEERING LINKAGE ........................................................................................................................................................................365
STEERING PUMP ...........................................................................................................................................................................366
CENTER HINGE PIN.........................................................................................................................................................................367
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
TROUBLESHOOTING..........................................................................................................................................................................377
TROUBLESHOOTING TABLE ...............................................................................................................................................................378
1. Steering wheel does not turn......................................................................................................................................................378
2. Steering wheel is sluggish........................................................................................................................................................379
3. Steering wheel moves unsteadily or is subjected to large shock....................................................................................................................380
4. Machine tends to turn naturally in one particular direction when traveling........................................................................................................380
5. Left and right turning radii are different........................................................................................................................................380
42 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................381
STEERING GEAR BOX........................................................................................................................................................................382
REMOVAL .............................................................................................................................................................................382
INSTALLATION ........................................................................................................................................................................383
DISASSEMBLY .........................................................................................................................................................................384
ASSEMBLY ............................................................................................................................................................................385
STEERING VALVE...........................................................................................................................................................................387
REMOVAL .............................................................................................................................................................................387
INSTALLATION ........................................................................................................................................................................389
DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................391
STEERING PUMP AND POC PUMP...............................................................................................................................................................393
REMOVAL .............................................................................................................................................................................393
INSTALLATION ........................................................................................................................................................................394
STEERING CYLINDER........................................................................................................................................................................395
REMOVAL .............................................................................................................................................................................395
INSTALLATION ........................................................................................................................................................................396
DISASSEMBLY .........................................................................................................................................................................397
ASSEMBLY ............................................................................................................................................................................399
CENTER HINGE PIN.........................................................................................................................................................................402
REMOVAL .............................................................................................................................................................................402
INSTALLATION ........................................................................................................................................................................408
44 MAINTENANCE STANDARD......................................................................................................................................................................415
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 SYSTEM..........................................................................................................................................................................425
51 STRUCTURE AND FUNCTION....................................................................................................................................................................427
GENERAL .................................................................................................................................................................................428
AIR TANK ................................................................................................................................................................................431
SAFETY VALVE ............................................................................................................................................................................431
BRAKE VALVE .............................................................................................................................................................................432
BRAKE ACTUATED.......................................................................................................................................................................433
OPERATING IN BALANCE.................................................................................................................................................................434
BRAKE RELEASED.......................................................................................................................................................................435
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 ADJUSTING.....................................................................................................................................................................453
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
TROUBLESHOOTING..........................................................................................................................................................................467
TROUBLESHOOTING TABLE ...............................................................................................................................................................468
1. Air pressure does not rise at all.................................................................................................................................................468
2. Air pressure does not rise to the specified range.................................................................................................................................469
3. Brake is ineffective or not very effective........................................................................................................................................470
4. Brake does not release, or drags..................................................................................................................................................471
5. Parking brake does not release, or drags. (Applies to machine equiped with air parking brake.)...................................................................................472
53 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................473
AIR GOVERNOR.............................................................................................................................................................................474
DISASSEMBLY .........................................................................................................................................................................474
ASSEMBLY ............................................................................................................................................................................475
BRAKE VALVE..............................................................................................................................................................................476
REMOVAL .............................................................................................................................................................................476
INSTALLATION.........................................................................................................................................................................477
DISASSEMBLY .........................................................................................................................................................................478
ASSEMBLY ............................................................................................................................................................................480
BRAKE CHAMBER............................................................................................................................................................................482
REMOVAL .............................................................................................................................................................................482
INSTALLATION ........................................................................................................................................................................484
DISASSEMBLY .........................................................................................................................................................................486
ASSEMBLY ............................................................................................................................................................................489
SLACK ADJUSTER...........................................................................................................................................................................492
REMOVAL .............................................................................................................................................................................492
INSTALLATION.........................................................................................................................................................................492
DISASSEMBLY .........................................................................................................................................................................493
ASSEMBLY ............................................................................................................................................................................494
BRAKE....................................................................................................................................................................................495
REMOVAL .............................................................................................................................................................................495
INSTALLATION ........................................................................................................................................................................497
DISASSEMBLY .........................................................................................................................................................................500
ASSEMBLY ............................................................................................................................................................................504
SPRING CYLINDER..........................................................................................................................................................................508
REMOVAL .............................................................................................................................................................................508
INSTALLATION ........................................................................................................................................................................509
DISASSMBLY...........................................................................................................................................................................510
ASSEMBLY.............................................................................................................................................................................510
PARKING BRAKE............................................................................................................................................................................511
REMOVAL .............................................................................................................................................................................511
INSTALLATION ........................................................................................................................................................................514
PARKING BRAKE PAD........................................................................................................................................................................517
REMOVAL..............................................................................................................................................................................517
INSTALLATION.........................................................................................................................................................................517
54 MAINTENANCE STANDARD......................................................................................................................................................................519
BRAKE VALVE .............................................................................................................................................................................520
BRAKE CHAMBER ...........................................................................................................................................................................522
SLACK ADJUSTER ..........................................................................................................................................................................523
BRAKE ...................................................................................................................................................................................524
PARKING BRAKE ...........................................................................................................................................................................526
SPRING CYLINDER .........................................................................................................................................................................527
60 WORK EQUIPMENT SYSTEM.........................................................................................................................................................................529
61 STRUCTURE AND FUNCTION....................................................................................................................................................................531
GENERAL .................................................................................................................................................................................532
HYDRAULIC CIRCUIT SYSTEM ................................................................................................................................................................534
HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................................535
WORK EQUIPMENT LEVER LINKAGE ............................................................................................................................................................536
HYDRAULK TANK............................................................................................................................................................................538
OIL FILTER BYPASS VALVE..............................................................................................................................................................539
BREATHER.............................................................................................................................................................................539
HYDRAULIC PUMPS..........................................................................................................................................................................540
HYDRAULtC PUMP.......................................................................................................................................................................540
SWtTCH PUMP..........................................................................................................................................................................540
POC PUMP.............................................................................................................................................................................541
POC VALVE ...............................................................................................................................................................................542
MAIN CONTROL VALVE ......................................................................................................................................................................550
RELIEF VALVE.........................................................................................................................................................................552
SAFETY VALVE.........................................................................................................................................................................553
SUCTION VALVE........................................................................................................................................................................554
FLOAT SELECTOR VALVE AND UNLOADER VALVE..............................................................................................................................................555
HYDRAULIC CYLINDER ......................................................................................................................................................................562
BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................................................564
BUCKET LINKAGE ..........................................................................................................................................................................566
BUCKET ..................................................................................................................................................................................568
ACCUMULATOR .............................................................................................................................................................................569
62 TESTING AND ADJUSTING.....................................................................................................................................................................571
STANDARD VALUE TABLE.....................................................................................................................................................................572
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
TROUBLESHOOTING..........................................................................................................................................................................585
TROUBLESHOOTING TABLE ...............................................................................................................................................................586
1. Lift arm does not rise............................................................................................................................................................586
*** MISSING 2-7 (PGS 62-15 THROUGH 62-22)............................................................................................................................................555
8. Bucket does not tilt back.........................................................................................................................................................587
9. Bucket moves slowly or has insufficient tilt back power...........................................................................................................................588
10. Bucket movement becomes slow during tilt back....................................................................................................................................589
11. Bucket cannot be held down by the bucket cylinder................................................................................................................................589
12. Bucket has large hydraulic drift.................................................................................................................................................589
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 sluggishly..................................................................................................................590
63 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................591
HYDRAULIC TANK...........................................................................................................................................................................592
REMOVAL .............................................................................................................................................................................592
INSTALLATION ........................................................................................................................................................................593
HYDRAULIC PUMP...........................................................................................................................................................................594
REMOVAL .............................................................................................................................................................................594
INSTALLATION ........................................................................................................................................................................594
HYDRAULIC FILTER.........................................................................................................................................................................595
REMOVAL .............................................................................................................................................................................595
INSTALLATION.........................................................................................................................................................................595
SWITCH PUMP..............................................................................................................................................................................596
REMOVAL..............................................................................................................................................................................596
INSTALLATION ........................................................................................................................................................................597
POC VALVE................................................................................................................................................................................598
REMOVAL .............................................................................................................................................................................598
INSTALLATION ........................................................................................................................................................................600
DISASSEMBLY .........................................................................................................................................................................602
ASSEMBLY ............................................................................................................................................................................602
MAIN CONTROL VALVE.......................................................................................................................................................................603
REMOVAL .............................................................................................................................................................................603
INSTALLATION ........................................................................................................................................................................605
DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................608
DUMP CYLINDER............................................................................................................................................................................610
REMOVAL .............................................................................................................................................................................610
INSTALLATION.........................................................................................................................................................................612
LIFT CYLINDER............................................................................................................................................................................614
REMOVAL .............................................................................................................................................................................614
INSTALLATION ........................................................................................................................................................................615
LIFT AND DUMP CYLINDERS..................................................................................................................................................................617
DISASSEMBLY .........................................................................................................................................................................617
ASSEMBLY ............................................................................................................................................................................619
WORK EQUIPMENT...........................................................................................................................................................................622
REMOVAL..............................................................................................................................................................................622
INSTALLATION.........................................................................................................................................................................626
COUNTERWEIGHT............................................................................................................................................................................633
REMOVAL..............................................................................................................................................................................633
INSTALLATION.........................................................................................................................................................................633
64 MAINTENANCE STANDARD .....................................................................................................................................................................635
MAIN CONTROL VALVE ......................................................................................................................................................................636
DUMP CYLINDER ...........................................................................................................................................................................638
LIFT CYLINDER ...........................................................................................................................................................................639
BUCKET LINKAGE...........................................................................................................................................................................640
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 FUNCTION....................................................................................................................................................................647
ELECTRICAL WIRING DIAGRAM CIRCUIT........................................................................................................................................................648
ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER .......................................................................................................................................653
ENGINE STARTING CIRCUIT .................................................................................................................................................................654
ENGINE STOP CIRCUIT .....................................................................................................................................................................657
PREHEATING CIRCUIT.......................................................................................................................................................................659
PREHEATING WITH STARTING SWITCH......................................................................................................................................................659
AUTOMATIC PREHEATING.................................................................................................................................................................660
COMBINATION SWITCH.......................................................................................................................................................................661
ELECTRICAL TRANSMISSION CONTROL .........................................................................................................................................................662
TRANSMISSION CUT-OFF SWITCH..........................................................................................................................................................663
TRANSMISSION CUT-OFF SELECTOR SWITCH.................................................................................................................................................664
NEUTRALIZER RELAY....................................................................................................................................................................665
ELECTRICAL PARKING BRAKE CONTROL ........................................................................................................................................................666
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).............................................................................................................................................675
MONITOR PANEL........................................................................................................................................................................675
INDICATION ON MONITOR PANEL..........................................................................................................................................................679
CONTROLLER...........................................................................................................................................................................681
WIRING HARNESS.......................................................................................................................................................................682
SENSORS .............................................................................................................................................................................684
CONTACT SWITCH.......................................................................................................................................................................689
OPERATION OF CONTACT SWITCH .............................................................................................................................................................690
82 TESTING AND ADJUSTING.....................................................................................................................................................................695
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ..............................................................................................................................................696
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR ........................................................................................................................................699
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR ...........................................................................................................................................701
TROUBLESHOOTING..........................................................................................................................................................................703
CHECK BEFORE TROUBLESHOOTING ........................................................................................................................................................704
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ...................................................................................................................................705
CONNECTOR TERMINAL NUMBERS ..........................................................................................................................................................707
PRECAUTION WHEN HANDLING CONNECTOR ..................................................................................................................................................711
ELECTRICAL WIRING DIAGRAM............................................................................................................................................................713
ELETRICAL CIRCUIT SYSTEM.............................................................................................................................................................714
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-15)..............................................................................................................................723
E-1 ENGINE DOES NOT START........................................................................................................................................................724
E-1A ENGINE DOES NOT START (STARTING MOTOR ROTATES)..............................................................................................................................726
E-2 ENGINE DOES NOT STOP.........................................................................................................................................................729
E-3 ENGINE STOPS WHEN TRAVELING..................................................................................................................................................730
E-4 a)PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON)......................................................................................................................732
b)PARKlNG BRAKE DOES NOT WORK. (AIR PRESSURE LESS THAN 2.0kg/cm2)............................................................................................................732
E-5 PARKING BRAKE IS NOT RELEASED................................................................................................................................................736
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON...............................................................................................................740
E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................................................................................................740
E-8 MACHINE DOES NOT TRAVEL FORWARD..............................................................................................................................................744
E-9 MACHINE DOES NOT TRAVEL REVERSE..............................................................................................................................................748
E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).....................................................................................................................752
E-11 MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON......................................................................................................................754
E-12 TRANSMISSION CANNOT BE CUT-OFF..............................................................................................................................................755
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL ....................................................................................................................................756
E-14 PREHEATING DISPLAY DOES NOT GO OUT..........................................................................................................................................758
E-15 PREHATING DOES NOT WORK.....................................................................................................................................................759
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 ITEM..................................................764
a) BRAKE OIL LEVEL FLASHES...................................................................................................................................................764
b) ENGINE OIL LEVEL FLASHES..................................................................................................................................................765
c) COOLANT LEVEL FLASHES.....................................................................................................................................................766
M-2 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES........................................................767
a) BATTERY CHARGE FLASHES....................................................................................................................................................767
b) FUEL LEVEL FLASHES........................................................................................................................................................768
c) CLOGGING IN TRANsMlSSl0N OIL FILTER FLASHES...............................................................................................................................769
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASHES........................................................770
a) FAILURE IN BRAKE LINE FLASHES.............................................................................................................................................770
b) ENGINE OIL PRESSURE FLASHES...............................................................................................................................................771
c) COOLANT LEVEL FLASHES.....................................................................................................................................................772
d) DROP IN AIR PRESSURE FLASHES..............................................................................................................................................773
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 ABNORM.................................................776
a) PARKING BRAKE DISPLAY DOES NOT GO OUT.....................................................................................................................................776
b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP...................................................................................................................................777
c) WORKING LAMP DISPLAY DOES NOT GO OUT......................................................................................................................................778
d) WORKING LAMP DISPLAY DOES NOT LIGHT UP....................................................................................................................................779
e) PREHEAT DISPLAY LIGHTS UP.................................................................................................................................................780
f) PREHEAT DISPLAY DOES NOT LIGHT UP.........................................................................................................................................781
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 UP....................................................................................................................................786
I) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP............................................................................................................................787
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 UP.......................................................................................................................788
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP........................................................................................................................788
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP...............................................................................................................789
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP................................................................................................................790
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP....................................................................................................................................791
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT......................................................................................................................................792
M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...................................................................................................................................793
M-7 SERVICE METER DOES NOT WORK NORMALLY.........................................................................................................................................794
M-8 ABNORMALITY IN MONITOR PANEL.................................................................................................................................................796
a) NONE OF MONITOR PANEL WORKS...............................................................................................................................................796
*** 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 INTERMITTENTLY.......................................................................................799
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY...............................................................................................................................800
h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY.........................................................................................801
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY................................................................................................................................802
M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR .......................................................................................................................................804
a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED.............................................................................................804
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS .............................................................................................................................806
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP...............................................................................................................................807
d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP................................................................................................808
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP..............................................................................................................................809
M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP. ...............................................................................................................................810
a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND..............................................................................................................810
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH.........................................................................................812
M-11 ABNORMALITY IN GAUGE. ......................................................................................................................................................814
a) FUEL GAUGE .............................................................................................................................................................814
b) AIR PRESSURE GUAGE........................................................................................................................................................816
c) COOLANT TEMPERATURE GAUGE.................................................................................................................................................818
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE....................................................................................................................................820
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 STOPPED..............................................................................................................................838
M-3 RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS STOPPED..........................................................................................................................840
M-4 BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING................................................................................................................................840
M-5 TRANSMISSION OIL FILTER CLOGGING FLASHES WHEN ENGINE IS RUNNING. ............................................................................................................842
M-6 FUEL LEVEL FLASHES WHEN ENGINE IS RUNNING....................................................................................................................................844
M-7 BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING. ..........................................................................................................................844
M-8 ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING...........................................................................................................................846
M-9 RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS RUNNING.........................................................................................................................846
M-10 DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING.........................................................................................................................848
M-11 ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.....................................................................................................................848
M-12 TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.............................................................................................................848
M-13 PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP....................................................................................................................850
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 UP.....................................................................................................................852
a) if working lamp stays lighted up..........................................................................................................................................852
b) If working lamp does not light up.........................................................................................................................................852
M-15 PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP..................................................................................................................................854
a) Preheating lights up......................................................................................................................................................854
b) Preheating does not light up..............................................................................................................................................854
M-16 TRANSMISSION CUT-OFF LIGHTS UP, DOES NOT LIGHT UP...........................................................................................................................856
a) Transmission cut-off lights up............................................................................................................................................856
b) Transmission cut-off does not light up....................................................................................................................................856
M-17 TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP............................................................................................................................858
a) Turn signal (right) pilot display lights up...............................................................................................................................858
b) Turn signal (left) pilot display lights up................................................................................................................................859
c) Turn signal (right) pilot display does not light up.......................................................................................................................860
d) Turn signal (left) pilot display does not light up........................................................................................................................860
e) Hi beam pilot does not light up...........................................................................................................................................861
f) Hi beam pilot stays lighted up............................................................................................................................................861
M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON............................................................................................................863
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 up...........................................................................................................................................866
b) Except for speedometer module, none of monitor panel lights up............................................................................................................866
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 actuated.............................................................................................868
b) (Battery charge) flashes, and warning lamp lights up......................................................................................................................868
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 up...........................................................................................870
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 UP......................................................................................................879
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 SYSTEM.......................................................................................................................884
a) If nothing is displayed in display area...................................................................................................................................884
b) If indicator remains at minimum level.....................................................................................................................................884
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 ASSEMBLY..................................................................................................................................................................889
MONITOR MACHINE .........................................................................................................................................................................890
Serial No. 10001-10662...............................................................................................................................................................890
REMOVAL..........................................................................................................................................................................890
INSTALLATION.....................................................................................................................................................................890
Serial No. 10663 and up..............................................................................................................................................................891
REMOVAL..........................................................................................................................................................................891
INSTALLATION.....................................................................................................................................................................892
90 OTHERS........................................................................................................................................................................................893
91 OTHERS....................................................................................................................................................................................893
CAB......................................................................................................................................................................................894
AIR CONDITIONER..........................................................................................................................................................................895
PIPING...............................................................................................................................................................................895
AIR CONDITIONER WIRING DIAGRAM.......................................................................................................................................................896
AIR CONDITIONER ELECTRIC CIRCUIT.....................................................................................................................................................897
AIR CONDITIONER UNIT.................................................................................................................................................................898
COMPRESSOR...........................................................................................................................................................................900
CONDENSER............................................................................................................................................................................901
DRY RESERVOIR........................................................................................................................................................................902
93 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................903
CAB......................................................................................................................................................................................904
REMOVAL..............................................................................................................................................................................904
INSTALLATION.........................................................................................................................................................................905
AIR CONDITIONER UNIT (If equipped).......................................................................................................................................................906
REMOVAL..............................................................................................................................................................................906
INSTALLATION.........................................................................................................................................................................908
AIR CONDITIONER CONDENSER................................................................................................................................................................910
REMOVAL..............................................................................................................................................................................910
INSTALLATION.........................................................................................................................................................................910
DRY RESERVOIR............................................................................................................................................................................911
REMOVAL..............................................................................................................................................................................911
INSTALLATION.........................................................................................................................................................................911
COMPRESSOR FOR AIR CONDITIONER...........................................................................................................................................................912
(For DAIKIN air conditioner).........................................................................................................................................................912
REMOVAL..........................................................................................................................................................................912
INSTALLATION.....................................................................................................................................................................912
(For DENS0 air conditioner)..........................................................................................................................................................913
REMOVAL..........................................................................................................................................................................913
INSTALLATION.....................................................................................................................................................................914
97 GEAR PUMP SA SERIES.......................................................................................................................................................................915
STRUCTURE................................................................................................................................................................................916
TESTING AND ADJUSTING....................................................................................................................................................................919
DISASSEMBLY..............................................................................................................................................................................922
ASSEMBLY.................................................................................................................................................................................926
MAINTENANCE STANDARD.....................................................................................................................................................................931
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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