Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual A50001 and up – PDF DOWNLOAD
Original price was: $45.95.$28.95Current price is: $28.95.
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual
Book Code: CEBM003702
SERIAL NUMBERS : WA900-3LC A50001 and UP
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA900-3LC Avance Loader
Serial Number: A50001 and up
Book Code: CEBM003702
Language: English
Pages: 939
File Format: Portable Document Format (PDF)
KOMATSU WA900-3LC AVANCE LOADER WHEEL LOADER SHOP MANUAL A50001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA900-3LC Avance Loader Wheel Loader Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER PAGE................................................................................................................................... 1 CONTENTS..................................................................................................................................... 2 00 FOREWORD.................................................................................................................................. 13 SAFETY................................................................................................................................... 13 SAFETY NOTICE........................................................................................................................ 13 IMPORTANT SAFETY NOTICE.......................................................................................................... 13 GENERAL PRECAUTIONS.............................................................................................................. 13 PREPARATIONS FOR WORK............................................................................................................ 13 PRECAUTIONS DURING WORK.......................................................................................................... 13 GENERAL.................................................................................................................................. 15 HOW TO READ THE SHOP MANUAL.............................................................................................................. 16 VOLUMES.............................................................................................................................. 16 DISTRIBUTION AND UPDATING............................................................................................................ 16 FILING METHOD........................................................................................................................ 16 REVISED EDITION MARK................................................................................................................. 16 REVISIONS............................................................................................................................ 16 SYMBOLS.............................................................................................................................. 16 HOISTING INSTRUCTIONS.................................................................................................................... 17 HOISTING............................................................................................................................. 17 WIRE ROPES........................................................................................................................... 17 COATING MATERIALS........................................................................................................................ 18 STANDARD TIGHTENING TORQUE............................................................................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS......................................................................................... 20 TIGHTENING TORQUE OF HOSE NUTS....................................................................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.............................................................................................. 21 TIGHTENING TORQUE FOR FLARED NUTS.................................................................................................... 21 ELECTRIC WIRE CODE....................................................................................................................... 22 CLASSIFICATION BY THICKNESS.......................................................................................................... 22 CLASSIFICATION BY COLOR AND CODE..................................................................................................... 22 CONVERSION TABLES........................................................................................................................ 23 METHOD OF USING THE CONVERSION TABLE................................................................................................. 23 01 GENERAL.................................................................................................................................. 29 SPECIFICATION DRAWING.................................................................................................................... 30 SPECIFICATIONS........................................................................................................................... 31 WEIGHT TABLE............................................................................................................................. 34 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 35 ENGINE OIL SPECIFICATIONS............................................................................................................ 36 NORMAL OPERATION................................................................................................................. 36 ARCTIC OPERATION................................................................................................................. 36 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM................................ 37 FINAL DRIVE OIL SPECIFICATIONS................................................................................................... 37 DRIVE AXLE OIL SPECIFICATIONS.................................................................................................... 37 DIESEL FUEL SPECIFICATIONS....................................................................................................... 37 COOLANT SPECIFICATIONS........................................................................................................... 38 SUPPLEMENTAL COOLANT ADDITIVES................................................................................................... 40 COOLING SYSTEM TEST KIT.......................................................................................................... 44 10 STRUCTURE AND FUNCTION................................................................................................................... 45 POWER TRAIN.............................................................................................................................. 50 OUTLINE.............................................................................................................................. 50 ENGINE CONTROL........................................................................................................................... 52 OUTLINE.............................................................................................................................. 52 RADIATOR AND HYDRAULIC OIL COOLER........................................................................................................ 53 DAMPER................................................................................................................................... 54 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................. 55 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.................................................................................................... 56 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................... 57 TORQUE CONVERTER......................................................................................................................... 58 RELIEF VALVE......................................................................................................................... 61 OUTLINE.......................................................................................................................... 61 FUNCTION......................................................................................................................... 61 REGULATOR VALVE...................................................................................................................... 62 OPERATION........................................................................................................................ 62 TRANSMISSION............................................................................................................................. 63 CLUTCH............................................................................................................................... 66 OUTLINE.......................................................................................................................... 66 OPERATION........................................................................................................................ 66 FORWARD 1st...................................................................................................................... 67 FORWARD 2ND...................................................................................................................... 68 FORWARD 3RD...................................................................................................................... 69 REVERSE 1ST...................................................................................................................... 70 TRANSFER............................................................................................................................. 71 OUTLINE.......................................................................................................................... 71 TRANSMISSION PATH................................................................................................................ 71 CONTROL VALVE........................................................................................................................ 72 SOLENOID VALVE................................................................................................................... 73 TRANSMISSION SOLENOID VALVE.......................................................................................................... 74 UPPER VALVE...................................................................................................................... 76 LINE OIL FILTER.................................................................................................................. 77 PILOT OIL FILTER................................................................................................................. 77 MAIN RELIEF VALVE................................................................................................................ 78 PILOT REDUCING VALVE............................................................................................................. 79 PRIORITY VALVE................................................................................................................... 80 MODULATING VALVE AND QUICK RETURN VALVE.......................................................................................... 81 OPERATION........................................................................................................................ 81 REDUCING VALVE................................................................................................................... 83 EMERGENCY MANUAL SPOOL........................................................................................................... 84 LUBRICATION VALVE................................................................................................................ 85 HYDRAULIC CIRCUIT SCHEMATICS............................................................................................................. 86 FORWARD 1st.......................................................................................................................... 86 OPERATION............................................................................................................................ 87 TORQUE CONVERTER OIL COOLER.............................................................................................................. 88 OUTLINE.............................................................................................................................. 88 DRIVE SHAFT.............................................................................................................................. 89 OUTLINE.............................................................................................................................. 89 CENTER SUPPORT....................................................................................................................... 90 FUNCTION......................................................................................................................... 90 AXLE..................................................................................................................................... 91 FRONT AXLE........................................................................................................................... 91 FRONT DIFFERENTIAL................................................................................................................... 92 REAR AXLE............................................................................................................................ 93 REAR DIFFERENTIAL.................................................................................................................... 94 OUTLINE.............................................................................................................................. 95 FINAL DRIVE.............................................................................................................................. 96 OUTLINE.............................................................................................................................. 96 OPERATION............................................................................................................................ 96 MEMORANDA................................................................................................................................ 97 AXLE MOUNT............................................................................................................................... 98 FRONT AXLE........................................................................................................................... 99 REAR AXLE............................................................................................................................ 99 CENTER HINGE PIN.........................................................................................................................100 OUTLINE..............................................................................................................................100 TIRE AND WHEEL...........................................................................................................................101 OUTLINE..............................................................................................................................101 STEERING.................................................................................................................................102 PIPING...............................................................................................................................102 STEERING COLUMN......................................................................................................................103 STEERING PUMP........................................................................................................................104 OUTLINE..........................................................................................................................104 MEMORANDA................................................................................................................................106 SWITCH PUMP..............................................................................................................................107 OUTLINE..............................................................................................................................107 SWITCH PUMP (HPV 90 + 90)............................................................................................................108 CO - NC VALVE........................................................................................................................110 CO VALVE.............................................................................................................................112 FUNCTION.........................................................................................................................112 OPERATION........................................................................................................................112 NC VALVE.............................................................................................................................114 OPERATION........................................................................................................................114 STEERING DEMAND VALVE....................................................................................................................115 OVERLOAD RELIEF VALVE................................................................................................................116 FUNCTION.........................................................................................................................116 OPERATION........................................................................................................................116 MAIN RELIEF VALVE................................................................................................................118 OPERATION OF DEMAND VALVE............................................................................................................120 WHEN STEERING SPOOL IS OPERATED......................................................................................................121 OPERATION OF STEERING VALVE..........................................................................................................123 ORBIT-ROLL VALVE.....................................................................................................................126 OUTLINE..............................................................................................................................127 STRUCTURE............................................................................................................................127 OPERATION........................................................................................................................128 TWO-WAY RESTRICTOR VALVE.............................................................................................................129 FUNCTION.........................................................................................................................129 OPERATION........................................................................................................................129 DIVERTER VALVE.......................................................................................................................130 FUNCTION.........................................................................................................................130 GROUND DRIVEN STEERING...................................................................................................................131 RELIEF VALVE.........................................................................................................................131 FUNCTION.........................................................................................................................131 OPERATION........................................................................................................................131 HYDRAULIC CIRCUIT SCHEMATICS.........................................................................................................132 PUMP, ENGINE WORKING NORMALLY....................................................................................................132 FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING..............................................................................133 BRAKE....................................................................................................................................134 PIPING...............................................................................................................................134 BRAKE CIRCUIT DIAGRAM................................................................................................................136 BRAKE VALVE..........................................................................................................................138 OUTLINE..........................................................................................................................138 OPERATION........................................................................................................................139 CHARGE VALVE.........................................................................................................................142 FUNCTION.........................................................................................................................142 OPERATION........................................................................................................................144 ACCUMULATOR..........................................................................................................................146 FUNCTION.........................................................................................................................146 SLACK ADJUSTER.......................................................................................................................147 FUNCTION.........................................................................................................................147 OPERATION........................................................................................................................148 BRAKE................................................................................................................................150 OPERATION........................................................................................................................150 FUNCTION.........................................................................................................................150 PARKING BRAKE........................................................................................................................151 OUTLINE..........................................................................................................................151 OPERATION........................................................................................................................152 SPRING CYLINDER......................................................................................................................153 OUTLINE..........................................................................................................................153 PARKING BRAKE SOLENOID VALVE.........................................................................................................154 FUNCTION.........................................................................................................................154 HYDRAULIC PIPING.........................................................................................................................156 MACHINE WITH JOYSTICK STEERING.......................................................................................................158 WORK EQUIPMENT LEVER LINKAGE.............................................................................................................162 HYDRAULIC TANK...........................................................................................................................163 OUTLINE..............................................................................................................................163 OIL FILTER BYPASS VALVE..............................................................................................................164 BREATHER.............................................................................................................................165 FUNCTION.........................................................................................................................165 MAIN PISTON PUMP.........................................................................................................................166 OUTLINE..............................................................................................................................166 PISTON PUMP (HPV90 + 90).............................................................................................................167 FUNCTION.........................................................................................................................169 STRUCTURE........................................................................................................................169 OPERATION........................................................................................................................170 CONTROL PUMP (BAR025)................................................................................................................172 RELIEF VALVE.........................................................................................................................173 ES (ENGINE SENSING) VALVE................................................................................................................174 FUNCTION.............................................................................................................................174 OPERATION............................................................................................................................175 SERVO VALVE..............................................................................................................................176 OPERATION............................................................................................................................177 PPC VALVE................................................................................................................................179 OPERATION............................................................................................................................181 PPC RELIEF VALVE.........................................................................................................................183 FUNCTION.............................................................................................................................183 OPERATION............................................................................................................................183 ACCUMULATOR (PPC VALVE)..................................................................................................................184 FUNCTION.............................................................................................................................184 OPERATION............................................................................................................................184 MAIN CONTROL VALVE.......................................................................................................................185 FUNCTION.............................................................................................................................186 RELIEF VALVE.........................................................................................................................187 FUNCTION.........................................................................................................................187 OPERATION........................................................................................................................187 SAFETY VALVE (with suction valve)....................................................................................................188 FUNCTION.........................................................................................................................188 OPERATION........................................................................................................................188 SUCTION VALVE....................................................................................................................189 OPERATION........................................................................................................................189 FLOAT SELECTOR VALVE AND UNLOADER VALVE..............................................................................................190 FUNCTION.........................................................................................................................190 OPERATION........................................................................................................................190 OPERATION OF HYDRAULIC CIRCUIT.......................................................................................................192 BOOM AND DUMP SPOOLS IN “HOLD”...................................................................................................192 LIFT SPOOL IN “RAISE”............................................................................................................193 LIFT SPOOL IN “LOWER”............................................................................................................194 BOOM SPOOL IN “FLOAT”............................................................................................................195 DUMP SPOOL IN “DUMP”.............................................................................................................196 DUMP SPOOL IN “TILT BACK”........................................................................................................197 WORK EQUIPMENT...........................................................................................................................198 LUBRICATION..........................................................................................................................198 LINKAGE..............................................................................................................................200 BUCKET POSITIONER AND BOOM KICKOUT.......................................................................................................202 BUCKET POSITIONER....................................................................................................................203 BOOM KICK-OUT........................................................................................................................203 OPERATION OF PROXIMITY SWITCH........................................................................................................204 BOOM RAISE.......................................................................................................................204 BUCKET TILT......................................................................................................................206 CAB......................................................................................................................................208 ROPS CANOPY..............................................................................................................................209 AIR CONDITIONER..........................................................................................................................210 AIR CONDITIONER PIPING...............................................................................................................210 AIR CONDITIONER CONDENSER............................................................................................................211 AIR CONDITIONER COMPRESSOR...........................................................................................................211 DRY RESERVOIR........................................................................................................................212 ELECTRIC CIRCUIT DIAGRAM.................................................................................................................215 MACHINE MONITOR SYSTEM...................................................................................................................233 OUTLINE..............................................................................................................................233 MAIN MONITOR.............................................................................................................................234 OUTLINE..............................................................................................................................234 DISPLAY FUNCTION.....................................................................................................................235 SWITCH FUNCTION......................................................................................................................236 TROUBLE DATA DISPLAY MODE............................................................................................................237 MAINTENANCE MONITOR..................................................................................................................238 OUTLINE..........................................................................................................................238 DISPLAY FUNCTION.................................................................................................................239 ENGINE START AND STOP CIRCUIT............................................................................................................241 SAFETY RELAY.........................................................................................................................243 FUNCTION.........................................................................................................................244 ENGINE START.....................................................................................................................244 ENGINE STOP......................................................................................................................244 PREHEATING CIRCUIT...................................................................................................................245 OUTLINE..........................................................................................................................245 ELECTRICAL TRANSMISSION CONTROL..........................................................................................................246 FUNCTION.............................................................................................................................246 COMBINATION SWITCH...................................................................................................................247 OUTLINE..............................................................................................................................247 OPERATION............................................................................................................................248 KICK-DOWN, HOLD SWITCH...............................................................................................................249 KICK-DOWN SWITCH.....................................................................................................................249 OPERATION........................................................................................................................249 CANCELLATION (or not actuated)...................................................................................................249 HOLD SWITCH......................................................................................................................249 PARKING BRAKE............................................................................................................................250 ELECTRIC CONTROL.....................................................................................................................250 OUTLINE..........................................................................................................................250 FUNCTION.........................................................................................................................251 PARKING BRAKE SWITCH.............................................................................................................251 PARKING BRAKE SOLENOID VALVE.....................................................................................................252 PARKING SAFETY RELAY.............................................................................................................252 NEUTRALIZER RELAY................................................................................................................252 EMERGENCY BRAKE SWITCH...........................................................................................................252 OPERATION............................................................................................................................253 STARTING SWITCH OFF..............................................................................................................253 STARTING SWITCH ON...............................................................................................................254 PARKING BRAKE SWITCH OFF (RELEASED)..............................................................................................256 PARKING BRAKE SWITCH ON (actuated)...............................................................................................257 WHEN MAIN BRAKE OIL PRESSURE DROPS (emergency brake actuated)....................................................................258 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................259 STANDARD VALUE TABLE FOR ENGINE..........................................................................................................260 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................261 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................267 TESTING AND ADJUSTING ...................................................................................................................277 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.....................................................................................278 MEASURING ENGINE SPEED...............................................................................................................280 ADJUSTING VALVE CLEARANCE............................................................................................................282 MEASURING COMPRESSION PRESSURE.......................................................................................................283 MEASURING BLOW-BY PRESSURE...........................................................................................................284 FUEL INJECTION TIMING................................................................................................................285 MEASURING ENGINE OIL PRESSURE........................................................................................................287 MEASURING EXHAUST TEMPERATURE........................................................................................................288 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).......................................................................................289 ALTERNATOR BELT TENSION..............................................................................................................290 AIR CONDITIONER COMPRESSOR BELT TENSION..............................................................................................291 MEASURING ACCELERATOR PEDAL..........................................................................................................292 TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE.......................................................................................293 PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL.....................................................................................296 STEERING OIL PRESSURE................................................................................................................298 GROUND DRIVEN STEERING OIL PRESSURE..................................................................................................299 BLEEDING AIR FROM STEERING CIRCUIT...................................................................................................301 STEERING STOP VALVE..................................................................................................................302 TESTING WHEEL BRAKE PERFORMANCE......................................................................................................303 TESTING WHEEL BRAKE OIL PRESSURE DROP................................................................................................304 MEASURING WEAR OF WHEEL BRAKE DISC...................................................................................................306 ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE.......................................................................................307 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT................................................................................................309 TESTING PARKING BRAKE PERFORMANCE....................................................................................................310 MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE.....................................................................................311 PARKING BRAKE PAD....................................................................................................................312 PPC PRESSURE.........................................................................................................................314 ADJUSTING PPC VALVE LINKAGE..........................................................................................................316 WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................................................317 BLEEDING AIR FROM PISTON PUMP........................................................................................................319 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT.............................................................................................320 ADJUSTING WORK EQUIPMENT LEVER LINKAGE...............................................................................................321 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................323 BUCKET PROXIMITY SWITCH..............................................................................................................324 BOOM PROXIMITY SWITCH................................................................................................................325 TESTING PROXIMITY ACTUATION PILOT LAMP...............................................................................................326 ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR.........................................................................................327 ADJUSTING JOYSTICK LEVER POTENTIOMETER...............................................................................................328 ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH....................................................................................330 TROUBLESHOOTING..........................................................................................................................331 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................332 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................333 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................334 POINTS TO REMEMBER WHEN HANDLING ELECTRICAL EQUIPMENT............................................................................334 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS......................................................................339 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.............................................................................340 CHECKS BEFORE TROUBLESHOOTING........................................................................................................342 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................343 CONNECTOR ARRANGEMENT DIAGRAM .......................................................................................................347 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................352 EXPLANATION OF FUNCTION OF ELECTRICAL CONTROL MECHANISM..............................................................................365 TRANSMISSION CONTROL SYSTEM......................................................................................................365 MAIN MONITOR SYSTEM..............................................................................................................366 MAINTENANCE MONITOR SYSTEM.......................................................................................................367 JOYSTICK STEERING ...............................................................................................................368 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE....................................................................................369 CHART OF ACTION CODES AND FAILURE CODES AND RE-ENACTION..............................................................................371 TRANSMISSION CONTROLLER LED DISPLAY..................................................................................................373 METHOD OF USING JUDGEMENT TABLE......................................................................................................374 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................375 METHOD OF USING MATRIX TROUBLESHOOTING TABLES........................................................................................377 METHOD OF USING TROUBLESHOOTING ENGINE RELATED CHARTS................................................................................379 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)............................................................................................383 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKE TIME)....................................................................384 S-2 ENGINE DOES NOT START.......................................................................................................385 (1) ENGINE DOES NOT TURN.....................................................................................................385 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...................................................386 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START..........................................................................387 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)........................................................................388 S-4 ENGINE STOPS DURING OPERATION...............................................................................................389 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...................................................................................390 S-6 ENGINE LACKS OUTPUT (NO POWER)..............................................................................................391 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)................................................................................392 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).......................................................................393 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................394 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................395 S-11 OIL IN COOLANT WATER, OR WATER SPURTS BACK OR WATER LEVEL GOES DOWN.........................................................396 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)..........................................................................397 S-13 OIL LEVEL RISES.............................................................................................................398 S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................................................399 S-15 ABNORMAL NOISE IS MADE......................................................................................................400 S-16 VIBRATION IS EXCESSIVE......................................................................................................401 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T-MODE)...........................................................................403 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS.................................................................404 ACTION TAKEN BY CONTROLLERS WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................................406 ELECTRICAL DIAGRAM FOR TANSMISSION CONTROLLER SYSTEM.............................................................................411 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACK UP LAMP RELAY) IS DISPLAYED........412 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED................413 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED................414 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED..............415 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED..............416 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED..............417 T-7 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.........................418 T-8 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED.................................420 T-9 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH SYSTEM) IS DISPLAYED........................................424 T-10 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED................................................427 T-11 FAIURE CODE [23] (SHORT CIRCUIT, DISCONNECTION, ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED....................................428 T-12 SHIFT-UP SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT) AND HOLD SIGNAL SYSTEM (AUTO-SHIFT (OP) ................................429 T-13 KICK-DOWN SIGNAL SYSTEM AND SHIFT DOWN SIGNAL SYSTEM (JOYSTICK (OP) MANUAL SHIFT)...........................................429 T-14 TRANSMISSION CUT-OFF SIGNAL SYSTEM..........................................................................................430 T-15 NEUTRALIZER SIGNAL SYSTEM...................................................................................................431 T-16 BUZZER SIGNAL SYSTEM........................................................................................................432 T-17 NETWORK SYSTEM..............................................................................................................433 T-18 TRANSMISSION CONTROLLER POWER SOURCE........................................................................................434 T-19 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM.................................................................................435 T-20 ABNORMALITY IN MACHINE SELECTION WIRE HARNESS...............................................................................436 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)......................................................................................437 TROUBLE DATA DISPLAY.............................................................................................................439 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM.............................................................................441 M-1 MAIN MONITOR DOES NOT WORK BACKUP LAMP RELAY) IS DISPLAYED..................................................................442 M-2 WHEN STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT UP................443 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY..................................................................................444 M-4 ABNORMALITY IN SHIFT INDICATOR..............................................................................................445 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP.........................................................................................448 M-6 TURN SIGNAL DISPLAY NOT LIGHT UP............................................................................................449 M-7 ABNORMALITY IN PARKING DISPLAY..............................................................................................450 M-8 ABNORMALITY IN PREHEATING SYSTEM............................................................................................451 M-9 NIGHT LIGHTING DOES NOT LIGHT UP............................................................................................455 M-10 ABNORMALITY IN FRONT WORKING LAMP..........................................................................................456 M-11 ABNORMALITY IN REAR WORKING LAMP............................................................................................458 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.........................................................................................460 M-13 ABNORMALITY IN LOW IDLE SELECTION...........................................................................................462 M-14 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY....................................................................464 M-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...............................................................................465 M-16 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING (WHEN JOYSTICK STEERING MODE (OP).............................................467 M-17 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR NOT ACTUATED............469 M-18 ABNORMALITY IN BUZZER.......................................................................................................470 M-19 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY.......................................................................471 M-20 ABNORMALITY IN FAILURE DISPLAY MODE.........................................................................................472 M-21 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER..................................................473 M-22 ABNORMALITY IN AUTO-GREASING SYSTEM (OP)....................................................................................474 M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) (OP)......................................................476 TROUBLEHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)................................................................................477 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR...............................................................................479 K-1 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO....480 K-2 WHEN STARTER SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)........481 K-3 WHEN ENGINE IS STARTED IMMEDIATLY AFTER STARTER SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE GO OUT.......482 K-4 WHEN STARTER SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH........................................................483 K-5 WHEN STARTER SWITCH IS TURNED ON (ENGINE STARTED), CAUTION) ITEMS FLASH.....................................................485 K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND........................................................................492 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS........................................................493 K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES..................................................494 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHT UP..............................495 K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHT SWITCH IS TURNED ON.................................496 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHT SWITCH IS TURNED OFF...............................................................497 K-12 SERVICE METER DOES NOT WORK.................................................................................................498 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED........................................................................498 K-14 ABNORMALITY IN GAUGE DISPLAY................................................................................................499 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................................................................503 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING...........................................................................................505 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING ..........................................................................................506 ENGINE PRE-LUBRICATION SYSTEM....................................................................................................507 ELECTRICAL DIA. - BOOM KICK-OUT / BUCKET POSITIONER..............................................................................511 E-1 ENGINE DOES NOT START.......................................................................................................512 E-2 ENGINE DOES NOT STOP (STD SPEC.)............................................................................................517 E-3 ABNORMALITY IN PREHEATING SYSTEM............................................................................................519 E-4 PARKING BRAKE DOES NOT HAVE EFFECT..........................................................................................523 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING..........................................................................524 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH TURNED ON....................................................................526 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.......................................................526 E-8 KICK-DOWN SWITCH DOES NOT WORK..............................................................................................528 E-9 BOOM KICK-OUT DOES NOT WORK.................................................................................................530 E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION...................................................................................534 E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP ..........................................................................537 E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP.............................................................................537 E-13 ABNORMALITY IN TRANSMISSION CUT-OFF.........................................................................................537 E-14 ABNORMALITY IN LOW IDLE SELECTION...........................................................................................537 E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...............................................................................537 E-16 ABNORMALITY IN BUZZER.......................................................................................................537 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)..........................................................................539 H-1 MACHINE DOES NOT MOVE.......................................................................................................540 H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)............................................................................541 H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...................................................................542 H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....................................................................................543 H-5 STEERING DOES NOT TURN......................................................................................................544 H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK (OP)].........................................................................545 H-7 TURNING, RESPONSE OF STEERING IS POOR.......................................................................................546 H-8 TURNING RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK(OP)]............................................................547 H-9 STEERING IS HEAVY...........................................................................................................548 H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK(OP)] ..............................................................................548 H-11 STEERING WHEEL SHAKES OR JERKS..............................................................................................549 H-12 STEERING WHEEL SHAKES OR JERKS SHOCK [MACHINE WITH JOYSTICK (OP)]...........................................................550 H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING.....................................................550 H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR..........................................................................551 H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG................................................................................552 H-16 BOOM DOES NOT RISE..........................................................................................................553 H-17 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.................................................................554 H-18 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT...........................................................................555 H-19 BOOM CYLINDER CANNOT HOLD DOWN BUCKET.......................................................................................555 H-20 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT....................................................................................555 H-21 BOOM FLUCTUATES WHILE WORKING...............................................................................................556 H-22 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE............................................................556 H-23 BUCKET DOES NOT TILT BACK...................................................................................................557 H-24 BUCKET MOVES SLOWLY AND HAS INSUFFICIENT TILT BACK POWER....................................................................558 H-25 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...............................................................................559 H-26 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET.....................................................................................559 H-27 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT..................................................................................559 H-28 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD................................................................................560 H-29 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT...........................................................560 H-30 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY.................................................................................561 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J-MODE)......................................................................563 JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM...................................................................................564 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS...............................................................................566 ELECTRIC DIAGRAM FOR JOYSTICK STEERING SYSTEM....................................................................................570 J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED.......................................572 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED..................573 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED...................574 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED...............................575 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED................................576 J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING RIGHT SOLENOID CUT RELAY OUTPUT) IS DISPLAYED...................577 J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED..........................578 J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED......................579 J-9 ABNORMALITY IN POWER SUPPLY, POWER SUPPLY VOLTAGE...........................................................................580 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT.............................................................................581 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID....................................................................................582 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.....................................................................................583 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................585 METHOD OF USING MANUAL...................................................................................................................589 PRECAUTIONS DURING OPERATION.........................................................................................................590 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.......................................................................................590 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK..................................................................................591 PRECAUTIONS WHEN COMPLETING THE OPERATIONS.......................................................................................592 OTHER PRECAUTIONS................................................................................................................592 SPECIAL TOOL LIST........................................................................................................................593 SKETCHES OF SPECIAL TOOLS................................................................................................................601 ENGINE...................................................................................................................................609 ALTERNATOR...........................................................................................................................609 CYLINDER HEAD........................................................................................................................609 DAMPER...............................................................................................................................609 ENGINE OIL COOLER....................................................................................................................609 ENGINE FRONT SEAL....................................................................................................................609 ENGINE REAR SEAL.....................................................................................................................609 FUEL INJECTION PUMP FOR LEFT BANK....................................................................................................609 FUEL INJECTION PUMP FOR RIGHT BANK...................................................................................................609 NOZZLE HOLDER........................................................................................................................609 STARTING MOTOR.......................................................................................................................609 TURBOCHARGER.........................................................................................................................609 WATER PUMP...........................................................................................................................609 RADIATOR.................................................................................................................................610 REMOVAL..............................................................................................................................610 INSTALLATION.........................................................................................................................613 ENGINE...................................................................................................................................614 REMOVAL..............................................................................................................................614 INSTALLATION.........................................................................................................................620 TORQUE CONVERTER AND TRANSMISSION........................................................................................................621 REMOVAL..............................................................................................................................621 INSTALLATION.........................................................................................................................629 TORQUE CONVERTER.........................................................................................................................631 DISASSEMBLY..........................................................................................................................631 ASSEMBLY.............................................................................................................................635 TORQUE CONVERTER VALVE...................................................................................................................640 DISASSEMBLY..........................................................................................................................640 ASSEMBLY.............................................................................................................................640 TRANSMISSION.............................................................................................................................641 DISASSEMBLY..........................................................................................................................641 ASSEMBLY.............................................................................................................................657 TRANSMISSION VALVE.......................................................................................................................673 REMOVAL..............................................................................................................................673 INSTALLATION.........................................................................................................................673 UPPER VALVE..........................................................................................................................674 DISASSEMBLY......................................................................................................................674 ASSEMBLY.........................................................................................................................675 LOWER VALVE..........................................................................................................................676 DISASSEMBLY......................................................................................................................676 ASSEMBLY.........................................................................................................................676 RELIEF VALVE.........................................................................................................................677 DISASSEMBLY......................................................................................................................677 ASSEMBLY.........................................................................................................................677 TRANSFER.................................................................................................................................678 DISASSEMBLY..........................................................................................................................678 ASSEMBLY.............................................................................................................................686 PTO......................................................................................................................................696 DISASSEMBLY..........................................................................................................................696 ASSEMBLY.............................................................................................................................698 CENTER SUPPORT...........................................................................................................................701 REMOVAL..............................................................................................................................701 INSTALLATION.........................................................................................................................702 DISASSEMBLY..........................................................................................................................703 ASSEMBLY.............................................................................................................................705 DRIVE SHAFT..............................................................................................................................708 DISASSEMBLY..........................................................................................................................708 ASSEMBLY.............................................................................................................................710 FRONT AXLE...............................................................................................................................712 REMOVAL..............................................................................................................................712 INSTALLATION.........................................................................................................................714 REAR AXLE................................................................................................................................715 REMOVAL..............................................................................................................................715 INSTALLATION.........................................................................................................................721 DIFFERENTIAL.............................................................................................................................723 REMOVAL..............................................................................................................................723 INSTALLATION.........................................................................................................................725 DISASSEMBLY..........................................................................................................................726 ASSEMBLY.............................................................................................................................730 FINAL DRIVE..............................................................................................................................736 DISASSEMBLY..........................................................................................................................736 ASSEMBLY.............................................................................................................................739 ORBIT-ROLL...............................................................................................................................742 REMOVAL..............................................................................................................................742 INSTALLATION.........................................................................................................................743 GROUND DRIVEN STEERING PUMP..............................................................................................................744 REMOVAL..............................................................................................................................744 INSTALLATION.........................................................................................................................744 DIVERTER VALVE...........................................................................................................................745 REMOVAL..............................................................................................................................745 INSTALLATION.........................................................................................................................745 DISASSEMBLY..........................................................................................................................746 ASSEMBLY.............................................................................................................................747 ACCUMULATOR CHARGE VALVE.................................................................................................................749 REMOVAL..............................................................................................................................749 INSTALLATION.........................................................................................................................749 DISASSEMBLY..........................................................................................................................750 ASSEMBLY.............................................................................................................................751 STEERING STOP VALVE......................................................................................................................753 REMOVAL..............................................................................................................................753 INSTALLATION.........................................................................................................................753 STEERING CYLINDER........................................................................................................................754 REMOVAL..............................................................................................................................754 INSTALLATION.........................................................................................................................755 STEERING VALVE...........................................................................................................................756 REMOVAL..............................................................................................................................756 INSTALLATION.........................................................................................................................757 BRAKE VALVE..............................................................................................................................758 REMOVAL..............................................................................................................................758 INSTALLATION.........................................................................................................................758 SLACK ADJUSTER...........................................................................................................................759 REMOVAL..............................................................................................................................759 INSTALLATION.........................................................................................................................759 DISASSEMBLY..........................................................................................................................760 ASSEMBLY.............................................................................................................................761 BRAKE....................................................................................................................................762 REMOVAL..............................................................................................................................762 INSTALLATION.........................................................................................................................763 DISASSEMBLY..........................................................................................................................764 ASSEMBLY.............................................................................................................................767 PARKING BRAKE CALIPERS...................................................................................................................771 REMOVAL..............................................................................................................................771 INSTALLATION.........................................................................................................................772 DISASSEMBLY..........................................................................................................................773 ASSEMBLY.............................................................................................................................774 PARKING BRAKE PAD........................................................................................................................776 REMOVAL..............................................................................................................................776 INSTALLATION.........................................................................................................................777 PARKING BRAKE SPRING CYLINDER............................................................................................................778 REMOVAL..............................................................................................................................778 INSTALLATION.........................................................................................................................778 BRAKE OIL TANK...........................................................................................................................779 REMOVAL..............................................................................................................................779 INSTALLATION.........................................................................................................................779 HYDRAULIC PUMP...........................................................................................................................780 REMOVAL..............................................................................................................................780 INSTALLATION.........................................................................................................................782 HYDRAULIC TANK AND FILTER CASE...........................................................................................................783 REMOVAL..............................................................................................................................783 INSTALLATION.........................................................................................................................784 PPC VALVE................................................................................................................................785 REMOVAL..............................................................................................................................785 INSTALLATION.........................................................................................................................786 DISASSEMBLY..........................................................................................................................787 ASSEMBLY.............................................................................................................................787 WORK EQUIPMENT CONTROL VALVE.............................................................................................................788 REMOVAL..............................................................................................................................788 INSTALLATION.........................................................................................................................789 DISASSEMBLY..........................................................................................................................790 ASSEMBLY.............................................................................................................................792 CAB......................................................................................................................................794 REMOVAL..............................................................................................................................794 INSTALLATION.........................................................................................................................797 FLOOR FRAME..............................................................................................................................798 REMOVAL..............................................................................................................................798 INSTALLATION.........................................................................................................................801 CENTER HINGE PIN.........................................................................................................................802 REMOVAL..............................................................................................................................802 INSTALLATION.........................................................................................................................808 WORK EQUIPMENT...........................................................................................................................812 REMOVAL..............................................................................................................................812 INSTALLATION.........................................................................................................................817 BOOM FRONT END BUSHING...................................................................................................................818 REPLACEMENT..........................................................................................................................818 BUCKET CYLINDER..........................................................................................................................819 REMOVAL..............................................................................................................................819 INSTALLATION.........................................................................................................................819 LIFT CYLINDER............................................................................................................................821 REMOVAL..............................................................................................................................821 INSTALLATION.........................................................................................................................822 HYDRAULIC CYLINDER.......................................................................................................................823 DISASSEMBLY..........................................................................................................................823 ASSEMBLY.............................................................................................................................825 AIR CONDITIONER UNIT.....................................................................................................................827 REMOVAL..............................................................................................................................827 INSTALLATION.........................................................................................................................828 AIR CONDITIONER COMPRESSOR...............................................................................................................829 REMOVAL..............................................................................................................................829 INSTALLATION.........................................................................................................................829 RECEIVER TANK............................................................................................................................830 REMOVAL..............................................................................................................................830 INSTALLATION.........................................................................................................................830 AIR CONDITIONER CONDENSER................................................................................................................831 REMOVAL..............................................................................................................................831 INSTALLATION.........................................................................................................................832 TRANSMISSION AND STEERING CONTROLLER.....................................................................................................833 REMOVAL..............................................................................................................................833 INSTALLATION.........................................................................................................................833 MAIN MONITOR.............................................................................................................................834 REMOVAL..............................................................................................................................834 INSTALLATION.........................................................................................................................835 FUEL TANK................................................................................................................................836 REMOVAL..............................................................................................................................836 INSTALLATION.........................................................................................................................837 COUNTERWEIGHT - STANDARD.................................................................................................................838 REMOVAL..............................................................................................................................838 INSTALLATION.........................................................................................................................839 COUNTERWEIGHT - HIGH-LIFT................................................................................................................840 REMOVAL..............................................................................................................................840 INSTALLATION.........................................................................................................................841 40 MAINTENANCE STANDARD.....................................................................................................................843 ENGINE MOUNT.............................................................................................................................844 TRANSMISSION MOUNT.......................................................................................................................845 DAMPER...................................................................................................................................846 HYDRAULIC PUMPS..........................................................................................................................848 TORQUE CONVERTER CHARGING, PPC AND BRAKE.............................................................................................848 TORQUE CONVERTER.........................................................................................................................850 REGULATOR VALVE......................................................................................................................851 TRANSMISSION.............................................................................................................................852 CLUTCH...............................................................................................................................852 GEAR.................................................................................................................................854 TRANSMISSION CONTROL VALVE...............................................................................................................856 UPPER VALVE..........................................................................................................................856 LOWER VALVE..........................................................................................................................858 DRIVE SHAFT..............................................................................................................................861 CENTER SUPPORT...........................................................................................................................862 DIFFERENTIAL.............................................................................................................................863 Assembly Torques.....................................................................................................................863 Gears................................................................................................................................864 FINAL DRIVE..............................................................................................................................866 AXLE MOUNT...............................................................................................................................868 CENTER HINGE PIN.........................................................................................................................870 STEERING COLUMN..........................................................................................................................872 STEERING DEMAND VALVE....................................................................................................................873 DIVERTER VALVE...........................................................................................................................875 STEERING CYLINDER MOUNT..................................................................................................................876 GROUND DRIVEN STEERING PUMP..............................................................................................................877 BRAKE VALVE..............................................................................................................................878 SLACK ADJUSTER...........................................................................................................................881 BRAKE....................................................................................................................................882 PARKING BRAKE............................................................................................................................884 PPC VALVE................................................................................................................................886 PPC RELIEF VALVE.........................................................................................................................888 CONTROL PUMP (BAR025)....................................................................................................................889 MAIN CONTROL VALVE.......................................................................................................................891 HYDRAULIC CYLINDER.......................................................................................................................893 BUCKET LINKAGE...........................................................................................................................895 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................897 90 OTHERS (SHOP MANUAL FOLDOUTS).............................................................................................................899 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 1 OF 6)........................................................................901 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 2 OF 6)....................................................................903 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 3 OF 6)....................................................................905 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 4 OF 6)....................................................................907 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 5 OF 6)....................................................................909 FOLDOUT 10-169 ELECTRICAL CIRCUIT DIAGRAM (1 OF 2) (SHEET 6 OF 6)....................................................................911 FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 1 OF 4)........................................................................913 FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 2 OF 4)....................................................................915 FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 3 OF 4)....................................................................917 FOLDOUT 10-173 ELECTRICAL CIRCUIT DIAGRAM (2 OF 2) (SHEET 4 OF 4)....................................................................919 FOLDOUT 20-217 CONNECTOR ARRANGEMENT DIAGRAM (1 OF 3)....................................................................................921 FOLDOUT 20-219 CONNECTOR ARRANGEMENT DIAGRAM (2 OF 3)....................................................................................923 FOLDOUT 20-409 ELECTRICAL DIAGRAM FOR TRANSMISSION CONTROLLER............................................................................925 FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 1 OF 4)................................................................927 FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 2 OF 4)............................................................929 FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 3 OF 4)............................................................931 FOLDOUT 20-505 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR (SHEET 4 OF 4)............................................................933 FOLDOUT 20-603 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM.................................................................935 FOLDOUT 20-703 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING, AND PREHEATING.............................937
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]
