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Komatsu WD600-3 Wheel Dozer Shop Manual 50001 and up – PDF DOWNLOAD
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Komatsu WD600-3 Wheel Dozer Shop Manual
Book Code: SEBM022904
MACHINE MODEL SERIAL NO.
WD600-3 50001 and up
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Description
Komatsu WD600-3 Wheel Dozer Shop Manual
FILE DETAILS:
Komatsu WD600-3 Wheel Dozer Shop Manual
Brands: Komatsu
Equipment Type: Wheel Dozer
Manuals Type: Shop Manual
Machine Model: WD600-3
Serial Number: 50001 and up
Book Code: SEBM022904
Language: English
Pages: 861
File Format: Portable Document Format (PDF)
KOMATSU WD600-3 WHEEL DOZER SHOP MANUAL 50001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WD600-3 Wheel Dozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WD600-3 Wheel Dozer Shop Manual
COVER................................................................................................................................................................ 1 CONTENTS............................................................................................................................................................. 2 01 GENERAL........................................................................................................................................................... 27 GENERAL ASSEMBLY DRAWING......................................................................................................................................... 28 SPECIFICATIONS................................................................................................................................................... 29 WEIGHT TABLE..................................................................................................................................................... 32 LIST OF LUBRICANT AND WATER...................................................................................................................................... 33 10 STRUCTURE AND FUNCTION............................................................................................................................................ 35 COOLING SYSTEM................................................................................................................................................... 36 GENERAL.......................................................................................................................................................... 38 POWER TRAIN SYSTEM............................................................................................................................................... 39 TORQUE CONVERTER AND TRANSMISSION PIPING......................................................................................................................... 41 TORQUE CONVERTER................................................................................................................................................. 42 TORQUE CONVERTER REGULATOR VALVE................................................................................................................................. 46 LOCK-UP VALVE.................................................................................................................................................... 48 LOCK-UP SOLENOID VALVE........................................................................................................................................... 52 TORQUE CONVERTER RELIEF VALVE.................................................................................................................................... 53 TRANSMISSION..................................................................................................................................................... 54 TRANSMISSION CONTROL VALVE....................................................................................................................................... 59 LUBRICATION BYPASS VALVE......................................................................................................................................... 69 TRANSMISSION SOLENOID VALVE...................................................................................................................................... 70 EMERGENCY MANUAL SPOOL........................................................................................................................................... 72 TRANSFER......................................................................................................................................................... 73 DRIVE SHAFT...................................................................................................................................................... 74 CENTER SUPPORT................................................................................................................................................... 75 AXLE............................................................................................................................................................. 76 DIFFERENTIAL..................................................................................................................................................... 78 FINAL DRIVE...................................................................................................................................................... 86 AXLE AND CENTER HINGE PIN........................................................................................................................................ 87 STEERING PIPING.................................................................................................................................................. 88 STEERING COLUMN.................................................................................................................................................. 90 STEERING UNIT (ORBIT-ROLL VALVE)................................................................................................................................. 91 STEERING VALVE................................................................................................................................................... 94 TWO-WAY RESTRICTION VALVE........................................................................................................................................105 STOP VALVE.......................................................................................................................................................106 EMERGENCY STEERING PIPING........................................................................................................................................107 DIVERTER VALVE (FOR EMERGENCY STEERING)..........................................................................................................................108 BRAKE PIPING.....................................................................................................................................................111 BRAKE VALVE......................................................................................................................................................112 CHARGE VALVE.....................................................................................................................................................117 ACCUMULATOR (FOR BRAKE)..........................................................................................................................................121 SLACK ADJUSTER...................................................................................................................................................122 BRAKE............................................................................................................................................................125 PARKING BRAKE....................................................................................................................................................127 SPRING CYLINDER..................................................................................................................................................129 PARKING BRAKE SOLENOID VALVE.....................................................................................................................................130 HYDRAULIC PIPING.................................................................................................................................................131 WORK EQUIPMENT LEVER LINKAGE.....................................................................................................................................132 HYDRAULIC TANK...................................................................................................................................................133 ACCUMULATOR (FOR PPC VALVE)......................................................................................................................................136 PPC VALVE........................................................................................................................................................137 PPC RELIEF VALVE.................................................................................................................................................142 WORK EQUIPMENT VALVE.............................................................................................................................................143 DECO VALVE.......................................................................................................................................................154 AIR CONDITIONER..................................................................................................................................................165 MACHINE MONITOR SYSTEM...........................................................................................................................................168 MAIN MONITOR.....................................................................................................................................................169 MAINTENANCE MONITOR..............................................................................................................................................173 ENGINE STARTING CIRCUIT..........................................................................................................................................175 ENGINE STOP CIRCUIT..............................................................................................................................................176 PRE-HEATING CIRCUIT..............................................................................................................................................177 ELECTRIC TRANSMISSION CONTROL....................................................................................................................................178 KICK-DOWN,HOLD SWITCH............................................................................................................................................181 TRANSMISSION AND JOYSTICK STEERING SYSTEM........................................................................................................................182 THROTTLE CONTROL SYSTEM..........................................................................................................................................200 20 TESTING AND ADJUSTING.............................................................................................................................................206 STANDARD VALUE TABLE FOR ENGINE..................................................................................................................................207 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................208 STANDARD VALUE TABLE FOR ELECTRICAL PARTS........................................................................................................................214 TESTING AND ADJUSTING............................................................................................................................................225 TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.....................................................................................................226 MEASURING ENGINE SPEED.......................................................................................................................................228 MEASURING EXHAUST GAS COLOR..................................................................................................................................230 ADJUSTING VALVE CLEARANCE....................................................................................................................................231 TESTING AND ADJUSTING INJECTOR LIFT..........................................................................................................................232 MEASURING COMPRESSION PRESSURE...............................................................................................................................234 MEASURING BLOW-BY PRESSURE...................................................................................................................................236 MEASURING ENGINE OIL PRESSURE................................................................................................................................237 REPLACING FAN BELT ADJUSTING AUTO-TENSIONER..................................................................................................................238 TESTING AND ADJUSTING ALTERNATOR BELT TENSION................................................................................................................239 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR............................................................................................240 HANDLING EQUIPMENT IN FUEL CIRCUIT...........................................................................................................................241 MEASURING FUEL PUMP OUTLET PORT PRESSURE.....................................................................................................................241 BLEEDING AIR FROM FUEL CIRCUIT...............................................................................................................................242 MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE)...............................................................................................................244 MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER)............................................................................................................245 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...............................................................................................................246 ADJUSTING SPEED SENSOR.......................................................................................................................................247 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION..................................................................................................248 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...............................................................................................................251 TESTING AND ADJUSTING STEERING OIL PRESSURE..................................................................................................................253 TESTING AND ADJUSTING STEERING STOP VALVE....................................................................................................................255 TESTING BRAKE OIL PRESSURE...................................................................................................................................256 MEASURING WEAR OF BRAKE DISC.................................................................................................................................257 MEASURING BRAKE PERFORMANCE..................................................................................................................................258 TESTING AND ADJUSTING PARKING BRAKE..........................................................................................................................259 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE.........................................................................................261 TESTING AND ADJUSTING PPC OIL PRESSURE.......................................................................................................................262 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE......................................................................................................264 ADJUSTING WORK EQUIPMENT LEVER LINKAGE.......................................................................................................................265 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)..................................................................................................................267 BLEEDING AIR.................................................................................................................................................268 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................269 TROUBLESHOOTING..................................................................................................................................................270 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................271 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................272 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.............................................................................................................273 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................281 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................................................282 CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................286 CONNECTION TABEL FOR CONNECTOR PIN NUMBERS...................................................................................................................290 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................307 METHOD OF USING MATRIX TROUBLESHOOTING TABLES................................................................................................................309 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....................................................................................................................311 METHOD OF USING TROUBLESHOOTING CHART....................................................................................................................312 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................................................................................316 S-2 ENGINE DOES NOT START................................................................................................................................318 (1) ENGINE DOES NOT TURN.............................................................................................................................318 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).........................................................................319 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).........................................................................320 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR).................................................................................................321 S-4 ENGINE STOPS DURING OPERATIONS.......................................................................................................................322 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)............................................................................................................323 S-6 ENGINE LACKS OUTPUT..................................................................................................................................324 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).......................................................................................................325 S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..............................................................................................326 S-9 OIL BECOMES CONTAMINATED QUICKLY.....................................................................................................................327 S-10 FUEL CONSUMPTION IS EXCESSIVE.......................................................................................................................328 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...............................................................................329 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................................................330 S-13 OIL LEVEL RISES.....................................................................................................................................331 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................................................................................332 S-15 ABNORMAL NOISE IS MADE..............................................................................................................................333 S-16 VIBRATION IS EXCESSIVE..............................................................................................................................334 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)........................................................................................................335 METHOD OF ERROR CODE DISPLAY.............................................................................................................................337 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED.........................................................................339 SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM..............................................................................................................347 EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY).................................................................................................349 EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR...............................................................................................349 EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM).................................................................350 EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)......................................................................................351 EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL).....................................................................353 EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)......................................................................354 EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL).......................................................................355 EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)........................................................................356 EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)......................................................................................357 EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)..........................................................................358 EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)...........................................................................359 EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL).............................................................................360 EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)..............................................................................361 EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIGH LEVEL)............................................................................362 EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL).............................................................................363 EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1)).........................................................................................364 EA-17 ERROR CODE [144] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM HIGH LEVEL).......................................................................365 EA-18 ERROR CODE [145] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM LOW LEVEL)........................................................................366 EA-19 ERROR CODE [151] (ABNORMAL RISE IN WATER TEMPERATURE)..............................................................................................366 EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)..................................................................367 EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM LOW LEVEL)...................................................................367 EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)....................................................................368 EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)...........................................................................369 EA-24 ERROR CODE [234] (OVERSPEED).......................................................................................................................371 EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)...............................................................................372 EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)..............................................................................................373 EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)...............................................................................................373 EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)........................................................................374 EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL).........................................................................374 EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)................................................................................375 EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)...............................................................................................376 EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)................................................................................376 EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)............................................................................................377 EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM).................................................................................378 EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2)).........................................................................................379 EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)......................................................................380 EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)................................................................................382 EA-38 ERROR CODE [432] (IDLING VALIDATION PROCESS ERROR).................................................................................................384 EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)........................................................................................387 EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL).......................................................................................387 EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)......................................................................388 EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL).......................................................................389 EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)................................................................................390 EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL).....................................................................................391 EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL).......................................................................................391 EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)...............................................................................................391 EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)....................................................................................392 EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLING VALIDATION SWITCH SYSTEM)................................................................................392 EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)...............................................................................393 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)..............................................................................................................395 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR..............................................................................................................397 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN.............................................................................................................399 M-1 MAIN MONITOR DOES NOT WORK...........................................................................................................................400 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP........................................................401 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...........................................................................................................402 M-4 ABNORMALITY IN SHIFT INDICATOR.......................................................................................................................403 a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F....................................................................................................403 b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R....................................................................................................403 c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N............................................................................................403 d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST......................................................................................404 e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND......................................................................................404 f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD......................................................................................404 g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH......................................................................................404 M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP..................................................................................................................406 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................407 a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................................407 b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP........................................................................................................407 M-7 ABNORMALITY IN PARKING LAMP DISPLAY..................................................................................................................408 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP............................................................................................................408 b) PARKING LAMP DISPLAY STAYS LIGHTED UP.............................................................................................................408 M-8 ABNORMALITY IN PREHEATING DISPLAY....................................................................................................................409 a) PREHEATING DISPLAY DOES NOT LIGHT UP..............................................................................................................409 b) PREHEATING DISPLAY STAYS LIGHTED UP...............................................................................................................409 M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP..........................................................................................................410 M-10 ABNORMALITY IN FRONT WORKING LAMP...................................................................................................................411 a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP...........................................................................................411 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................411 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP......................................................................................411 M-11 ABNORMALITY IN REAR WORKING LAMP....................................................................................................................413 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP............................................................................................413 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP......................................................................................413 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP......................................................................................413 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.................................................................................................................415 a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE..........................................415 b) TRANSMISSION CUT-OFF DOES NOT WORK OR STAYS WORKING...............................................................................................415 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.......................................................................................................416 a) WHEN PARKING BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N...........................416 b) WHEN PARKING BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....416 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED.............................417 a) ACTUATED CONTINUOUSLY.............................................................................................................................417 b) NOT ACTUATED......................................................................................................................................417 M-15 ABNORMALITY IN BUZZER...............................................................................................................................418 a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON...........................................................418 b) BUZZER ALWAYS SOUNDS..............................................................................................................................418 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...............................................................................................419 M-17 ABNORMALITY IN FAILURE DISPLAY MODE.................................................................................................................420 a) FAILURE DISPLAY MODE DOES NOT WORK................................................................................................................420 b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE.....................................................................420 M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY...........................................................................................................421 a) EMERGENCY STEERING DISPLAY DOES NOT FLASH.........................................................................................................421 b) EMERGENCY STEERING DISPLAY STAYS FLASHED..........................................................................................................421 M-19 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...................................................................................422 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).......................................................................................................423 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR.......................................................................................................424 K-1 WHEN STARTING SWITCH IS TURNED ON, ALL DISPLAY ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS MAINTENANCE MONITOR DOES NOT WORK................426 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP..........................................................................................................426 b) SOME LAMPS DO NOT LIGHT UP........................................................................................................................426 K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SECONDS..................................427 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS, NO LAMPS ON MAINTENANCE MONITOR GO OUT.......................428 K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CHECK ITEM DISPLAY FLASHES..................................................................429 a) ENGINE OIL LEVEL DISPLAY FLASHES..................................................................................................................429 b) ENGINE WATER LEVEL DISPLAY FLASHES................................................................................................................430 K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CAUTION ITEM DISPLAY FLASHES................................................................431 a) ENGINE OIL PRESSURE DISPLAY FLASHES...............................................................................................................431 b) BATTERY CHARGE DISPLAY FLASHES....................................................................................................................432 c) BRAKE OIL PRESSURE DISPLAY FLASHES................................................................................................................433 d) AIR CLEANER CLOGGED DISPLAY FLASHES...............................................................................................................434 K-6 CAUTION ITEM DISPLAY IS FLASHING, BUT CAUTION BUZZER DOES NOT SOUND..................................................................................435 K-7 NO MONITOR DISPLAY LIGHTS UP, BUT CAUTION BUZZER SOUNDS..............................................................................................436 K-8 CAUTION ITEM DISPLAY IS FLASHING, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH......................................................437 a) CHECK LAMP........................................................................................................................................437 b) CAUTION LAMP......................................................................................................................................437 K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP...................................................438 a) CHECK LAMP........................................................................................................................................438 b) CAUTION LAMP......................................................................................................................................438 K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON......................................................................439 K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF....................................................................................440 K-12 SERVICE METER DOES NOT WORK.........................................................................................................................441 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED................................................................................................441 K-14 ABNORMALITY IN GAUGES...............................................................................................................................442 a) ABNORMALITY IN FUEL GAUGE.........................................................................................................................442 b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.....................................................................................................443 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.............................................................................................444 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................445 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING SYSTEM.....................................................................446 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...............................................................................................447 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE.............................................................................................................449 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN.............................................................................................................450 E-1 ENGINE DOES NOT START................................................................................................................................451 E-2 PREHEATING FAULT.....................................................................................................................................457 E-3 PARKING BRAKE DOES NOT HAVE EFFECT...................................................................................................................458 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON................................................................................458 b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS................................................458 E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...................................................................................................459 E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON..........................................................................................461 E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY..............................................461 E-7 TRANSMISSION DOES NOT WORK PROPERLY..................................................................................................................463 a) ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT............................................464 b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT..................................................................................................467 c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT..................................................................................................469 d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT...................................................................................471 e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT.............................................................................................................476 f) AHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT.........................................................................................481 E-8 WHEN HOLD SWITCH IS PRESSED, GEAR SPEED IS NOT FIXED OR RESET........................................................................................486 E-9 KICK-DOWN SYSTEM DOES NOT WORK.......................................................................................................................486 E-10 POWER WINDOW DOES NOT WORK..........................................................................................................................487 a) POWER WINDOW DOES NOT RISE (THIS TROUBLESHOOTING SHOWS ABOUT L.H. POWER WINDOW)...................................................................487 b) POWER WINDOW DOES NOT LOWER (THIS TROUBLESHOOTING SHOWS ABOUT L.H. POWER WINDOW)..................................................................488 E-11 ABNORMALITY IN FRONT WORKING LAMP...................................................................................................................490 E-12 ABNORMALITY IN REAR WORKING LAMP....................................................................................................................490 E-13 ABNORMALITY IN TRANSMISSION CUT-OFF.................................................................................................................490 E-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.......................................................................................................490 E-15 ABNORMALITY IN BUZZER...............................................................................................................................490 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..................................................................................................491 H-1 MACHINE DOES NOT MOVE................................................................................................................................492 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS).....................................................................................................493 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)..................................................................................................493 H-4 MACHINE LACKS POWER OR SPEED WHEN TRAVELING..........................................................................................................494 H-5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR............................................................................................496 H-6 TORQUE CONVERTER OIL TEMPERATURE TOO HIGH............................................................................................................497 H-7 STEERING WHEEL DOES NOT TURN.........................................................................................................................498 H-8 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK].......................................................................................................499 H-9 TURNING, RESPONSE OF STEERING IS POOR................................................................................................................500 H-10 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK].......................................................................................501 H-11 STEERING IS HEAVY...................................................................................................................................503 H-12 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]...........................................................................................................503 H-13 STEERING WHEEL SHAKES OR JERKS......................................................................................................................504 H-14 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK].................................................................................505 H-15 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING..............................................................................505 H-16 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR..................................................................................................506 H-17 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG........................................................................................................508 H-18 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR...............................................................................................509 H-19 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)...................................................................510 H-20 BLADE DOES NOT RISE.................................................................................................................................511 H-21 BLADE MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER........................................................................................512 H-22 BLADE BECOMES SLOW AT CERTAIN HEIGHT WHEN RAISING...................................................................................................513 H-23 LIFT CYLINDER CANNOT HOLD DOWN BLADE................................................................................................................513 H-24 BLADE HAS LARGE AMOUNT OF HYDRAULIC DRIFT...........................................................................................................513 H-25 BLADE FLUCTUATES WHILE WORKING......................................................................................................................514 H-26 BLADE DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE...................................................................................514 H-27 BLADE DOES NOT TILT.................................................................................................................................515 H-28 BLADE MOVES SLOWLY OR HAS INSUFFICIENT TILT POWER...................................................................................................516 H-29 BLADE DOES NOT PITCH................................................................................................................................517 H-30 BLADE PITCH MOVEMENT IS SLOW OR LACKS POWER.........................................................................................................517 H-31 WORK EQUIPMENT LEVER DOES NOT MOVE SMOOTHLY.........................................................................................................518 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL).........................................519 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE........................................................................................................520 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM..........................................................................................................521 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE..............................................................................522 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...............................................................................................526 T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN LOCK-UP SOLENOID) IS DISPLAYED................................528 T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID) IS DISPLAYED......................................529 T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID) IS DISPLAYED......................................530 T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID) IS DISPLAYED....................................531 T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID) IS DISPLAYED....................................532 T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID) IS DISPLAYED....................................533 T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID) IS DISPLAYED....................................534 T-8 FAILURE CODE [19] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...............................................535 T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...........................................................536 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN SHIFT SWITCH SYSTEM) IS DISPLAYED................................................................539 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED...............................................................................542 T-12 FAILURE CODE [23] (SHORT CIRCUIT, OR DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED......................................................543 T-13 WHEN HOLD SWITCH IS PRESSED, GEAR SPEED IS NOT FIXED OR RESET SHIFT-UP DOES NOT WORK................................................................544 T-14 KICK-DOWN DOES NOT WORK SHIFT-DOWN DOES NOT WORK....................................................................................................544 T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING..................................................................................................545 T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING..........................................................................................................546 T-17 BUZZER DOES NOT WORK ...............................................................................................................................547 T-18 ABNORMALITY IN NETWORK SYSTEM.......................................................................................................................548 T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY.................................................................................................549 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM.........................................................................................................550 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS.....................................................................................................551 TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)............................................552 JUDGEMENT TABLE OF JOYSTICK CONTROL SYSTEM...............................................................................................................553 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...............................................................................554 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM..................................................................................................558 J-1 FAILURE CODE [56] (SHORT CIRCUIT, OR DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED.............................................................560 J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED...........................................561 J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED............................................562 J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED........................................................563 J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED.........................................................564 J-6 FAILURE CODE [61] (SHORT CIRCUIT, OR DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED...............................................565 J-7 FAILURE CODE [62] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED................................................566 J-8 FAILURE CODE [63] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER) IS DISPLAYED............................................567 J-9 ABNORMALITY IN POWER SUPPLY, OR POWER SUPPLY VOLTAGE.................................................................................................568 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT.....................................................................................................569 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID............................................................................................................570 J-12 DISCONNECTION IN STEERING LEFT SOLENOID.............................................................................................................571 TROUBLESHOOTING OF THROTTLE CONTROL SYSTEM (TH MODE).........................................................................................................572 JUDGEMENT TABLE FOR THROTTLE CONTROLLER SYSTEM RELATED PARTS.............................................................................................573 ELECTRIC CIRCUIT DIAGRAM OF THROTTLE CONTROLLER SYSTEM...................................................................................................574 TH-1 ABNORMALITY IN ACCELERATOR PEDAL SENSOR SYSTEM IS DISPLAYED.........................................................................................575 TH-2 SHORT CIRCUIT IN RPM-SET IDLE-UP/RESUME IDLE-DOWN SWITCH SYSTEM IS DISPLAYED........................................................................576 TH-3 DISCONNETION IN RPM-SET IDLE-UP/RESUME IDLE-DOWN SWITCH SYSTEM......................................................................................577 TH-4 ABNORMALITY IN ELECTRONIC GOVERNOR VOLTAGE COMMAND SYSTEM...........................................................................................578 TH-5 ABNORMALITY IN BRAKE PEDAL SWITCH SYSTEM............................................................................................................579 a) ABNORMALITY IN LEFT BRAKE PEDAL SWITCH............................................................................................................579 b) ABNORMALITY IN RIGHT BRAKE PEDAL SWITCH...........................................................................................................580 TH-6 ABNORMALITY IN RPM-SET ON/OFF SWITCH SYSTEM.........................................................................................................581 TH-7 SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY...............................................................582 30 DISASSEMBLY AND ASSEMBLY..........................................................................................................................................583 METHOD OF USING MANUAL...........................................................................................................................................585 PRECAUTIONS WHEN CARRYING OUT OPERATION..........................................................................................................................586 SPECIAL TOOL LIST................................................................................................................................................588 SKETCHES OF SPECIAL TOOLS........................................................................................................................................592 STARTING MOTOR...................................................................................................................................................596 REMOVAL AND INSTALLATION.....................................................................................................................................596 ALTERNATOR.......................................................................................................................................................597 REMOVAL AND INSTALLATION.....................................................................................................................................597 RADIATOR.........................................................................................................................................................598 REMOVAL......................................................................................................................................................598 INSTALLATION.................................................................................................................................................600 ENGINE AND TORQUE CONVERTER ASSEMBLY.............................................................................................................................601 REMOVAL......................................................................................................................................................601 INSTALLATION.................................................................................................................................................604 TORQUE CONVERTER.................................................................................................................................................605 REMOVAL......................................................................................................................................................605 INSTALLATION.................................................................................................................................................606 DISASSEMBLY..................................................................................................................................................607 ASSEMBLY.....................................................................................................................................................613 TRANSMISSION.....................................................................................................................................................620 REMOVAL......................................................................................................................................................620 INSTALLATION.................................................................................................................................................622 DISASSEMBLY..................................................................................................................................................623 ASSEMBLY.....................................................................................................................................................638 TRANSMISSION VALVE...............................................................................................................................................654 REMOVAL AND INSTALLATION.....................................................................................................................................654 TRANSFER.........................................................................................................................................................655 DISASSEMBLY..................................................................................................................................................655 ASSEMBLY.....................................................................................................................................................664 CENTER SUPPORT...................................................................................................................................................674 REMOVAL AND INSTALLATION.....................................................................................................................................674 DISASSEMBLY..................................................................................................................................................676 ASSEMBLY.....................................................................................................................................................678 DRIVE SHAFT......................................................................................................................................................681 DISASSEMBLY..................................................................................................................................................681 ASSEMBLY.....................................................................................................................................................684 FRONT AXLE.......................................................................................................................................................687 REMOVAL......................................................................................................................................................687 INSTALLATION.................................................................................................................................................688 FRONT DIFFERENTIAL...............................................................................................................................................689 REMOVAL......................................................................................................................................................689 INSTALLATION.................................................................................................................................................690 REAR AXLE........................................................................................................................................................691 REMOVAL......................................................................................................................................................691 INSTALLATION.................................................................................................................................................694 REAR DIFFERENTIAL................................................................................................................................................695 REMOVAL .....................................................................................................................................................695 INSTALLATION.................................................................................................................................................696 DIFFERENTIAL GEAR................................................................................................................................................697 DISASSEMBLY..................................................................................................................................................697 ASSEMBLY.....................................................................................................................................................701 FINAL DRIVE......................................................................................................................................................709 DISASSEMBLY..................................................................................................................................................709 ASSEMBLY.....................................................................................................................................................711 ORBIT-ROLL.......................................................................................................................................................714 REMOVAL AND INSTALLATION.....................................................................................................................................714 STEERING CYLINDER................................................................................................................................................715 REMOVAL......................................................................................................................................................715 INSTALLATION.................................................................................................................................................716 STEERING VALVE...................................................................................................................................................717 REMOVAL......................................................................................................................................................717 INSTALLATION.................................................................................................................................................718 BRAKE VALVE......................................................................................................................................................719 REMOVAL AND INSTALLATION.....................................................................................................................................719 BRAKE VALVE (R.H.)...............................................................................................................................................720 DISASSEMBLY..................................................................................................................................................720 ASSEMBLY.....................................................................................................................................................722 BRAKE VALVE (L.H.)...............................................................................................................................................724 DISASSEMBLY..................................................................................................................................................724 ASSEMBLY.....................................................................................................................................................726 SLACK ADJUSTER...................................................................................................................................................728 REMOVAL AND INSTALLATION.....................................................................................................................................728 DISASSEMBLY..................................................................................................................................................729 ASSEMBLY.....................................................................................................................................................730 BRAKE............................................................................................................................................................731 REMOVAL AND INSTALLATION.....................................................................................................................................731 DISASSEMBLY..................................................................................................................................................732 ASSEMBLY.....................................................................................................................................................735 HYDRAULIC PUMP...................................................................................................................................................739 REMOVAL......................................................................................................................................................739 INSTALLATION.................................................................................................................................................740 HYDRAULIC TANK...................................................................................................................................................741 REMOVAL......................................................................................................................................................741 INSTALLATION.................................................................................................................................................742 HYDRAULIC FILTER.................................................................................................................................................743 REMOVAL AND INSTALLATION.....................................................................................................................................743 PPC VALVE........................................................................................................................................................744 REMOVAL AND INSTALLATION.....................................................................................................................................744 DISASSEMBLY AND ASSEMBLY.....................................................................................................................................745 DECO VALVE.......................................................................................................................................................746 REMOVAL AND INSTALLATION.....................................................................................................................................746 WORK EQUIPMENT VALVE.............................................................................................................................................747 REMOVAL......................................................................................................................................................747 INSTALLATION.................................................................................................................................................748 PITCH & TILT CYLINDER............................................................................................................................................749 REMOVAL AND INSTALLATION.....................................................................................................................................749 LIFT CYLINDER....................................................................................................................................................750 REMOVAL .....................................................................................................................................................750 INSTALLATION.................................................................................................................................................751 CENTER HINGE PIN.................................................................................................................................................752 REMOVAL......................................................................................................................................................752 INSTALLATION.................................................................................................................................................757 WORK EQUIPMENT...................................................................................................................................................760 REMOVAL......................................................................................................................................................760 INSTALLATION.................................................................................................................................................763 BULKHEAD.........................................................................................................................................................764 REMOVAL......................................................................................................................................................764 INSTALLATION.................................................................................................................................................765 FLOOR FRAME......................................................................................................................................................766 REMOVAL......................................................................................................................................................766 INSTALLATION.................................................................................................................................................768 COUNTERWEIGHT....................................................................................................................................................769 REMOVAL AND INSTALLATION.....................................................................................................................................769 FUEL TANK........................................................................................................................................................770 REMOVAL......................................................................................................................................................770 INSTALLATION.................................................................................................................................................771 CAB..............................................................................................................................................................772 REMOVAL......................................................................................................................................................772 INSTALLATION.................................................................................................................................................774 STOP VALVE.......................................................................................................................................................775 REMOVAL AND INSTALLATION.....................................................................................................................................775 ACCUMULATOR......................................................................................................................................................776 REMOVAL AND INSTALLATION.....................................................................................................................................776 ACCUMULATOR CHARGE VALVE.........................................................................................................................................777 REMOVAL AND INSTALLATION.....................................................................................................................................777 PARKING BRAKE SOLENOID VALVE.....................................................................................................................................778 REMOVAL AND INSTALLATION.....................................................................................................................................778 DIVERTER VALVE...................................................................................................................................................779 REMOVAL AND INSTALLATION.....................................................................................................................................779 EMERGENCY STEERING PUMP..........................................................................................................................................780 REMOVAL AND INSTALLATION.....................................................................................................................................780 PARKING BRAKE....................................................................................................................................................781 REMOVAL AND INSTALLATION.....................................................................................................................................781 PARKING BRAKE CALIPERS...........................................................................................................................................782 DISASSEMBLY..................................................................................................................................................782 ASSEMBLY.....................................................................................................................................................783 PARKING BRAKE PAD................................................................................................................................................784 REMOVAL AND INSTALLATION.....................................................................................................................................784 REAR TIRES.......................................................................................................................................................785 REMOVAL AND INSTALLATION.....................................................................................................................................785 AIR CONDITIONER COMPRESSOR.......................................................................................................................................786 REMOVAL AND INSTALLATION.....................................................................................................................................786 AIR CONDITIONER CONDENSER........................................................................................................................................787 REMOVAL AND INSTALLATION.....................................................................................................................................787 RECEIVER TANK....................................................................................................................................................788 REMOVAL AND INSTALLATION.....................................................................................................................................788 AIR CONDITIONER UNIT.............................................................................................................................................789 REMOVAL......................................................................................................................................................789 INSTALLATION.................................................................................................................................................790 MONITOR..........................................................................................................................................................791 REMOVAL AND INSTALLATION.....................................................................................................................................791 40 MAINTENANCE STANDARD..............................................................................................................................................792 ENGINE MOUNT.....................................................................................................................................................793 TRANSMISSION MOUNT...............................................................................................................................................794 TORQUE CONVERTER.................................................................................................................................................795 LOCK-UP VALVE....................................................................................................................................................797 TORQUE CONVERTER REGULATOR VALVE.................................................................................................................................798 TRANSMISSION.....................................................................................................................................................799 TRANSMISSION SOLENOID VALVE......................................................................................................................................802 TRANSMISSION CONTROL VAVLE.......................................................................................................................................803 TRANSFER.........................................................................................................................................................807 DRIVE SHAFT......................................................................................................................................................809 CENTER SUPPORT...................................................................................................................................................810 DIFFERENTIAL.....................................................................................................................................................811 NON-SPIN DIFFERENTIAL............................................................................................................................................815 FINAL DRIVE......................................................................................................................................................817 AXLE MOUNT.......................................................................................................................................................819 CENTER HINGE PIN.................................................................................................................................................820 STEERING COLUMN..................................................................................................................................................822 STEERING VALVE...................................................................................................................................................823 EMERGENCY STEERING PUMP..........................................................................................................................................824 DIVERTER VALVE...................................................................................................................................................825 STEERING CYLINDER MOUNT..........................................................................................................................................826 BRAKE VALVE......................................................................................................................................................827 SLACK ADJUSTER...................................................................................................................................................830 BRAKE............................................................................................................................................................831 PARKING BRAKE....................................................................................................................................................832 HYDRAULIC PUMP...................................................................................................................................................833 PPC VALVE........................................................................................................................................................836 WORK EQUIPMENT VALVE.............................................................................................................................................837 HYDRAULIC CYLINDER...............................................................................................................................................839 WORK EQUIPMENT LINKAGE...........................................................................................................................................842 BLADE............................................................................................................................................................846 ROPS CANOPY......................................................................................................................................................847 90 OTHERS............................................................................................................................................................848 BRAKE CIRCUIT DIAGRAM............................................................................................................................................849 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................................................................................851 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................................852 ELECTRIC CIRCUIT DIAGRAM FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL..........................................................................854 ELECTRIC CIRCUIT DIAGRAM (1/8)...............................................................................................................................854 ELECTRIC CIRCUIT DIAGRAM (2/8)...............................................................................................................................855 ELECTRIC CIRCUIT DIAGRAM (3/8)...............................................................................................................................856 ELECTRIC CIRCUIT DIAGRAM (4/8)...............................................................................................................................857 ELECTRIC CIRCUIT DIAGRAM (5/8)...............................................................................................................................858 ELECTRIC CIRCUIT DIAGRAM (6/8)...............................................................................................................................859 ELECTRIC CIRCUIT DIAGRAM (7/8)...............................................................................................................................860 ELECTRIC CIRCUIT DIAGRAM (8/8)...............................................................................................................................861
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