Komatsu Wheel Loader WA800L avance Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA800L-3 avance, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA800L-3 avance workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 803 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM035603 - Wheel Loader WA800L-3 avance Shop Manual.pdf
TEN00007-02 - Wheel Loader WA800L-3 avance Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...28
GENERAL ASSEMBLY DRAWING...29
SPECIFICATIONS...30
WEIGHT TABLE...33
LIST OF LUBRICANT AND WATER...35
10 STRUCTURE AND FUNCTION...43
POWER TRAIN...44
POWER TRAIN SYSTEM...45
ENGINE CONTROL...46
RADIATOR AND COOLER...47
DAMPER...49
TORQUE CONVERTER AND TRNSMISSION PIPING...50
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...51
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...52
TORQUE CONVERTER...53
TRANSMISSION...58
TRANSFER...66
TRANSMISSION CONTROL VALVE...67
TORQUE CONVERTER OIL COOLER...83
DRIVE SHAFT...84
CENTER SUPPORT...85
AXLE...86
DIFFERENTIAL...88
FINAL DRIVE...91
CENTER HINGE PIN...92
AXLE MOUNT...93
TIRE AND WHEEL...95
STEERING PIPING...96
JOYSTICK STEERING LINKAGE...97
STEERING PUMP...98
SWITCH PUMP...100
STEERING DEMAND VALVE...102
EPC VALVE...113
ROTARY VALVE...114
TWO-WAY RESTRICTOR VALVE...116
DIVERTER VALVE...117
BRAKE PIPING...121
BRAKE CIRCUIT DIAGRAM...122
BRAKE VALVE...124
CHARGE VALVE...129
ACCUMULATOR (FOR BRAKE)...133
SLACK ADJUSTER...134
BRAKE...137
PARKING BRAKE...138
SPRING CYLINDER...140
PARKING BRAKE SOLENOID VALVE...141
HYDRAULIC PIPING...142
WORK EQUIPMENT LEVER LINKAGE...145
HYDRAULIC TANK...146
MAIN PISTON PUMP...149
ES VALVE (ENGINE SENSING VALVE)...157
SERVO VALVE...159
PPC VALVE (PROPORTIONAL PRESSURE VALVE)...162
PPC RELIEF VALVE...166
ACCUMULATOR (FOR PPC VALVE)...167
MAIN CONTROL VALVE...168
LUBRICATION OF WORK EQUIPMENT...181
WORK EQUIPMENT LINKAGE...184
BUCKET POSITIONER AND BOOM KICK-OUT...186
OPERATION OF PROXIMITY SWITCH...188
CAB AND ROPS CANOPY...192
AIR CONDITIONER...193
MACHINE MONITOR SYSTEM...197
MAIN MONITOR...198
MAINTENANCE MONITOR...202
ENGINE STARTING CIRCUIT...205
ENGINE STOP CIRCUIT...208
PREHEATING CIRCUIT...209
ELECTRICAL TRANSMISSION CONTROL...210
KICK-DOWN, HOLD SWITCH...211
AUTOMATIC TRANSMISSION (ATM) SYTEM...212
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)...222
ELECTRIC PARKING BRAKE CONTROL...227
20 TESTING AND ADJUSTING...236
STANDARD VALUE TABLE FOR ENGINE...237
STANDARD VALUE TABLE FOR CHASSIS...238
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...242
TESTING AND ADJUSTING...252
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...253
MEASURING ENGINE SPEED...255
MEASURING EXHAUST GAS COLOR...256
ADJUSTING VALVE CLEARANCE...257
MEASURING COMPRESSION PRESSURE...257
MEASURING BLOW-BY PRESSURE...257
TESTING AND ADJUSTING FUEL INJECTION TIMING...257
MEASURING ENGINE OIL PRESSURE...257
MEASURING EXHAUST TEMPERATURE...257
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...257
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...258
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...259
MEASURING ACCELERATOR PEDAL ...260
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE...261
PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS...263
TESTING AND ADJUSTING STEERING OIL PRESSURE ...265
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE ...266
BLEEDING AIR FROM STEERING CIRCUIT...268
TESTING AND ADJUSTING STEERING STOPPER BOLT...269
TESTING AND ADJUSTING STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR...270
TESTING WHEEL BRAKE PERFORMANCE...271
TESTING WHEEL BRAKE OIL PRESSURE DROP...272
MEASURING WEAR OF WHEEL BRAKE DISC...274
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...275
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT...277
TESTING PARKING BRAKE PERFORMANCE...278
MEASURING PARKING RAKE SOLENOID OUTPUT PRESSURE...279
CHECKING AND ADJUSTING PARKING BRAKE PAD...280
TESTING AND ADJUSTING PPC PRESSURE...282
ADJUSTING PPC VALVE LINKAGE...283
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...284
BLEEDING AIR FROM PISTON PUMP...286
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...287
ADJUSTING WORK EQUIPMENT LEVER LINKAGE...288
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...289
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH...290
TESTING AND ADJUSTING BOOM PROXIMITY SWITCH...290
TESTING PROXIMITY ACTUATION PILOT LAMP...291
ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR...292
TROUBLESHOOTING...293
POINTS TO REMEMBER WHEN TROUBLESHOOTING...294
SEQUENCE OF EVENTS IN TROUBLESHOOTING...295
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...296
CHECKS BEFORE TROUBLESHOOTING...304
TYPES AND LOCATIONS OF CONNECTORS...305
CONNECTOR LOCATION STEREOGRAM...311
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...317
T-BRANCH BOX AND T-BRANCH TABLE...342
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM...344
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE...348
CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION...350
TRANSMISSION CONTROLLER LED DISPLAY...352
METHOD OF USING JUDGEMENT TABLE...353
METHOD OF USING TROUBLESHOOTING CHARTS...354
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...356
TROUBLESHOOTING OF ENGINE (S MODE)...358
METHOD OF USING TROUBLESHOOTING CHARTS...359
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...363
S-2 ENGINE DOES NOT START...364
(1) ENGINE DOES NOT TURN...364
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (INCLUDING CASES WITH V-TYPE ENGINE WHERE THERE IS NO FUEL INJECTION FOR THE BANK ON ONE SIDE)...365
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...366
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...367
S-4 ENGINE STOPS DURING OPERATIONS (FOR V TYPE ENGINE, INCLUDING CASES WHERE ONE BANK STOPS)...368
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...369
S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH V-TYPE ENGINE, FOR CASES WHERE THERE IS INJECTION FOR ONLY ONE BANK, GO TO TROUBLESHOOTING S-2-(2) OR S-4.)...370
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...371
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...372
S-9 OIL BECOMES CONTAMINATED QUICKLY...373
S-10 FUEL CONSUMPTION IS EXCESSIVE...374
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...375
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...376
S-13 OIL LEVEL RISES...377
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...378
S-15 ABNORMAL NOISE IS MADE...379
S-16 VIBRATION IS EXCESSIVE...380
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE)...381
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM RELATED PARTS...382
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...383
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...387
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN BACKUP LAMP RELAY) IS DISPLAYED...389
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS DISPLAYED...390
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS DISPLAYED...391
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED...392
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED...393
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED...394
T-7 FAILURE CODE [20] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK LEVER SWITCH SYSTEM) IS DISPLAYED...395
T-8 FAILURE CODE [21] (SHORT CIRCUIT OR DISCONNECTION IN JOYSTICK SHIFT-UP/SHIFT-DOWN SWITCH SYSTEM) IS DISPLAYED...396
T-9 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR) IS DISPLAYED...397
T-10 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...398
T-11 KICKDOWN SWITCH SIGNAL SYSTEM AND HOLD SWITCH SIGNAL SYSTEM...399
T-12 TRANSMISSION CUT-OFF SIGNAL SYSTEM...400
T-13 NEUTRALIZER SIGNAL SYSTEM...401
T-14 BUZZER SIGNAL SYSTEM...402
T-15 NETWORK SYSTEM...403
T-16 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM...404
T-17 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...405
T-18 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...406
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...407
TROUBLE DATA DISPLAY...409
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM...411
M-1 MAIN MONITOR DOES NOT WORK...413
M-2 WHEN STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS) AND ENGINE S STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP...414
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...415
M-4 ABNORMALITY IN SHIFT INDICATOR...416
a) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT F...416
b) DISPLAYS N EVEN WHEN DIRECTIONAL SWITCH IS AT R...416
c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL SWITCH IS AT N (DISPLAY 1ST-3RD)...416
M-5 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...418
a) L.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...418
b) R.H. TURN SIGNAL DISPLAY DOES NOT LIGHT UP...418
M-6 ABNORMALITY IN PARKING DISPLAY...420
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...420
b) PARKING LAMP DISPLAY STAYS LIGHTED UP...420
M-7 NIGHT LIGHTING DOES NOT LIGHT UP...421
M-8 ABNORMALITY IN FRONT WORKING LAMP...423
a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP...423
b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...423
c) MONITOR DISPLAY LIGHTS UP BUT FRONT WORKING LAMP DOES NOT LIGHT UP...423
M-9 ABNORMALITY IN REAR WORKING LAMP...425
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...425
b) REAR WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...425
c) MONITOR DISPLAY LIGHTS UP BUT REAR WORKING LAMP DOES NOT LIGHT UP...425
M-10 ABNORMALITY IN TRANSMISSION CUT-OFF...427
a) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE...427
b) WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF, MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION IS ACTUATED WHEN PEDAL IS DEPRESSED...427
c) WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED...427
d) CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)...427
e) MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURNED ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED...428
M-11 ABNORMALITY IN LOW IDLE SELECTION...429
a) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE LOW IDLE SPEED DOES NOT RISE AND DISPLAY DOES NOT CHANGE...429
b) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED ON, THE MONITOR LIGHTS UP BUT THE LOW IDLE SPEED DOES NOT RISE...429
c) WHEN MONITOR SWITCH (LOW IDLE SELECTOR SWITCH) IS TURNED OFF, THE MONITOR GOES OFF BUT THE LOW IDLE SPEED DOES NOT LOWER...430
M-12 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY...431
M-13 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY...432
a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP...432
b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP...432
M-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...433
a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL SWITCH IS AT N...433
b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL SWITCH IS AT POSITION OTHER THAN N...433
M-15 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED...434
a) ACTUATED CONTINUOUSLY...434
b) NOT ACTUATED...434
M-16 ABNORMALITY IN BUZZER...435
a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3 SECONDS) (DURING SELF-CHECK)...435
b) BUZZER ALWAYS SOUNDS...435
M-17 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...436
M-18 ABNORMALITY IN FAILURE DISPLAY MODE...437
a) DOES NOT ENTER FAILURE DISPLAY MODE...437
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...437
M-19 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION & JOYSTICK STEERING CONTROLLER...438
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM...439
a) FORCED GREASING CANNOT BE CARRIED OUT...439
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...439
c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...439
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) CONFIRM THAT GREASE IS NOT EMPTY...440
e) MONITOR DISPLAY GOES OUT...440
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...441
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...442
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM...443
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOSE NOT WORK...445
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...445
b) SOME LAMPS DO NOT LIGHT UP...445
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS)...446
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT...447
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...449
a) ENGINE OIL LEVEL DISPLAY FLASHES...449
b) ENGINE WATER LEVEL DISPLAY FLASHES...450
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH...451
a) ENGINE OIL PRESSURE DISPLAY FLASHES...451
b) BATTERY CHARGE LEVEL DISPLAY FLASHES...452
c) BRAKE OIL PRESSURE DISPLAY FLASHES (CHECK THAT THE BRAKE OIL PRESSURE IS CORRECT.)...453
d) AIR CLEANER (R.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (R.H.) IS NOT CLOGGED.)...455
e) AIR CLEANER (L.H.) CLOGGING DISPLAY FLASHES (CHECK THAT THE AIR CLEANER (L.H.) IS NOT CLOGGED.)...456
f) TRANSMISSION OIL FILTER DISPLAY FLASHES (THE TRANSMISSION OIL FILTER MUST NOT BE CLOGGED.)...457
K-6 CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND...458
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS...459
K-8 CAUTION ITEMS ARE FLASHING BUT NEITHER CHECK LAMP NOR CAUTION LAMP FLASHES...460
a) CHECK LAMP...460
b) CAUTION LAMP...460
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT CHECK LAMP OR CAUTION LAMP LIGHTS UP...461
a) CHECK LAMP...461
b) CAUTION LAMP...461
K-10 ONLY NIGHT LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP WHEN LIGHTING SWITCH IS TURNED ON...462
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LIGHTING SWITCH IS TURNED OFF...463
K-12 SERVICE METER DOES NOT WORK...464
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...464
K-14 ABNORMALITY IN GAUGE DISPLAY...466
a) ABNORMALITY IN FUEL GAUGE...466
b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...467
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...468
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...469
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING AND PREHEATING...470
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE...472
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER...473
E-1 ENGINE DOES NOT START...474
a) STARTING MOTOR DOES NOT TURN...474
b) STARTING MOTOR TURNS...478
E-2 ENGINE DOES NOT...479
E-3 ABNORMALITY IN PREHEATING SYSTEM...482
a) DOES NOT CARRY OUT PREHEATING...482
b) ONLY MONITOR DISPLAY LIGHTS UP...482
c) MONITOR DISPLAY DOES NOT LIGHT UP WHEN PREHEATING IS COMPLETED...483
d) MONITOR DISPLAY KEEPS LIGHTING UP WHEN PREHEATING IS NOT COMPLETED...483
E-4 PARKING BRAKE DOES NOT HAVE EFFECT...485
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...485
b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE (ACCUMULATOR PRESSURE) DROPS (DOES NOT WORK AS EMERGENCY BRAKE)...485
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...486
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...488
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)...488
E-8 KICK-DOWN SWITCH DOES NOT WORK...490
a) KICK-DOWN SWITCH DOES NOT WORK EVEN THOUGH GEAR SHIFT WORKS NORMALLY...490
b) KICK-DOWN CANNOT BE CANCELED...491
E-9 BOOM KICK-OUT DOES NOT WORK...492
E-10 ABNORMALITY IN BUCKET POSITIONER FUNCTION...495
E-11 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP...498
E-12 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP...498
E-13 ABNORMALITY IN TRANSMISSION CUT-OFF...498
E-14 ABNORMALITY IN LOW IDLING SELECTION...498
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...498
E-16 ABNORMALITY IN BUZZER...498
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...499
H-1 MACHINE DOES NOT MOVE...500
H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)...501
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...502
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...503
H-5 STEERING DOES NOT TURN...504
H-6 TURNING, RESPONSE OF STEERING IS POOR...505
H-7 JOYSTICK LEVER IS HEAVY...506
H-8 STEERING WHEEL SHAKES OR JERKS...507
H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT...508
H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...509
H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...510
H-12 BOOM DOES NOT RISE...511
H-13 BOOM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...512
H-14 WHEN RAISING BOOM, BECOMES SLOW AT CERTAIN HEIGHT...513
H-15 BOOM CYLINDER CANNOT HOLD DOWN BUCKET...513
H-16 BOOM HAS LARGE AMOUNT OF HYDRAULIC DRIFT...513
H-17 BOOM FLUCTUATES WHILE WORKING...514
H-18 BOOM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE...514
H-19 BUCKET DOES NOT TILT BACK...515
H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...516
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...517
H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET...517
H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT...517
H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE "HOLD")...518
H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT...518
H-26 BOOM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY...519
TROUBLESHOOTING OF AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM (A MODE)...520
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM...521
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY...522
ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL...526
A-1 FAILURE CODE [56] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN CAUTION BUZZER RELAY SYSTEM) IS DISPLAYED...528
A-2 FAILURE CODE [57] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER ANGLE SENSOR SYSTEM) IS DISPLAYED...529
A-3 FAILURE CODE [58] (DEVIATION OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR SIGNALS) IS DISPLAYED...530
A-4 FAILURE CODE [59] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN FRAME ANGLE SENSOR SYSTEM) IS DISPLAYED...531
A-5 FAILURE CODE [60] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING LEVER LOCK PRESSURE SWITCH SYSTEM) IS DISPLAYED...532
A-6 FAILURE CODE [62] (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN STEERING NEUTRAL INTERLOCK RELAY SYSTEM) IS DISPLAYED...533
A-7 FAILURE CODE [63] (DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND, OR SHORT CIRCUIT WITH POWER SOURCE IN STEERING MAIN PRESSURE CONTROL EPC SOLENOID SYSTEM) IS DISPLAYED...534
A-8 STEERING SPEEDS IN BOTH DIRECTIONS ARE DIFFERENT...535
A-9 ABNORMALITY IN CONSOLE SWITCH (ADJUSTMENT OF STEERING LEVER ANGLE SENSOR AND FRAME ANGLE SENSOR IS IMPOSSIBLE)...536
A-10 ABNORMALITY IN POWER SOURCE AND VOLTAGE...537
30 DISASSEMBLY AND ASSEMBLY...538
METHOD OF USING MANUAL...540
PRECAUTIONS WHEN CARRYING OUT OPERATION...542
SPECIAL TOOL LIST...544
SKETCHES OF SPECIAL TOOLS...550
ENGINE RELATED PARTS...558
STARTING MOTOR...558
ALTERNATOR...558
ENGINE OIL COOLER...558
FUEL INJECTION PUMP FOR LEFT BANK...558
FUEL INJECTION PUMP FOR RIGHT BANK...558
WATER PUMP...558
NOZZELE HODLER...558
TURBOCHARGER...558
ENGINE FRONT SEAL...558
ENGINE REAR SEAL...558
CYLINDER HEAD...558
REMOVAL AND INSTALLATION OF RADIATOR...559
REMOVAL AND INSTALLATION OF ENGINE...562
REMOVAL AND INSTALLATION OF DAMPER ...567
DISASSEMBLY AND ASSEMBLY OF DAMPER...568
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...572
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER...579
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE...586
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION...587
REMOVAL AND INSTALLATION OF TRANSMISSION VALVE...611
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE...612
DISASSEMBLY AND ASSEMBLY OF TRANSFER...616
DISASSEMBLY AND ASSEMBLY OF PTO...628
REMOVAL AND INSTALLATION OF CENTER SUPPORT...633
DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT...635
DISASSEMBLY AND ASSEMBLY OF DRIVE SHAFT...639
REMOVAL AND INSTALLATION OF FRONT AXLE...642
REMOVAL AND INSTALLATION OF REAR AXLE...644
REMOVAL AND INSTALLATION OF DIFFERENTIAL...649
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL...651
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE...659
REMOVAL AND INSTALLATION OF ROTARY VALVE...664
REMOVAL AND INSTALLATION OF EMERGENCY STEERING PUMP...665
REMOVAL AND INSTALLATION OF DIVERTER VALVE...666
DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE...667
REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE...669
DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE...670
REMOVAL AND INSTALLATION OF STEERING CYLINDER...672
REMOVAL AND INSTALLATION OF STEERING VALVE...674
REMOVAL AND INSTALLATION OF BRAKE VALVE...676
REMOVAL AND INSTALLATION OF SLACK ADJUSTER...677
DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER...678
REMOVAL AND INSTALLATION OF BRAKE...680
DISASSEMBLY AND ASSEMBLY OF BRAKE...681
REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS...685
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS...686
REMOVAL AND INSTALLATION OF PARKING BRAKE PAD...688
REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER...689
REMOVAL AND INSTALLATION OF BRAKE OIL TANK...690
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP...691
REMOVAL AND INSTALLATION OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY...693
REMOVAL AND INSTALLATION OF PPC VALVE...695
DISASSEMBLY AND ASSEMBLY OF PPC VALVE...697
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...698
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE...700
REMOVAL AND INSTALLATION OF CAB...703
REMOVAL AND INSTALLATION OF FLOOR FRAME...705
REMOVAL AND INSTALLATION OF CENTER HINGE PIN...708
REMOVAL AND INSTALLATION OF WORK EQUIPMENT...715
REPLACEMENT OF BOOM FRONT END BUSH...720
REMOVAL AND INSTALLATION OF BUCKET CYLINDER...721
REMOVAL AND INSTALLATION OF LIFT CYLINDER...722
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER...724
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT...728
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR...730
REMOVAL AND INSTALLATION OF RECEIVER TANK...731
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER...732
REMOVAL AND INSTALLATION OF TRANSMISSION AND JOYSTICK STEERING CONTROLLER...733
REMOVAL AND INSTALLATION OF MAIN MONITOR...734
REMOVAL AND INSTALLATION OF FUEL TANK...736
REMOVAL AND INSTALLATION OF COUNTERWEIGHT...738
40 MAINTENANCE STANDARD...739
ENGINE MOUNT...740
TRANSMISSION MOUNT...741
DAMPER...742
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP...744
TORQUE CONVERTER...746
TORQUE CONVERTER REGULATOR VALVE...747
TRANSMISSION (1/2)...748
TRANSMISSION (2/2)...750
TRANSFER...751
TRANSMISSION CONTROL VALVE...752
DRIVE SHAFT...757
CENTER SUPPORT...758
DIFFERENTIAL (1/2)...759
DIFFERENTIAL (2/2)...760
FINAL DRIVE...762
AXLE MOUNT...764
CENTER HINGE PIN...766
STEERING DEMAND VALVE...768
DIVERTER VALVE...770
STEERING CYLINDER MOUNT...771
EMERGENCY STEERING PUMP...772
BRAKE VALVE...773
SLACK ADJUSTER...776
BRAKE...777
PARKING BRAKE...779
PPC VALVE...781
PPC RELIEF VALVE...783
CONTROL PUMP...784
STEERING PUMP...785
SWITCH PUMP...786
MAIN PISTON PUMP...787
MAIN CONTROL VALVE...788
HYDRAULIC CYLINDER...790
WORK EQUIPMENT LINKAGE...791
BUCKET POSITIONER AND BOOM KICK-OUT...793
ROPS CANOPY...794
90 OTHERS...795
HYDRAULIC CIRCUIT DIAGRAM...796
ELECTRICAL CIRCUIT DIAGRAM (1/5)...797
ELECTRICAL CIRCUIT DIAGRAM (2/5)...798
ELECTRICAL CIRCUIT DIAGRAM (3/5)...799
ELECTRICAL CIRCUIT DIAGRAM (4/5)...800
ELECTRICAL CIRCUIT DIAGRAM (5/5)...801
ELECTRICAL CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)...802
ELECTRICAL CIRCUIT DIAGRAM (AUTO-GREASING)...803
COVER.....1
FOREWORD.....2
FOREWORD.....3
SAFETY INFORMATION.....6
INTRODUCTION.....8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....8
VISIBILITY FROM OPERATOR'S SEAT.....9
NECESSARY INFORMATION.....10
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....10
ENGINE SERIAL NO. PLATE AND POSITION.....10
POSITION OF SERVICE METER.....11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....11
CONTENTS.....12
SAFETY.....15
SAFETY.....16
SAFETY LABELS.....18
LOCATION OF SAFETY LABELS.....18
GENERAL PRECAUTIONS.....24
SAFETY RULES.....24
IF ABNORMALITIES ARE FOUND.....24
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....24
FIRE EXTINGUISHER AND FIRST AID KIT.....24
SAFETY FEATURES.....24
KEEP MACHINE CLEAN.....25
INSIDE OPERATOR'S COMPARTMENT.....25
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....26
HANDRAILS AND STEPS.....27
MOUNTING AND DISMOUNTING.....27
NO PEOPLE ON ATTACHMENTS.....27
DO NOT GET CAUGHT IN ARTICULATED PORTION.....28
PREVENTION OF BURNS.....28
FIRE PREVENTION.....29
ACTION IF FIRE OCCURS.....30
WINDOW WASHER LIQUID.....30
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).....30
PRECAUTIONS FOR ATTACHMENTS, OPTIONS.....30
UNAUTHORIZED MODIFICATION.....30
SAFETY AT WORKSITE.....31
WORKING ON LOOSE GROUND.....31
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....32
ENSURE GOOD VISIBILITY.....32
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS.....33
CHECKING SIGNALMAN'S SIGNALS AND SIGNS.....33
EMERGENCY EXIT FROM OPERATOR'S CAB.....33
BE CAREFUL ABOUT ASBESTOS DUST.....33
PRECAUTIONS FOR OPERATION.....34
STARTING ENGINE.....34
CHECKS BEFORE STARTING ENGINE.....34
PRECAUTIONS WHEN STARTING.....34
PRECAUTIONS IN COLD AREAS.....35
OPERATION.....36
CHECKS BEFORE OPERATION.....36
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE.....36
PRECAUTIONS WHEN TRAVELING.....37
TRAVELING ON SLOPES.....38
PROHIBITED OPERATIONS.....39
PRECAUTIONS WHEN OPERATING.....40
METHODS OF USING BRAKE.....40
OPERATE CAREFULLY ON SNOW.....41
PARKING MACHINE .....42
TRANSPORTATION.....44
LOADING AND UNLOADING.....44
SHIPPING.....44
BATTERY.....45
BATTERY HAZARD PREVENTION.....45
STARTING WITH BOOSTER CABLES.....46
TOWING.....47
PRECAUTIONS FOR MAINTENANCE.....48
WARNING TAG .....48
KEEP WORK PLACE CLEAN AND TIDY.....48
APPOINT LEADER WHEN WORKING WITH OTHERS.....48
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.....49
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.....51
PROPER TOOLS.....52
WORK EQUIPMENT SUPPORT.....52
ACCUMULATOR.....52
PERSONNEL.....52
ATTACHMENTS .....53
NOISE.....53
PRECAUTIONS WHEN USING HAMMER.....53
REPAIR WELDING .....53
REMOVING BATTERY TERMINAL .....53
PRECAUTIONS WITH HIGH-PRESSURE OIL.....54
HANDLING HIGH-PRESSURE HOSES.....54
WASTE MATERIALS .....54
MAINTENANCE OF AIR CONDITIONER.....54
COMPRESSED AIR.....55
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .....55
PRECAUTIONS WITH TIRES.....56
HANDLING TIRES.....56
PRECAUTIONS WHEN STORING TIRES.....56
OPERATION.....57
GENERAL VIEW.....58
GENERAL VIEW OF MACHINE.....58
GENERAL VIEW OF CONTROLS AND GAUGES.....59
EXPLANATION OF COMPONENTS.....61
MACHINE MONITOR.....61
SWITCHES.....74
CONTROL LEVERS, PEDALS.....85
MAIN MONITOR TILT LEVER.....89
CAP WITH LOCK.....90
SAFETY BAR.....91
TOWING PIN.....91
ENGINE SHUT-DOWN SWITCH.....91
FUEL STOP LEVER.....92
GREASE PUMP.....92
BACKUP ALARM.....92
CAB DOOR OPEN LOCK.....92
TOOL BOX.....93
FUSE.....94
SLOW BLOW FUSE.....95
LUNCH BOX TRAY.....96
POWER OUTLET.....96
AM/FM RADIO-CASSETTE STEREO.....97
AIR CONDITIONER.....105
PRECAUTIONS WHEN HANDLING ACCUMULATOR.....110
OPERATION.....112
CHECK BEFORE STARTING ENGINE, ADJUST.....112
STARTING ENGINE.....129
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....132
STOPPING ENGINE.....134
CHECK AFTER STOPPING ENGINE.....134
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....135
TURNING.....143
OPERATION OF WORK EQUIPMENT.....144
WORK POSSIBLE USING WHEEL LOADER.....146
PRECAUTIONS FOR OPERATION.....152
ADJUSTING WORK EQUIPMENT POSTURE.....154
REMOVAL AND INSTALLATION OF THE BUCKET.....156
PARKING MACHINE.....159
CHECKS AFTER COMPLETION OF OPERATION.....161
LOCKING.....161
HANDLING THE TIRES.....162
OPERATING AUTO-GREASING SYSTEM.....164
TRANSPORTATION.....177
TRANSPORTATION PROCEDURE.....177
LOADING, UNLOADING WORK.....177
METHOD OF SECURING MACHINE.....177
METHOD OF LIFTING MACHINE.....179
COLD WEATHER OPERATION.....183
PRECAUTIONS FOR LOW TEMPERATURE.....183
PRECAUTIONS AFTER COMPLETION OF WORK.....185
AFTER COLD WEATHER.....186
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.....186
LONG-TERM STORAGE.....187
BEFORE STORAGE.....187
DURING STORAGE.....187
AFTER STORAGE.....187
TROUBLESHOOTING.....188
WHEN MACHINE RUNS OUT OF FUEL.....188
METHOD OF TOWING MACHINE.....189
IF BATTERY IS DISCHARGED.....193
OTHER TROUBLE.....197
MAINTENANCE.....202
GUIDES TO MAINTENANCE.....203
OUTLINES OF SERVICE.....205
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....205
OUTLINE OF ELECTRIC SYSTEM.....208
WEAR PARTS.....209
WEAR PARTS LIST.....209
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....210
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....210
FUEL, OIL AND COOLANT SPECIFICATIONS.....212
ENGINE OIL SPECIFICATIONS.....212
TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.....213
DRIVE AXLE OIL SPECIFICATIONS.....213
DIESEL FUEL SPECIFICATIONS.....213
COOLANT SPECIFICATIONS.....214
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....220
TORQUE LIST.....220
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....221
MAINTENANCE SCHEDULE CHART.....223
MAINTENANCE SCHEDULE CHART.....223
SERVICE PROCEDURE.....225
INITIAL 250 HOURS SERVICE.....225
WHEN REQUIRED.....226
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.....226
CLEAN INSIDE OF COOLING SYSTEM.....228
CHECK TRANSMISSION OIL LEVEL, ADD OIL.....230
CHECK AXLE OIL LEVEL, ADD OIL.....232
CLEAN AXLE CASE BREATHER.....232
CLEAN AIR CONDITIONER CONDENSER.....233
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.....233
CLEAN RADIATOR FINS.....234
CHECK ELECTRICAL INTAKE AIR HEATER.....234
REPLACE BUCKET TEETH.....235
LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES).....238
CHECK AIR CONDITIONER.....238
BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT.....239
BLEEDING AIR FROM PPC CIRCUIT.....239
REPLACE SLOW BLOW FUSE.....240
BLEEDING AIR FROM HYDRAULIC TANK.....241
REPLACE FAN BELT.....242
SELECTION AND INSPECTION OF TIRES.....244
DRAIN WATER FROM WATER SEPARATOR.....246
CHECK BEFORE STARTING.....247
EVERY 50 HOURS SERVICE.....248
DRAIN WATER, SEDIMENT FROM FUEL TANK.....248
EVERY 100 HOURS SERVICE.....249
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....249
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.....250
EVERY 250 HOURS SERVICE.....251
CHECK BATTERY ELECTROLYTE LEVEL.....251
CHECK PARKING BRAKE.....252
CHECK ALTERNATOR BELT TENSION, ADJUST.....253
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....254
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN.....255
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.....255
EVERY 500 HOURS SERVICE.....256
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....256
REPLACE FUEL FILTER CARTRIDGE.....258
REPLACE TRANSMISSION OIL FILTER ELEMENT.....260
LUBRICATE CENTER DRIVE SHAFT.....261
CHECK FAN BELT FOR WEAR .....261
EVERY 1000 HOURS SERVICE.....262
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER.....262
CLEAN TRANSMISSION CASE BREATHER.....264
LUBRICATING.....264
CHECK TIGHTENING PARTS OF TURBOCHARGER.....265
CLEAN FUEL STRAINER.....265
TIGHTEN ROPS CANOPY.....265
REPLACE CORROSION RESISTOR CARTRIDGE.....266
EVERY 2000 HOURS SERVICE.....267
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....267
CLEAN HYDRAULIC TANK STRAINER.....270
REPLACE HYDRAULIC TANK BREATHER ELEMENT.....271
CHANGE AXLE OIL.....272
REPLACE FILTER ELEMENT IN BRAKE OIL TANK.....274
REPLACE BRAKE OIL TANK BREATHER.....275
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.....275
CLEAN PPC CIRCUIT STRAINER.....275
CHECK ALTERNATOR, STARTING MOTOR.....275
CHECK ENGINE VALVE CLEARANCE, ADJUST.....276
CHECK BRAKE DISC WEAR.....276
CLEAN AND CHECK TURBOCHARGER.....276
CHECK PLAY OF TURBOCHARGER ROTOR.....276
CHECK ACCUMULATOR FUNCTION.....277
CHECK ACCUMULATOR GAS PRESSURE.....277
LUBRICATE ENGINE FRONT TRUNNION.....277
EVERY 4000 HOURS SERVICE.....278
CHECK WATER PUMP.....278
CHECK VIBRATION DAMPER.....278
CHECK FAN PULLEY AND TENSION PULLEY.....278
SPECIFICATIONS.....279
SPECIFICATIONS.....280
INDEX.....281
