Komatsu Wheel Loader WA500L Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA500-1L, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA500-1L 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: 1,361 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAMW25010 - Wheel Loader WA500-1L Operation & Maintenance Manual.pdf
CEBMW25010 - Wheel Loader WA500-1L Shop Manual.pdf
SEAMA4250101 - Wheel Loader WA500-1L Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
CONTENTS...5
10 ENGINE...19
12 TESTING AND ADJUSTING...19
STANDARD VALUE TABLE...20
TOOL LIST...22
VALVE CLEARANCE ...23
COMPRESSION PRESSURE ...25
FUEL INJECTION ...26
TESTING TIMING...26
ADJUSTING TIMING BY DELIVERY CHECK...27
BLOW-BY PRESSURE ...28
ALTERNATOR FAN BELT ...29
ENGINE FAN BELT ...29
EXHAUST GAS COLOR ...30
OIL PRESSURE ...32
OIL TEMPERATURE ...32
ACCELERATOR PEDAL ...33
OPERATING FORCE...33
ENGINE ...34
13 DISASSEMBLY AND ASSEMBLY...35
STARTING MOTOR ...37
REMOVAL...37
INSTALLATION...37
ALTERNATOR ...38
REMOVAL...38
INSTALLATION...38
OIL COOLER ...39
REMOVAL...39
INSTALLATION...39
FUEL INJECTION PUMP ...40
REMOVAL...40
INSTALLATION...40
WATER PUMP ...41
REMOVAL...41
INSTALLATION...41
NOZZLE HOLDER ...42
REMOVAL...42
INSTALLATION...42
TURBOCHARGER...43
REMOVAL...43
INSTALLATION...43
AIR COMPRESSOR ...44
REMOVAL...44
INSTALLATION...44
CYLINDER HEAD ...45
REMOVAL...45
INSTALLATION...50
RADIATOR ...56
REMOVAL...56
INSTALLATION...59
ENGINE...62
REMOVAL ...62
INSTALLATION...68
FUEL TANK ...75
REMOVAL...75
INSTALLATION...77
14 MAINTENANCE STANDARD ...79
ENGINE MOUNT ...80
20 POWER TRAIN ...81
21 STRUCTURE AND FUNCTION ...81
GENERAL ...83
HYDRAULIC CIRCUIT FOR POWER TRAIN ...86
HYDRAULIC DIAGRAM FOR POWER TRAIN ...87
DAMPER ...89
TORQUE CONVERTER AND TRANSMISSION PIPING ...91
RADIATOR AND OIL COOLER ...92
TORQUE CONVERTER AND PTO ...93
TORQUE CONVERTER OIL FILTER ...95
TRANSMISSION...96
TRANSMISSION foldout # 1...97
TRANSMISSION CONTROL VALVE...101
UPPER VALVE...102
LOWER VALVE...103
TRANSMISSION SOLENOID VALVE ...104
TRANSMISSION SOLENOID VALVE ...105
EMERGENCY MANUAL SPOOL ...107
FORWARD 1st ...108
PRIORITY VALVE ...110
MODULATING VALVE AND QUICK RETURN VALVE ...111
ACCUMULATOR VALVE ...114
PILOT REDUCING VALVE ...117
MAIN RELIEF VALVE ...119
REDUCING VALVE ...120
TORQUE CONVERTER RELIEF VALVE ...122
LUBRICATION BY-PASS VALVE ...124
TRANSMISSION PILOT OIL FILTER ...126
TRANSFER ...127
DRIVE SHAFT ...128
CENTER SUPPORT ...129
AXLES ...130
FRONT ...130
REAR ...131
DIFFERENTIAL ...132
FRONT ...132
REAR ...133
TORQUE PROPORTIONING DIFFERENTIAL...135
FINAL DRIVE ...136
AXLE MOUNT ...138
TIRE AND WHEEL ...140
22 TESTING AND ADJUSTING ...141
STANDARD VALUE TABLE ...143
TOOL LIST ...144
ENGINE STALL SPEED ...145
TORQUE CONVERTER STALL...145
HYDRAULIC STALL...146
FULL STALL...146
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE ...147
SHIFT LEVER ...149
EMERGENCY MANUAL SPOOL ...151
OPERATION...151
TIRE AND WHEEL ...153
TROUBLESHOOTING...154
PRECAUTIONS WHEN TROUBLESHOOTING ...155
METHOD OF READING TROUBLESHOOTING TABLES...157
PREVENTING RECURRENCE OF TROUBLE...159
JUDGEMENT ON POWER TRAIN...160
TROUBLESHOOTING TABLE...162
Machine does not move...162
Machine lacks power or speed...164
Excessive time lag when starting machine or shifting gear...166
Torque converter oil temperature too high...167
23 DISASSEMBLY AND ASSEMBLY ...169
DAMPER ...172
REMOVAL ...172
INSTALLATION ...176
DISASSEMBLY ...180
ASSEMBLY ...183
TORQUE CONVERTER CHARGING PUMP ...187
REMOVAL ...187
INSTALLATION ...187
TORQUE CONVERTER AND TRANSMISSION ...188
REMOVAL ...188
INSTALLATION ...196
TORQUE CONVERTER ASSEMBLY...206
DISASSEMBLY...206
PTO ASSEMBLY...208
Disassembly...208
ASSEMBLY...210
PTO ASSEMBLY...210
Assembly...210
TORQUE CONVERTER ASSEMBLY...212
ASSEMBLY...212
TRANSMISSION ASSEMBLY...215
DISASSEMBLY...215
ASSEMBLY...225
TRANSFER CASE ASSEMBLY...237
DISASSEMBLY...237
ASSEMBLY...242
TRANSMISSION CONTROL VALVE...248
REMOVAL...248
INSTALLATION...249
LOWER VALVE ASSEMBLY...250
DISASSEMBLY...251
ASSEMBLY...251
UPPER VALVE ASSEMBLY...252
DISASSEMBLY...253
ASSEMBLY...253
MAIN RELIEF VALVE ASSEMBLY...254
DISASSEMBLY...254
ASSEMBLY...254
CENTER SUPPORT...255
REMOVAL...255
INSTALLATION...256
DISASSEMBLY...257
ASSEMBLY...259
DRIVE SHAFT...261
DISASSEMBLY...261
ASSEMBLY...263
FRONT AXLE...265
REMOVAL...265
INSTALLATION...267
FRONT DIFFERENTIAL...269
REMOVAL...269
INSTALLATION...272
REAR AXLE...275
REMOVAL...275
INSTALLATION...279
REAR DIFFERENTIAL...283
REMOVAL...283
INSTALLATION...284
DIFFERENTIAL GEAR ASSEMBLY...286
DISASSEMBLY...286
FINE DISASSEMBLY OF PINION ASSEMBLY...288
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...289
ASSEMBLY...290
FINE ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...290
FINE ASSEMBLY OF PINION ASSEMBLY...291
ASSEMBLY OF DIFFERENTIAL ASSEMBLY...292
FINAL DRIVE...297
DISASSEMBLY...297
ASSEMBLY...300
24 MAINTENANCE STANDARD...305
TRANSMISSION MOUNT ...306
DAMPER ...307
TORQUE CONVERTER CHARGING PUMP ...308
TORQUE CONVERTER AND PTO ...309
TRANSMISSION ...310
TRANSMISSION CONTROL VALVE ...314
UPPER VALVE ...314
LOWER VALVE ...316
SOLENOID VALVE ...318
TRANSFER ...320
DIFFERENTIAL ...322
FINAL DRIVE ...326
DRIVE SHAFT ...327
CENTER SUPPORT ...328
AXLE MOUNT...330
40 STEERING SYSTEM...333
41 STRUCTURE AND FUNCTION...333
CENTER HINGE PIN ...334
STEERING PIPING ...335
STEERING CIRCUIT DIAGRAM ...336
STEERING COLUMN AND GEAR BOX ...337
STEERING LINKAGE ...338
STEERING CONTROL SYSTEM ...339
STEERING VALVE ...339
ROTOR SEAL ...341
STEERING RELIEF VALVE ...342
SAFETY VALVE (WITH SUCTION VALVE) ...343
OPERATION OF DEMAND SPOOL...345
OPERATION OF THE STEERING VALVE ...348
TWO-WAY RESTRICTOR VALVE ...351
42 TESTING AND ADJUSTING...353
STANDARD VALUE TABLE ...354
TOOL LIST ...354
STEERING WHEEL PLAY ...355
OPERATING FORCE OF STEERING WHEEL ...356
OPERATING TIME OF STEERING WHEEL ...357
STEERING OIL PRESSURE ...358
STEERING LINKAGE ...360
TROUBLESHOOTING TABLES...363
1. Steering wheel does not turn. ...364
2. Steering wheel is sluggish. ...365
3. Steering wheel moves unsteadily or is subject to large shock. ...366
4. Machine tends to turn naturally in one particular direction when traveling. ...366
5. Left and right turning radii are different. ...366
43 DISASSEMBLY AND ASSEMBLY...367
STEERING GEAR ...369
REMOVAL ...369
INSTALLATION...371
STEERING GEAR BOX ...372
DISASSEMBLY ...372
ASSEMBLY ...373
STEERING AND PPC PUMP ...376
REMOVAL ...376
INSTALLATION ...377
STEERING VALVE ...378
REMOVAL ...378
INSTALLATION ...380
DISASSEMBLY ...382
ASSEMBLY...383
STEERING CYLINDER...384
REMOVAL...384
INSTALLATION...386
DISASSEMBLY...388
ASSEMBLY...390
CENTER HINGE PIN ...393
REMOVAL ...393
INSTALLATION ...400
44 MAINTENANCE STANDARD...409
CENTER HINGE PIN...410
STEERING LINKAGE AND STEERING COLUMN ...412
STEERING GEAR BOX ...414
STEERING PUMP ...415
STEERING CYLINDER MOUNT ...416
STEERING VALVE ...418
50 BRAKE AND AIR SYSTEM...421
51 STRUCTURE AND FUNCTION...421
GENERAL ...422
AIR SYSTEM ...422
BRAKE CIRCUIT ...422
BRAKE AND AIR SCHEMATICS ...423
BRAKE AND AIR PIPING ...423
BRAKE AND AIR CIRCUIT DIAGRAM ...423
BRAKE AND AIR CIRCUIT SYSTEM ...423
AIR TANK ...424
WET TANK ...424
DRY TANK (UPPER) ...425
DRY TANK (LOWER) ...426
SAFETY VALVE ...427
BRAKE VALVE ...428
BRAKE ACTUATED ...429
OPERATING IN BALANCE ...430
BRAKE RELEASED ...431
AIR GOVERNOR ...432
TWO-WAY VALVE ...434
BRAKE CHAMBER...435
SLACK ADJUSTER ...437
CHECK VALVE ...440
BRAKE ...441
PARKING BRAKE ...443
PARKING BRAKE SOLENOID VALVE ...445
SPRING CYLINDER ...446
BRAKE CALIPER ...447
52 TESTING AND ADJUSTING...449
STANDARD VALUE TABLE ...451
TOOL LIST ...452
BRAKE PEDAL ...453
AIR PRESSURE ...454
BRAKE PERFORMANCE ...457
BRAKE OIL PRESSURE ...458
BRAKE DISC ...459
AIR BLEEDING FROM BRAKE LINE ...460
PARKING BRAKE ...461
PERFORMANCE...461
CHECKING AND ADJUSTING...462
TROUBLESHOOTING...465
TROUBLESHOOTING TABLE ...466
1. Air pressure does not rise at all. ...466
2. Air pressure does not rise to the specified range. ...467
3. Brake is ineffective or not very effective. ...468
4. Brake does not release, or drags. ...469
5. Parking brake does not release, or drags. (Applies to machine equipped with air park- ing brake.) ...470
53 DISASSEMBLY AND ASSEMBLY...471
BRAKE VALVE ...473
REMOVAL ...473
INSTALLATION...475
DISASSEMBLY...477
ASSEMBLY...479
BRAKE CHAMBER...481
REMOVAL ...481
INSTALLATION ...483
DISASSEMBLY ...482
ASSEMBLY...487
SLACK ADJUSTER ...490
REMOVAL ...490
INSTALLATION ...490
DISASSEMBLY ...491
ASSEMBLY ...492
BRAKE ASSEMBLY...493
REMOVAL ...493
INSTALLATION...495
DISASSEMBLY (FRONT OR REAR) ...499
ASSEMBLY (FRONT OR REAR) ...502
SPRING CYLINDER ...506
REMOVAL ...506
INSTALLATION...507
PARKING BRAKE ...508
REMOVAL ...508
INSTALLATION...511
PARKING BRAKE PAD ...514
REMOVAL ...514
INSTALLATION ...514
AIR GOVERNOR ...515
DISASSEMBLY ...515
ASSEMBLY ...516
54 MAINTENANCE STANDARD...517
BRAKE VALVE ...518
BRAKE CHAMBER ...520
SLACK ADJUSTER ...521
BRAKE ...522
PARKING BRAKE ...524
SPRING CYLINDER ...526
60 WORK EQUIPMENT SYSTEM...527
61 STRUCTURE AND FUNCTION...527
GENERAL ...529
HYDRAULIC PIPING ...530
HYDRAULIC CIRCUIT...530
SCHEMATICS...530
DIAGRAM ...530
HYDRAULIC TANK ...531
OIL FILTER By-pass VALVE ...532
BREATHER ...533
PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE) ...534
OPERATION OF PPC VALVE ...536
PPC RELIEF VALVE ...540
MAIN CONTROL VALVE ...541
RELIEF VALVE...544
SAFETY VALVE (with suction valve)...545
SUCTION VALVE ...546
FLOAT SELECTOR VALVE AND UNLOADER VALVE...547
ACCUMULATOR ...549
OPERATION OF MAIN CONTROL VALVE ...550
LIFT AND DUMP SPOOLS AT ?HOLD? ...550
LIFT SPOOL AT ?RAISE?...551
LIFT SPOOL AT ?LOWER? ...552
LIFT SPOOL AT ?FLOAT ...553
DUMP SPOOL AT ?DUMP?...554
DUMP SPOOL AT ?TILT BACK?...555
BUCKET LINKAGE ...556
BUCKET ...558
BUCKET POSITIONER AND BOOM KICK-OUT ...559
Bucket positioner...560
Boom kick-out...560
WORK EQUIPMENT LEVER LINKAGE ...561
62 TESTING AND ADJUSTING...563
STANDARD VALUE TABLE ...565
TOOL LIST ...566
EMERGENCY MANUAL SPOOL...567
METHOD FOR OPERATION...567
OUTLINE...567
OPERATION...567
DUMP AND LIFT CONTROL LEVER ...569
MEASURING ...569
ADJUSTING ...570
HYDRAULIC CIRCUIT FLUSHING...572
PPC RELIEF VALVE ...575
MEASURING PRESSURE...575
ADJUSTING...577
WORK EQUIPMENT ...578
RELIEF VALVE...578
MEASURING TIME...580
HYDRAULIC DRIFT ...581
BUCKET POSITIONER ...582
BOOM KICK-OUT ...583
TROUBLESHOOTING ...584
TROUBLESHOOTING TABLE ...584
1. Lift arm does not rise. ...584
2. Lift arm moves slowly or does not have sufficient lifting power. ...585
3. Lift arm movement becomes slow after it reaches a certain height. ...586
4. Bucket cannot be held down with lift arm cylinder...586
5. Lift arm has large hydraulic drift...586
6. Lift arm movement is unsteady during work...586
7. Lift arm descends momentarily when control lever is shifted from ?Hold? to ?Raise?...586
8. Bucket does not tilt back. ...587
9. Bucket moves slowly or has insufficient tilt back power. ...588
10. Bucket movement becomes slow during tilt back...589
11. Bucket cannot be held down by the bucket cylinder. ...589
12. Bucket has large hydraulic drift. ...589
13. Bucket moves unsteadily when machine travels 10. Bucket movement becomes slow during tilt back. under load. (Main control valve in ?Hold?). Checks before troubleshooting Checks before troubleshooting ...589
14. Bucket dumps momentarily when control lever is shifted from ?Hold? to ?Tilt back?. Check before troubleshooting ...589
15. Control levers of lift arm and dump move stiffly and sluggishly. ...590
63 DISASSEMBLY AND ASSEMBLY...591
HYDRAULIC TANK ...593
REMOVAL ...593
INSTALLATION ...595
HYDRAULIC FILTER ...597
REMOVAL ...597
INSTALLATION ...597
WORK EQUIPMENT PUMP ...598
REMOVAL ...598
INSTALLATION ...600
SWITCH PUMP...601
REMOVAL...601
INSTALLATION...603
PPC VALVE ASSEMBLY ...604
REMOVAL ...604
INSTALLATION...606
DISASSEMBLY...608
ASSEMBLY...608
PPC RELIEF VALVE ASSEMBLY...609
DISASSEMBLY...609
ASSEMBLY...609
MAIN CONTROL VALVE ...610
REMOVAL ...610
INSTALLATION ...613
DISASSEMBLY ...613
ASSEMBLY ...622
DUMP CYLINDER ...625
REMOVAL ...625
INSTALLATION...627
LIFT CYLINDER...629
REMOVAL ...629
INSTALLATION ...631
LIFT AND DUMP CYLINDERS ...633
DISASSEMBLY ...633
ASSEMBLY ...635
WORK EQUIPMENT ...638
REMOVAL ...638
INSTALLATION ...642
COUNTERWEIGHT ...646
REMOVAL ...646
INSTALLATION ...646
64 MAINTENANCE STANDARD ...647
HYDRAULIC AND SWITCH PUMP ...648
HYDRAULIC PUMP SAR(3)-100 ...648
SWITCH PUMP SAR(3)-100 ...648
PPC PUMP ...649
SAR(1)-014 ...649
PPC VALVE ...650
MAIN CONTROL VALVE ...652
HYDRAULIC CYLINDERS ...654
STEERING CYLINDER ...654
LIFT CYLINDER ...654
DUMP CYLINDER ...655
BUCKET LINKAGE ...656
BUCKET ...660
BUCKET POSITIONER AND BOOM KICK-OUT ...662
80 ELECTRIC AND ELECTRONIC SYSTEM...665
81 STRUCTURE AND FUNCTION ...665
ELECTRICAL WIRING DIAGRAM ...667
ENGINE STARTING CIRCUIT ...668
ENGINE STOP CIRCUIT ...670
PREHEATING CIRCUIT ...671
PREHEATING AND AFTER-HEATING WITH HEATER SWITCH ...671
PREHEATING WITH STARTING SWITCH...672
AUTOMATIC PREHEATING...674
COMBINATION SWITCH ...677
TRANSMISSION CUT-OFF SWITCH ...678
TRANSMISSION CUT-OFF SELECTOR SWITCH...679
NEUTRALIZER RELAY ...680
KICK-DOWN SWITCH ...681
KICK-DOWN ELECTRIC CIRCUIT ...682
ELECTRICAL PARKING BRAKE CONTROL ...688
PARKING BRAKE VALVE...690
PARKING SAFETY RELAY...690
NEUTRALIZER RELAY...690
EMERGENCY BRAKE SWITCH...690
CONDITIONS ...691
1. STARTING SWITCH OFF...691
2. STARTING SWITCH ON ...692
2-1. When parking brake switch is turned ON before starting switch is turned ON. ...692
2-2. Parking brake switch turned OFF (released) before starting switch is turned ON. Electric ...693
3. PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON...694
4. PARKING BRAKE SWITCH ON (operated)...695
5. WHEN AIR PRESSURE DROPS. (Emergency brake actuated) ...696
BUCKET POSITIONER AND BOOM KICK-OUT ...697
Bucket positioner...698
Boom kick-out...698
PROXIMITY SWITCH ...699
OPERATION ...699
Lift arm RAISE ...699
Kick-out ...701
BUCKET "TILT" ...702
Hold ...702
Tilt...703
Positioned ...704
ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE ...705
ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER ...706
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ...707
INDICATION ON MONITOR PANEL ...709
MONITOR WIRING HARNESS ...712
SENSORS ...713
ENGINE OIL LEVEL SENSOR ...713
BRAKE OIL LEVEL...714
COOLANT LEVEL...714
FUEL GAUGE...715
ENGINE OIL PRESSURE...716
PARKING BRAKE...717
AIR PRESSURE...718
TORQUE CONVERTER OILTEMPERATURE...719
COOLANT TEMPERATURE...719
ROTATIONAL SPEED...720
BRAKE LINE FAILURE...720
TRANSMISSION OIL FILTER CLOGGING SENSOR ...721
82 TESTING AND ADJUSTING ...723
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ...726
MACHINE MONITOR (SPEEDOMETER MODULE) ...729
TROUBLESHOOTING...731
CHECKS BEFORE TROUBLESHOOTING ...732
JUDGEMENT ON POWER TRAIN...733
METHOD OF READING TROUBLESHOOTING TABLE ...734
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ...734
PRECAUTION WHEN HANDLING CONNECTOR ...736
CONNECTOR TERMINAL NUMBERS ...738
ELECTRICAL WIRING DIAGRAM ...744
ELECTRICAL CONNECTOR (CN) DIAGRAM ...744
VEHICLE MONITOR SYSTEM DIAGRAM ...744
ELECTRICAL CIRCUIT SYSTEM ...745
ENGINE STARTING AND STOP CIRCUIT SYSTEM...745
PARKING BRAKE SYSTEM...746
KICK-DOWN CIRCUIT SYSTEM...747
PREHEATING CIRCUIT SYSTEM...748
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...749
POSITION OF CONNECTORS TROUBLESHOOTING ...751
TROUBLESHOOTING ...750
E-1 ENGINE DOES NOT START ...760
E-2 ENGINE DOES NOT STOP ...764
E-3 ENGINE STOPS WHEN TRAVELING...765
E-4 PARKING BRAKE DOES NOT WORK ...766
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING...768
E-6 PARKING BRAKE IS RELEASED WHEN STARTING ...770
E-7 SHIFT LEVER DOES NOT ENTER NEUTRAL...770
E-8 TRANSMISSION DOES NOT WORK NORMALLY...772
E-9 KICK-DOWN SWITCH DOES NOT WORK ...794
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON ...797
E-11 KICK-DOWN OPERATION IS NOT CANCELED...798
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2...800
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED...800
E-14 PREHEAT DISPLAY STAYS ON...802
E-15 PREHEAT DOSE NOT STOP...802
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM ...803
POSITION OF CONNECTORS FOR TROUBLESHOOTING ...804
TROUBLESHOOTING ...816
M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...816
M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...817
M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED...818
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING...818
M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING...820
M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING...821
M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING...821
M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING...823
M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING...823
M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING...825
M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING...825
M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING...825
M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP...827
M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP...829
M-15 (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP...831
M-16 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP...833
M-17 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP...835
M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON...840
M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...841
M-20 HOURMETER DISPLAY DOES NOT WORK NORMALLY...842
M-21 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PARTS WORKS...843
M-22 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT...844
M-23 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED...845
M-24 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP...847
M-25 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH THE C...852
M-26 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS...852
M-27 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. T...854
M-28 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP...855
M-29 ABNORMALITY IN THE FUEL GAUGE SYSTEM...856
M-30 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM...858
M-31 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM...860
M-32 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM...862
83 DISASSEMBLY AND ASSEMBLY ...865
MACHINE MONITOR ...866
REMOVAL ...866
INSTALLATION ...867
90 OTHERS...869
91 STRUCTURE AND FUNCTION ...869
GENERAL ...871
BASIC INFORMATION ON AIR CONDITIONERS ...871
UNITS RELATED TO REFRIGERATION ...871
Heat ...871
Temperature...871
Pressure...872
Humidity ...873
PRINCIPLE OF COOLING...874
Why do coolers cool?...874
Refrigerator using evaporation latent heat...874
Refrigeration method (Vapor compression)...874
Refrigerating cycle ...875
Heating cycle...877
REFRIGERANTS ...878
SAFETY PRECAUTIONS ...878
REFRIGERATOR OIL (LUBE OIL)...879
SPECIFICATIONS...880
PIPING DIAGRAM ...881
ELECTRIC WIRING DIAGRAM ...882
COMPRESSOR (CRANK TYPE) ...883
MAGNETIC CLUTCH ...886
CONDENSER ...887
RECEIVER W/SIGHT GLASS ...889
AIR CONDITIONER UNIT ...891
EXPANSION VALVE ...892
EVAPORATOR ...894
THERMOSTAT ...894
PRESSURE SWITCH ...895
HEATER ...897
BLOWER UNIT ...897
PIPING ...898
AIR CONTROL SYSTEM ...899
CONTROL PANEL ...900
BLOWER SWITCH...900
AIR CONDITIONER SWITCH...900
TEMPERATURE CONTROL LEVER...900
AIR SOURCE SELECTOR LEVER...900
92 TESTING AND ADJUSTING...901
SERVICE TOOLS ...903
GAUGE MANIFOLD ...903
GAS LEAK DETECTOR ...906
HALIDE TORCH LEAK DETECTOR...906
ELECTRIC LEAK TESTER...908
VALVE FOR SERVICE CANS ...909
MAINTENANCE PROCEDURE ...910
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING ...910
PROHIBITED WORK...910
OTHER PRECAUTIONS...910
BLEEDING AIR FROM REFRIGERATION CIRCUIT ...912
PURPOSE...912
CONNECTING GAUGE MANIFOLD...912
EVACUATION...913
AIR-TIGHTNESS CHECK...913
GAS-LEAK CHECK...913
EVACUATION (REPEATING)...914
CHARGINGTHE REFRIGERATION CIRCUIT WITH REFRIGERANT ...915
CHARGING FROM THE HIGH-PRESSURE SIDE...915
CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHING THE REFRIGERATION CIRCUIT)...916
WHEN THE AMBIENT TEMPERATURE IS LOW...917
WHEN THE AMBIENT TEMPERATURE IS HIGH...917
REPLACING SERVICE CANS ...918
CHECKING THE AMOUNT OF REFRIGERANT ...918
REMOVAL OF GAUGE MANIFOLD ...920
DISCHARGING THE REFRIGERANT ...920
DAILY CHECKS ...921
CHECK REFRIGERANT LEVEL...921
CLEANING THE CONDENSER...921
CHECKING THE V-BELT...921
CHECKING OIL LEVEL ...922
PROCEDURE FOR CHECKING...922
PROCEDURE FOR CHECKING OIL LEVEL...922
ADDING AND REMOVING OIL...923
ADDING OIL BY EVACUATION...923
TROUBLESHOOTING...924
VISUAL AND ACOUSTICAL CHECKS ...924
DEFECTIVE COOLING ...925
TROUBLESHOOTING TABLES ...926
DEFECTIVE HEATING ...928
TROUBLESHOOTING USING GAUGE MANIFOLD ...929
PREPARATIONS BEFORE MEASURING...929
INSUFFICIENT REFRIGERANT...929
EXCESSIVE REFRIGERANT OR INSUFFICIENT 3. COOLING OF CONDENSER ...930
AIR INSIDE REFRIGERATION SYSTEM ...930
MOISTURE IN REFRIGERATING SYSTEM ...931
REFRIGERANT DOES NOT CIRCULATE ...932
FAILURE OF EXPANSION VALVE ...933
DEFECTIVE MOUNTING OF HEAT SENSING TUBE...933
DEFECTIVE COMPRESSION BY COMPRESSOR ...933
93 DISASSEMBLY AND ASSEMBLY ...935
SPECIAL TOOLS ...936
MAGNETIC CLUTCH ...937
DISASSEMBLY OF ...937
CHECKS BEFORE DISASSEMBLY...938
REMOVAL OF ROTOR AND STATOR...938
REMOVAL OF CENTER PIECE FROM ROTOR...939
REMOVAL OF BEARING FROM ROTOR...940
ASSEMBLY OF ...941
ASSEMBLY OF BEARING TO ROTOR...941
ASSEMBLY OF CENTER PIECE TO ROTOR...941
ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR...942
AIR CONDITIONER UNIT ...943
DISASSEMBLY OF ...943
CHECKS BEFORE DISASSEMBLY...943
REMOVAL OF CONTROL PANEL AND THERMOSTAT...947
REMOVAL OF UNIT COVER...949
REMOVAL OF WATER VALVE...949
REMOVAL OF EXPANSION VALVE...951
REMOVAL OF EVAPORATOR...953
REMOVAL OF HEATER CORE ...953
REMOVAL OF PRESSURE SWITCHES ...953
BLOWER UNIT ...954
DISASSEMBLY OF ...954
CHECKS BEFORE DISASSEMBLY...954
REMOVAL OF BLOWER RESISTOR...954
REMOVAL OF BLOWER MOTOR AND FAN...955
CONDENSER ...956
DISASSEMBLY OF ...956
CHECKS BEFORE DISASSEMBLY...956
REMOVAL OF CONDENSER, FAN MOTOR...957
REMOVAL OF PRESSURE SWITCH...958
REMOVAL OF RESISTOR ...958
97 GEAR PUMP...959
GENERAL...960
PRINCIPLE OF OPERATION ...961
PRESSURE LOADED TYPE GEAR PUMP ...964
FIXED SIDE PLATE TYPE GEAR PUMP...966
SA SERIES ...967
STRUCTURE ...967
TESTING AND ADJUSTING ...971
DISASSEMBLY ...974
ASSEMBLY ...978
MAINTENANCE STANDARD ...983
99 METRIC CONVERSIONS ...985
