Komatsu Wheel Loader WA500LC Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA500-1LC, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA500-1LC 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: 1,151 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAMW25050 - Wheel Loader WA500-1LC Operation & Maintenance Manual.pdf
CEBMW25050 - Wheel Loader WA500-1LC Shop Manual.pdf
MAIN SECTIONS
MAIN MENU...0
CONTENTS...5
10 ENGINE...19
12 TESTING AND ADJUSTING...19
STANDARD VALUE TABLE...20
FOR ENGINE ON TEST BENCH...20
FOR ENGINE ON CHASSIS...21
TOOL LIST FOR ENGINE...22
MEASURING ENGINE STALL SPEED...23
Measuring torque converter stall...23
Measuring hydraulic stall...24
Measuring full stall...24
VALVE CLEARANCE...25
VALVE AND FIXED INJECTORS...26
BLOW-BY PRESSURE...27
ALTERNATOR FAN BELT...28
EXHAUST GAS COLOR...29
OIL PRESSURE...31
OIL TEMPERATURE...32
ACCELERATOR PEDAL...33
OPERATING ANGLE...33
OPERATING FORCE...34
13 DISASSEMBLY AND ASSEMBLY...35
STARTING MOTOR ASSEMBLY...37
REMOVAL...37
INSTALLATION...37
ALTERNATOR ASSEMBLY...38
REMOVAL...38
INSTALLATION...38
OIL COOLER ASSEMBLY...39
REMOVAL...39
INSTALLATION...39
FUEL PUMP ASSEMBLY...40
REMOVAL...40
INSTALLATION...40
WATER PUMP ASSEMBLY...41
REMOVAL...41
INSTALLATION...41
INJECTOR ASSEMBLY...42
REMOVAL...42
INSTALLATION...42
TURBOCHARGER ASSEMBLY...43
REMOVAL...43
INSTALLATION...43
AFTERCOOLER ASSEMBLY...44
REMOVAL...44
INSTALLATION...45
AIR COMPRESSOR ASSEMBLY...46
REMOVAL...46
INSTALLATION...47
CYLINDER HEAD ASSEMBLY...48
REMOVAL...48
INSTALLATION...50
RADIATOR ASSEMBLY...53
REMOVAL...53
INSTALLATION...56
ENGINE...59
REMOVAL...59
INSTALLATION...65
DAMPER ASSEMBLY...72
REMOVAL...72
INSTALLATION...76
DISASSEMBLY OF...80
ASSEMBLY OF...83
FUEL TANK ASSEMBLY...87
REMOVAL...87
INSTALLATION...87
14 MAINTENANCE STANDARD...91
ENGINE MOUNT...92
20 POWER TRAIN...93
21 STRUCTURE AND FUNCTION...93
GENERAL...95
HYDRAULIC CIRCUIT FOR POWER TRAIN...97
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...98
DAMPER...99
TORQUE CONVERTER AND TRANSMISSION PIPING...101
RADIATOR AND OIL COOLER...102
TORQUE CONVERTER AND PTO...103
TORQUE CONVERTER OIL FILTER...105
TRANSMISSION...106
TRANSMISSION foldout #7...107
TRANSMISSION CONTROL VALVE...111
UPPER VALVE...112
LOWER VALVE...113
TRANSMISSION SOLENOID VALVE...114
TRANSMISSION SOLENOID VALVE...115
EMERGENCY MANUAL SPOOL...116
FORWARD 1st...117
PRIORITY VALVE...119
MODULATING VALVE AND QUICK RETURN VALVE...120
ACCUMULATOR VALVE...123
PILOT REDUCING VALVE...125
MAIN RELIEF VALVE...126
REDUCING VALVE...127
TORQUE CONVERTER RELIEF VALVE...128
LUBRICATION BY-PASS VALVE...129
TRANSMISSION PILOT OIL FILTER...130
TRANSFER...131
DRIVE SHAFT...132
CENTER SUPPORT...133
AXLES...134
FRONT...134
REAR...135
DIFFERENTIAL...136
FRONT...136
REAR...137
TORQUE PROPORTIONING DIFFERENTIAL...139
FINAL DRIVE...140
AXLE MOUNT...142
TIRE AND WHEEL...144
22 TESTING AND ADJUSTING...145
STANDARD VALUE TABLE...146
TOOL LIST FOR TESTING AND ADJUSTING...147
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...148
MEASURING SHIFT LEVER...150
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...152
TIRE AND WHEEL...154
TROUBLESHOOTING...155
PRECAUTIONS WHEN TROUBLESHOOTING...156
METHOD OF READING TROUBLESHOOTING TABLES...158
PREVENTING RECURRENCE OF TROUBLE...160
JUDGEMENT ON POWER TRAIN...161
TROUBLESHOOTING TABLE...163
Machine does not move...163
Machine lacks power or speed...165
Excessive time lag when starting machine or shifting gear...166
Torque converter oil temperature too high...167
23 DISASSEMBLY AND ASSEMBLY...169
TORQUE CONVERTER CHARGING AND PPC PUMP...171
REMOVAL...171
INSTALLATION...171
TORQUE CONVERTER AND TRANSMISSION...172
REMOVAL...172
INSTALLATION...180
TORQUE CONVERTER ASSEMBLY...190
DISASSEMBLY OF...190
PTO ASSEMBLY...192
Disassembly of...192
ASSEMBLY OF...194
PTO ASSEMBLY...194
Assembly of...194
TRANSMISSION ASSEMBLY...199
DISASSEMBLY OF...199
ASSEMBLY OF...209
TRANSFER CASE ASSEMBLY...221
DISASSEMBLY OF...221
ASSEMBLY OF...226
TRANSMISSION CONTROL VALVE...232
REMOVAL OF...232
INSTALLATION OF...233
LOWER VALVE ASSEMBLY...234
DISASSEMBLY OF...235
ASSEMBLY OF...235
UPPER VALVE ASSEMBLY...236
DISASSEMBLY OF...237
ASSEMBLY OF...237
MAIN RELIEF VALVE ASSEMBLY...238
DISASSEMBLY OF...238
ASSEMBLY OF...238
CENTER SUPPORT...239
REMOVAL OF...239
INSTALLATION OF...240
DISASSEMBLY OF...241
ASSEMBLY OF...243
DRIVE SHAFT...245
DISASSEMBLY OF...245
ASSEMBLY OF...247
FRONT AXLE...249
REMOVAL OF...249
INSTALLATION OF...251
FRONT DIFFERENTIAL...253
REMOVAL OF...253
INSTALLATION OF...256
REAR AXLE...259
REMOVAL OF...259
INSTALLATION OF...263
REAR DIFFERENTIAL...267
REMOVAL OF...267
INSTALLATION OF...268
DIFFERENTIAL GEAR ASSEMBLY...270
DISASSEMBLY OF...270
FINE DISASSEMBLY OF PINION ASSEMBLY...272
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY...273
ASSEMBLY OF...274
FINE ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...274
FINE ASSEMBLY OF PINION ASSEMBLY...275
ASSEMBLY OF DIFFERENTIAL ASSEMBLY...276
FINAL DRIVE...281
DISASSEMBLY OF...281
ASSEMBLY OF...284
24 MAINTENANCE STANDARD...289
TRANSMISSION MOUNT...290
TORQUE CONVERTER CHARGING PUMP...291
DAMPER...292
TORQUE CONVERTER AND PTO...294
TRANSMISSION...296
TRANSMISSION CONTROL VALVE...300
UPPER VALVE...300
LOWER VALVE...302
SOLENOID VALVE...304
TRANSFER...306
DIFFERENTIAL...308
FINAL DRIVE...312
DRIVE SHAFT...313
CENTER SUPPORT...314
AXLE MOUNT...316
40 STEERING SYSTEM...319
41 STRUCTURE AND FUNCTION...319
CENTER HINGE PIN...320
STEERING PIPING...321
STEERING CIRCUIT DIAGRAM...322
STEERING COLUMN AND GEAR BOX...323
STEERING LINKAGE...324
STEERING CONTROL SYSTEM...325
STEERING VALVE...325
ROTOR SEAL...327
STEERING RELIEF VALVE...328
SAFETY VALVE (WITH SUCTION VALVE)...329
OPERATION OF DEMAND SPOOL...331
OPERATION OF THE STEERING VALVE...334
TWO-WAY RESTRICTOR VALVE...337
42 TESTING AND ADJUSTING...339
STANDARD VALUE TABLE...340
TOOL LIST FOR TESTING AND ADJUSTMENT...340
MEASURING STEERING WHEEL PLAY...341
MEASURING OPERATING FORCE OF STEERING WHEEL...342
OPERATING TIME OF STEERING WHEEL...343
STEERING OIL PRESSURE...344
STEERING LINKAGE...346
TROUBLESHOOTING TABLE...350
1. Steering wheel does not turn...350
2. Steering wheel is sluggish...351
3. Steering wheel moves unsteadily or is subject to large shock...352
4. Machine tends to turn naturally in one particular direction when traveling...352
5. Left and right turning radii are different...352
43 DISASSEMBLY AND ASSEMBLY...353
STEERING GEAR...355
REMOVAL OF...355
INSTALLATION OF...357
STEERING GEAR BOX...358
DISASSEMBLY OF...358
ASSEMBLY OF...359
STEERING AND PPC PUMP...362
REMOVAL OF...362
INSTALLATION OF...363
STEERING VALVE...364
REMOVAL OF...364
INSTALLATION OF...366
DISASSEMBLY OF...368
ASSEMBLY OF...369
STEERING CYLINDER...370
REMOVAL OF...370
INSTALLATION OF...372
DISASSEMBLY OF...374
ASSEMBLY OF...376
CENTER HINGE PIN...379
REMOVAL OF...379
INSTALLATION OF...386
44 MAINTENANCE STANDARD...395
CENTER HINGE PIN...396
STEERING LINKAGE AND STEERING COLUMN...398
STEERING GEAR BOX...400
STEERING PUMP...401
STEERING CYLINDER MOUNT...402
50 BRAKE AND AIR SYSTEM...403
51 STRUCTURE AND FUNCTION...403
GENERAL...404
AIR SYSTEM...404
BRAKE CIRCUIT...404
BRAKE AND AIR PIPING...405
BRAKE AND AIR CIRCUIT SYSTEM...406
AIR TANK...407
WET TANK...407
DRY TANK (UPPER)...407
DRY TANK (LOWER)...408
SAFETY VALVE...409
BRAKE VALVE...410
BRAKE ACTUATED...411
OPERATING IN BALANCE...412
BRAKE RELEASED...413
AIR GOVERNOR...414
TWO-WAY VALVE...416
BRAKE CHAMBER...417
SLACK ADJUSTER...419
CHECK VALVE...422
BRAKE...423
PARKING BRAKE...425
PARKING BRAKE SOLENOID VALVE...427
SPRING CYLINDER...428
BRAKE CALIPER...429
52 TESTING AND ADJUSTING...431
STANDARD VALUE TABLE...433
TOOL LIST...434
MEASURING BRAKE PEDAL...435
MEASURING AIR PRESSURE...436
BRAKE PERFORMANCE...439
CHECKING BRAKE OIL PRESSURE...440
MEASURING WEAR OF BRAKE DISC...441
AIR BLEEDING FROM BRAKE LINE...442
PARKING BRAKE PERFORMANCE...443
CHECKING AND ADJUSTING PARKING BRAKE...444
TROUBLESHOOTING...447
TROUBLESHOOTING TABLE...448
1. Air pressure does not rise at all...448
2. Air pressure does not rise to the specified range...449
3. Brake is ineffective or not very effective...450
4. Brake does not release, or drags...451
5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)...452
53 DISASSEMBLY AND ASSEMBLY...453
BRAKE VALVE...455
REMOVAL OF...455
INSTALLATION OF...457
DISASSEMBLY OF...459
ASSEMBLY OF...461
BRAKE CHAMBER...463
REMOVAL OF...463
INSTALLATION OF...465
DISASSEMBLY OF...466
ASSEMBLY OF...469
SLACK ADJUSTER...472
REMOVAL OF...472
INSTALLATION OF...472
DISASSEMBLY OF...473
ASSEMBLY OF...474
BRAKE ASSEMBLY...475
REMOVAL OF...475
INSTALLATION OF...477
DISASSEMBLY OF (FRONT OR REAR)...481
ASSEMBLY OF (FRONT OR REAR)...484
SPRING CYLINDER...488
REMOVAL OF...488
INSTALLATION OF...489
PARKING BRAKE...490
REMOVAL OF...490
INSTALLATION OF...493
PARKING BRAKE PAD...496
REMOVAL OF...496
INSTALLATION OF...496
54 MAINTENANCE STANDARD...497
BRAKE VALVE...498
BRAKE CHAMBER...500
SLACK ADJUSTER...501
BRAKE...502
PARKING BRAKE...504
SPRING CYLINDER...506
60 WORK EQUIPMENT SYSTEM...507
61 STRUCTURE AND FUNCTION...507
GENERAL...509
HYDRAULIC PIPING...510
HYDRAULIC CIRCUIT...510
SCHEMATICS...510
DIAGRAM...510
HYDRAULIC TANK...511
OIL FILTER BY-PASS VALVE...512
BREATHER...513
PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE)...514
OPERATION OF PPC VALVE...516
PPC RELIEF VALVE...520
MAIN CONTROL VALVE...521
RELIEF VALVE...524
SAFETY VALVE (with suction valve)...525
SUCTION VALVE...526
FLOAT SELECTOR VALVE AND UNLOADER VALVE...527
ACCUMULATOR...529
OPERATION OF MAIN CONTROL VALVE...530
LIFT AND DUMP SPOOLS AT "HOLD"...530
LIFT SPOOL AT "RAISE"...531
LIFT SPOOL AT "LOWER"...532
LIFT SPOOL AT "FLOAT"...533
DUMP SPOOL AT "DUMP"...534
DUMP SPOOL AT "TILT BACK"...535
BUCKET LINKAGE...536
BUCKET...538
BUCKET POSITIONER AND BOOM KICK-OUT...539
Bucket positioner...540
Boom kick-out...540
WORK EQUIPMENT LEVER LINKAGE...541
62 TESTING AND ADJUSTING...543
STANDARD VALUE TABLE...545
TOOL LIST...546
EMERGENCY MANUAL SPOOL METHOD FOR OPERATION...547
OUTLINE...547
OPERATION...547
DUMP AND LIFT CONTROL LEVERS...549
MEASURING...549
ADJUSTING...550
HYDRAULIC CIRCUIT FLUSHING...552
PPC RELIEF VALVE...555
MEASURING PRESSURE...555
ADJUSTING...557
WORK EQUIPMENT RELIEF VALVE...558
MEASURING TIME...560
HYDRAULIC DRIFT...561
BUCKET POSITIONER...562
BOOM KICK-OUT...563
TROUBLESHOOTING...564
TROUBLESHOOTING TABLE...564
1. Lift arm does not rise...564
2. Lift arm moves slowly or does not have sufficient lifting power...565
3. Lift arm movement becomes slow after it reaches a certain height...566
4. Bucket cannot be held down with lift arm cylinder...566
5. Lift arm has large hydraulic drift...566
6. Lift arm movement is unsteady during work...566
7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"...566
8. Bucket does not tilt back...567
9. Bucket moves slowly or has insufficient tilt back power...568
10. Bucket movement becomes slow during tilt back...569
11. Bucket cannot be held down by the bucket cylinder...569
12. Bucket has large hydraulic drift...569
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")...569
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"...569
15. Control levers of lift arm and dump move stiffly and sluggishly...570
63 DISASSEMBLY AND ASSEMBLY...571
HYDRAULIC TANK...573
REMOVAL...573
INSTALLATION...575
HYDRAULIC FILTER...577
REMOVAL...577
INSTALLATION...577
WORK EQUIPMENT PUMP...578
REMOVAL...578
INSTALLATION...580
SWITCH PUMP...581
REMOVAL...581
INSTALLATION...583
PPC VALVE ASSEMBLY...584
REMOVAL...584
INSTALLATION...586
DISASSEMBLY...588
ASSEMBLY...588
PPC RELIEF VALVE ASSEMBLY...589
DISASSEMBLY...589
ASSEMBLY...589
MAIN CONTROL VALVE...590
REMOVAL...590
INSTALLATION...593
DISASSEMBLY...598
ASSEMBLY...602
DUMP CYLINDER...605
REMOVAL...605
INSTALLATION...607
LIFT CYLINDER...609
INSTALLATION...611
LIFT AND DUMP CYLINDERS...613
DISASSEMBLY...613
ASSEMBLY...615
WORK EQUIPMENT...618
REMOVAL...618
INSTALLATION...622
COUNTERWEIGHT...626
REMOVAL...626
INSTALLATION...626
64 MAINTENANCE STANDARD...627
BUCKET LINKAGE...628
BUCKET POSITIONER AND BOOM KICK-OUT...630
BUCKET...631
80 ELECTRIC AND ELECTRONIC SYSTEM...633
81 STRUCTURE AND FUNCTION...633
ELECTRICAL WIRING DIAGRAM...635
ENGINE STARTING CIRCUIT...639
ENGINE STOP CIRCUIT...641
ELECTRICAL TRANSMISSION CONTROL...642
COMBINATION SWITCH...643
TRANSMISSION CUT-OFF SWITCH...644
TRANSMISSION CUT-OFF SELECTOR SWITCH...645
NEUTRALIZER RELAY...646
KICK-DOWN SWITCH...647
KICK-DOWN ELECTRIC CIRCUIT...648
ELECTRICAL PARKING BRAKE CONTROL...654
PARKING BRAKE VALVE...656
PARKING SAFETY RELAY...656
NEUTRALIZER RELAY...656
EMERGENCY BRAKE SWITCH...656
CONDITIONS...657
1. STARTING SWITCH OFF...657
2. STARTING SWITCH ON...658
2-1. When parking brake switch is turned ON before starting switch is turned ON...658
2-2. Parking brake switch turned OFF (released) before starting switch is turned ON...659
3. PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON...660
4. PARKING BRAKE SWITCH ON (operated)...661
5. WHEN AIR PRESSURE DROPS...662
BUCKET POSITIONER AND BOOM KICK-OUT...663
Bucket positioner...664
Boom kick-out...664
PROXIMITY SWITCH...665
OPERATION...665
Lift arm RAISE...665
Kick-out...667
BUCKET "TILT"...668
Hold...668
Tilt...669
Positioned...670
AIR GAUGE CIRCUIT DIAGRAM...671
ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS)...672
INDICATION ON MONITOR PANEL...674
MONITOR WIRING HARNESS...677
SENSORS...678
ENGINE OIL LEVEL...678
BRAKE OIL LEVEL...679
COOLANT LEVEL...679
FUEL GAUGE...680
ENGINE OIL PRESSURE...681
PARKING BRAKE...682
AIR PRESSURE...683
TORQUE CONVERTER OILTEMPERATURE...684
COOLANT TEMPERATURE...684
ROTATIONAL SPEED...685
BRAKE LINE FAILURE...685
TRANSMISSION OIL FILTER CLOGGING...686
82 TESTING AND ADJUSTING...688
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...691
MACHINE MONITOR (SPEEDOMETER MODULE)...694
TROUBLESHOOTING...696
CHECKS BEFORE TROUBLESHOOTING...697
JUDGMENT ON POWER TRAIN...698
METHOD OF READING TROUBLESHOOTING TABLE...699
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...699
PRECAUTION WHEN HANDLING CONNECTOR...701
CONNECTOR TERMINAL NUMBERS...703
ELECTRICAL WIRING DIAGRAM...709
ELECTRICAL CONNECTOR (CN) DIAGRAM...709
VEHICLE MONITOR SYSTEM DIAGRAM...709
ELECTRICAL CIRCUIT SYSTEM...710
ENGINE STARTING AND STOP CIRCUIT SYSTEM...710
PARKING BRAKE SYSTEM...711
KICK-DOWN CIRCUIT SYSTEM...712
ETHER INJECTION CIRCUIT SYSTEM...713
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...714
POSITION OF CONNECTORS FOR TROUBLESHOOTING...715
E-1 ENGINE DOES NOT START...723
E-2 ENGINE DOES NOT STOP...725
E-3 ENGINE STOPS WHEN TRAVELING...726
E-4 PARKING BRAKE DOES NOT WORK...727
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING...729
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...731
E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL, (PARKING BRAKE IS WORKING NORMALLY.)...731
E-8 TRANSMISSION DOES NOT WORK NORMALLY...733
E-9 KICK-DOWN SWITCH DOES NOT WORK...755
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)...758
E-11 KICK-DOWN OPERATION IS NOT CANCELED...759
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2...761
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED...761
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM...764
POSITION OF CONNECTORS FOR TROUBLESHOOTING...765
M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...776
M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...777
M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED...778
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING...778
M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING...780
M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING...781
M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING...781
M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING...783
M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING...783
M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING...785
M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING...785
M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING...785
M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP...787
M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP...789
M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP...791
M-16 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT...793
M-17 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON...798
M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...799
M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY...800
M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS...801
M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT...802
M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED...803
M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP...805
M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH ...811
M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS...811
M-26 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC...813
M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP...814
M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM...815
M-29 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM...817
M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM...819
M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM...821
83 DISASSEMBLY AND ASSEMBLY...824
MACHINE MONITOR...825
REMOVAL...825
INSTALLATION...826
90 OTHERS...828
91 AIR CONDITIONER STRUCTURE AND FUNCTION...828
GENERAL...830
BASIC INFORMATION ON AIR CONDITIONERS...830
UNITS RELATED TO REFRIGERATION...830
Heat...830
Temperature...830
Pressure...831
Humidity...832
PRINCIPLE OF COOLING...833
Why do coolers cool?...833
Refrigerator using evaporation latent heat...833
Refrigeration method (Vapor compression)...833
Refrigerating cycle...834
Heating cycle...836
REFRIGERANTS...837
SAFETY PRECAUTIONS...837
REFRIGERATOR OIL (LUBE OIL)...838
SPECIFICATIONS...839
PIPING DIAGRAM...840
ELECTRIC WIRING DIAGRAM...841
COMPRESSOR (CRANK TYPE)...842
MAGNETIC CLUTCH...845
CONDENSER...846
RECEIVER W/SIGHT GLASS...848
AIR CONDITIONER UNIT...850
EXPANSION VALVE...851
EVAPORATOR...853
THERMOSTAT...853
PRESSURE SWITCH...854
HEATER...856
BLOWER UNIT...856
PIPING...857
AIR CONTROL SYSTEM...858
CONTROL PANEL...859
BLOWER SWITCH...859
AIR CONDITIONER SWITCH...859
TEMPERATURE CONTROL LEVER...859
AIR SOURCE SELECTOR LEVER...859
92 AIR CONDITIONER TESTING AND ADJUSTING...860
SERVICE TOOLS...862
GAUGE MANIFOLD...862
GAS LEAK DETECTOR...865
HALIDE TORCH LEAK DETECTOR...865
ELECTRIC LEAK TESTER...867
VALVE FOR SERVICE CANS...868
MAINTENANCE PROCEDURE...869
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...869
PROHIBITED WORK...869
OTHER PRECAUTIONS...869
BLEEDING AIR FROM REFRIGERATION CIRCUIT...871
PURPOSE...871
CONNECTING GAUGE MANIFOLD...871
EVACUATION...872
AIR-TIGHTNESS CHECK...872
GAS-LEAK CHECK...872
EVACUATION (REPEATING)...873
CHARGINGTHE REFRIGERATION CIRCUIT WITH REFRIGERANT...874
CHARGING FROM THE HIGH-PRESSURE SIDE...874
CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHINGTHEREFRIGERATIONCIRCUIT)...875
WHEN THE AMBIENT TEMPERATURE IS LOW...876
WHEN THE AMBIENT TEMPERATURE IS HIGH...876
REPLACING SERVICE CANS...877
CHECKING THE AMOUNT OF REFRIGERANT...877
REMOVAL OF GAUGE MANIFOLD...879
DISCHARGING THE REFRIGERANT...879
DAILY CHECKS...880
CHECK REFRIGERANT LEVEL...880
CLEANING THE CONDENSER...880
CHECKING THE V-BELT...880
CHECKING OIL LEVEL...881
PROCEDURE FOR CHECKING...881
PROCEDURE FOR CHECKING OIL LEVEL...881
ADDING AND REMOVING OIL...882
ADDING OIL BY EVACUATION...882
TROUBLESHOOTING...883
VISUAL AND ACOUSTICAL CHECKS...883
DEFECTIVE COOLING...884
TROUBLESHOOTING TABLES...885
DEFECTIVE HEATING...887
TROUBLESHOOTING USING GAUGE MANIFOLD...888
PREPARATIONS BEFORE MEASURING...888
INSUFFICIENT REFRIGERANT...888
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER...889
AIR INSIDE REFRIGERATION SYSTEM...889
MOISTURE IN REFRIGERATING SYSTEM...890
REFRIGERANT DOES NOT CIRCULATE...891
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...892
DEFECTIVE MOUNTING OF HEAT SENSING TUBE...892
DEFECTIVE COMPRESSION BY COMPRESSOR...892
93 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY...894
SPECIAL TOOLS...895
MAGNETIC CLUTCH...896
DISASSEMBLY OF...896
CHECKS BEFORE DISASSEMBLY...897
REMOVAL OF ROTOR AND STATOR...897
REMOVAL OF CENTER PIECE FROM ROTOR...898
REMOVAL OF BEARING FROM ROTOR...899
ASSEMBLY OF...900
ASSEMBLY OF BEARING TO ROTOR...900
ASSEMBLY OF CENTER PIECE TO ROTOR...900
ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR...901
AIR CONDITIONER UNIT...902
DISASSEMBLY OF...902
CHECKS BEFORE DISASSEMBLY...902
REMOVAL OF CONTROL PANEL AND THERMOSTAT...906
REMOVAL OF UNIT COVER...908
REMOVAL OF WATER VALVE...908
REMOVAL OF EXPANSION VALVE...910
REMOVAL OF EVAPORATOR...912
REMOVAL OF HEATER CORE...912
REMOVAL OF PRESSURE SWITCHES...912
BLOWER UNIT...913
DISASSEMBLY OF...913
CHECKS BEFORE DISASSEMBLY...913
REMOVAL OF BLOWER RESISTOR...913
REMOVAL OF BLOWER MOTOR AND FAN...914
CONDENSER...915
DISASSEMBLY OF...915
CHECKS BEFORE DISASSEMBLY...915
REMOVAL OF CONDENSER, FAN MOTOR...916
REMOVAL OF PRESSURE SWITCH...917
REMOVAL OF RESISTOR...917
97 GEAR PUMP SA SERIES...918
GENERAL...919
PRINCIPLE OF OPERATION...920
PRESSURE LOADED TYPE GEAR PUMP...923
FIXED SIDE PLATE TYPE GEAR PUMP...925
SA SERIES...926
STRUCTURE...926
TESTING AND ADJUSTING...930
DISASSEMBLY...933
ASSEMBLY...937
MAINTENANCE STANDARD...942
99 METRIC CONVERSIONS...944
METRIC CONVERSIONS...945
MAIN MENU...0
FORWARD...5
SAFETY INFORMATION...6
INTRODUCTION...7
BREAKING IN THE NEW MACHINE ...7
MACHINE AND ENGINE SERIAL NUMBERS ...8
QUICK REFERENCE INFORMATION ...9
CONTENTS...10
SAFETY PRECAUTIONS -- SECTION 1...17
GENERAL PRECAUTIONS ...18
PERSONNEL PRECAUTIONS ...18
MACHINE PRECAUTIONS ...18
OPERATION ...19
BEFORE STARTING ...19
START-UP ...20
GENERAL OPERATING PRECAUTIONS ...20
DRIVING THE MACHINE ...21
OPERATING THE ATTACHMENTS ...22
PULLING/TOWING ...22
SHUTDOWN ...23
MAINTENANCE ...23
GENERAL MACHINE PRECAUTIONS ...23
GENERAL WORK PRECAUTIONS ...24
ACCUMULATORS ...25
ATTACHMENTS ...26
BRAKES ...26
CAB/ROPS ...26
COOLING ...26
ELECTRICAL ...26
ENGINE ...27
FUEL SYSTEM ...28
HYDRAULICS ...28
TIRES AND RIMS ...28
TURBOCHARGER ...28
SAFETY PRODUCT GRAPHICS AND LOCATIONS ...30
OPERATION -- SECTION 2...37
GENERAL VIEW ...38
INSTRUMENTS AND CONTROLS ...39
MONITOR PANEL...39
SYSTEM CHECK...40
CHECK MONITOR LAMP GROUP...41
Brake Oil Level Monitor...41
Engine Oil Level Monitor...42
Engine Coolant Level Monitor...42
CAUTION MONITOR LAMP GROUP...42
Charge Monitor...42
Fuel Level Monitor...43
Transmission Oil Filter Monitor...43
Brake Line Failure Monitor...43
Engine Oil Pressure Monitor...44
Engine Coolant Level Monitor...44
Air Pressure Monitor...44
Engine Coolant Temperature Monitor...44
Torque Converter Oil Temperature Monitor...45
Ground Driven Steering Operation Monitor - If Equipped...45
METER AND PILOT LAMP GROUP...46
Working Lamp Pilot Lamp...47
Transmission Cut-Off Selector Pilot Lamp...47
Air Pressure Gauge...47
Engine Coolant Temperature Gauge...47
Torque Converter Oil Temperature Gauge...48
Fuel Level Gauge...48
Turn Signal Pilot Lamp...48
Parking Brake Pilot Lamp...46
High Beam Pilot Lamp...48
Speedometer...49
Service Meter...49
SWITCHES ...50
TRANSMISSION CUT-OFF SELECTOR SWITCH...50
ETHER START SWITCH...50
HORN BUTTON...51
HAZARD LAMP SWITCH...51
PARKING BRAKE SWITCH...52
WORKING LAMP SWITCH...53
STARTING SWITCH...53
LAMP SWITCHES...53
Lamp switch...53
Turn signal lever...54
Dimmer switch...54
CIGARETTE LIGHTER...55
TRANSMISSION KICKDOWN SWITCH...55
FRONT WIPER SWITCH - IF EQUIPPED...56
REAR WIPER SWITCH - IF EQUIPPED...56
CAB DOME LAMP SWITCH - IF EQUIPPED...57
LEVERS AND PEDALS...58
DIRECTIONAL LEVER...58
SPEED CONTROL LEVER...59
SPEED CONTROL LEVER STOPPER...59
STEERING COLUMN TILT LEVER...59
ACCELERATOR PEDAL...60
BRAKE PEDALS...60
Right brake pedal...60
Left brake pedal...60
LIFT ARM CONTROL LEVER...61
BUCKET CONTROL LEVER...61
FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED...62
WORK EQUIPMENT CONTROL LEVER LOCK...62
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED ...62
AIR CLEANER SERVICE INDICATOR ...62
FRAME LOCKING BAR ...63
MAIN CIRCUIT BREAKER ...63
FUSE BOXES ...63
OPERATOR?S SEAT ...66
FORWARD-BACKWARD ADJUSTMENT...66
SEAT ANGLE ADJUSTMENT...66
WEIGHT ADJUSTMENT...66
BACKREST TILT ADJUSTMENT...66
HEIGHT ADJUSTMENT...66
RIGHT SIDE ARMREST ...66
HEIGHT ADJUSTMENT...66
ANGLE ADJUSTMENT...66
SEAT BELT ...67
CAB HEATER AND DEFROSTER - IF EQUIPPED ...68
CONTROL PANEL ...68
FAN SPEED SWITCH...68
TEMPERATURE CONTROL LEVER...68
AIR INTAKE SELECTOR LEVER...68
METHOD OF OPERATION...71
CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED ...70
CONTROL PANEL ...70
FAN SPEED SWITCH...70
AIR CONDITIONER SWITCH...70
TEMPERATURE CONTROL LEVER...70
AIR INTAKE SELECTOR LEVER...70
METHOD OF OPERATION ...71
PRECAUTIONS FOR USING AIR CONDITIONER...72
HANDLING AIR CONDITIONER IN SEASON...72
HANDLING AIR CONDITIONER IN OFF-SEASONS...72
LOCKING FILLER CAPS ...73
FUEL TANK FILLER CAP ...73
HYDRAULIC TANK FILLER CAP ...74
CHECKS BEFORE STARTING ENGINE ...75
WALK AROUND CHECK ...75
CHECKS BEFORE STARTING ...75
OPERATING MACHINE ...76
OPERATIONS BEFORE STARTING ENGINE ...76
STARTING ENGINE ...78
NORMAL STARTING...78
SPECIAL STARTING...78
COLD WEATHER STARTING...79
OPERATIONS AFTER STARTING ENGINE ...80
COLD WEATHER WARM-UP PROCEDURE ...80
MOVING MACHINE OFF ...81
SHIFTING GEAR ...83
SHIFTING BETWEEN FORWARD AND REVERSE ...84
STEERING MACHINE ...84
STOPPING MACHINE...85
OPERATIONAL PRECAUTIONS ...86
PERMISSIBLE WATER DEPTH...86
IF WHEEL BRAKES DO NOT WORK...86
WHEN TRAVELING UP OR DOWN SLOPES...86
Lower Center of Gravity When Turning...86
Braking on Downhill Slopes...86
If Engine Stops...86
POSSIBLE WORK USING LOADER ...87
EXCAVATION...87
LEVELING...89
LOAD AND CARRY OPERATIONS...90
LOADING...90
Cross Drive Loading...90
V-Shape Loading...90
PARKING MACHINE ...91
STOPPING ENGINE ...92
OPERATIONS AFTER STOPPING ENGINE ...92
ADJUSTMENT OF WORK EQUIPMENT ...93
ADJUSTING BOOM KICKOUT ...93
ADJUSTING BUCKET POSITIONER ...94
BUCKET LEVEL INDICATOR ...94
HANDLING TIRES ...95
PRECAUTIONS WHEN HANDLING TIRES ...95
PRECAUTIONS WHEN DRIVING MACHINE ...95
NORMAL OPERATING INFLATION PRESSURE ...96
INFLATING TIRES...96
PROPER BUCKET AND TIRE SELECTION TABLE ...98
TOWING ...99
TOWING THE MACHINE ...99
WHEN ENGINE CAN BE USED...99
WHEN ENGINE CANNOT BE USED...99
RELEASING PARKING BRAKE ...99
TRANSPORTATION ...100
COLD WEATHER OPERATION ...101
PREPARATION FOR LOW TEMPERATURE ...101
FUEL AND LUBRICANTS...101
COOLANT...101
BATTERY...101
CAUTIONS AFTER COMPLETION OF WORK...102
AFTER COLD WEATHER...102
LONG TERM STORAGE ...103
BEFORE STORAGE ...103
DURING STORAGE ...103
AFTER STORAGE ...103
HANDLING OF BATTERY ...104
PRECAUTIONS FOR CHARGING BATTERY ...104
REMOVAL AND INSTALLATION OF BATTERY ...104
STARTING ENGINE WITH BOOSTER CABLES ...105
BEFORE CONNECTING BOOSTER CABLES...105
CONNECTING BOOSTER CABLES...105
STARTING ENGINE...105
DISCONNECTING BOOSTER CABLES...106
TROUBLESHOOTING ...107
ELECTRICAL SYSTEM ...107
ENGINE ...107
CHASSIS ...108
TRANSMISSION...108
DRIVE AXLES...108
WHEEL BRAKES...108
PARKING BRAKE...108
STEERING...108
EQUIPMENT HYDRAULIC SYSTEM...108
MAINTENANCE -- SECTION 3...109
PERIODIC MAINTENANCE ...110
MAINTENANCE GUIDELINES ...110
OUTLINES OF SERVICE ...112
LUBRICATION WHEN SHIPPED ...112
RELATING TO ENGINE ...112
ENGINE OIL...112
COOLANT...112
DIESEL FUEL...113
RELATING TO HYDRAULIC SYSTEM ...113
RELATING TO ELECTRICAL SYSTEM ...113
RELATING TO LUBRICATION ...114
WEAR PARTS REPLACEMENT ...115
PERIODICAL PART REPLACEMENT ...116
LUBRICANTS, FUEL AND COOLANT ...117
PROPER SELECTION TABLE ...117
ENGINE OIL...118
Normal Operation...118
Arctic Operation...118
AXLE OIL...119
GREASE...119
DIESEL FUEL...119
COOLANT...119
SCHEDULED MAINTENANCE GUIDE ...125
FILLER AND LEVEL GAUGE POSITIONS ...130
INITIAL 250 HOURS SERVICE ONLY ...132
TRANSMISSION OIL FILTER ...132
WHEN REQUIRED ...132
COOLANT ADDITIVE CONCENTRATION - DCA4 ...132
AIR CLEANER ELEMENTS ...132
CHECKING...132
CLEANING OR REPLACING OUTER ELEMENT...132
REPLACING INNER ELEMENT...133
CLEANING OUTER ELEMENT...133
Using Compressed Air...133
Using Water...133
Using Water With Cleaning Agent...133
TRANSMISSION OIL LEVEL ...134
RADIATOR CORE ...135
DRIVE AXLE OIL LEVEL ...136
DRIVE AXLE HOUSING BREATHERS ...137
LUBRICATION ...138
HYDRAULIC TANK ...139
PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT ...139
WHEEL BRAKE HYDRAULIC CIRCUIT ...140
PARKING BRAKE ...141
BUCKET TEETH - IF EQUIPPED ...142
BUCKET EQUIPPED WITH BOLT-ON TEETH...142
BUCKET EQUIPPED WITH REPLACEABLE TOOTH TIP...142
BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED ...143
WINDOW WASHER TANKS - IF EQUIPPED ...143
AIR CONDITIONER CONDENSER - IF EQUIPPED ...144
AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED ...144
ALTERNATOR DRIVE BELT ...145
FAN DRIVE BELT ...145
WATER PUMP DRIVE BELT ...145
ALTERNATOR ...145
CRANKING MOTOR ...145
AIR GOVERNOR ...145
TRANSMISSION CONTROL LEVERS ...146
CHECKS BEFORE STARTING ENGINE ...147
COOLANT LEVEL ...147
ENGINE OIL LEVEL ...147
FUEL LEVEL ...148
AIR CLEANER SERVICE INDICATOR ...149
AIR TANKS ...149
BRAKE OIL LEVEL ...150
FUEL FILTER/WATER SEPARATOR ...150
ENGINE FAN ...151
DRIVE BELTS ...151
BELT INSPECTION...151
BELT TENSION CHECK...151
MONITOR PANEL ...152
ADDITIONAL CHECKS ...153
EVERY 50 HOURS SERVICE ...153
FUEL TANK ...153
TIRES ...153
ENGINE AIR INTAKE SYSTEM ...154
EVERY 100 HOURS SERVICE ...154
HYDRAULIC TANK OIL LEVEL ...154
LUBRICATION ...155
CAB AIR FILTER IF EQUIPPED ...155
EVERY 250 HOURS SERVICE ...156
ENGINE OIL AND FILTERS ...156
FUEL FILTERS ...158
GENERAL...158
REPLACEMENT...158
COOLANT FILTER...160
GENERAL...160
REPLACEMENT...160
ENGINE CRANKCASE BREATHER AND TUBE ...161
BATTERY ELECTROLYTE LEVELS ...161
LUBRICATION ...162
WHEEL HUB NUTS ...165
AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED ...165
EVERY 500 HOURS SERVICE ...167
TRANSMISSION OIL FILTER ...167
LUBRICATION ...167
AIR DRYER - IF EQUIPPED ...168
EVERY 1000 HOURS SERVICE ...168
TRANSMISSION OIL AND STRAINER ...168
TRANSMISSION CASE BREATHER ...169
LUBRICATION ...169
EVERY 1500 HOURS SERVICE ...171
ENGINE VALVES AND INJECTORS ...171
EVERY 2000 HOURS SERVICE ...172
ENGINE ...172
ENGINE MOUNTED HOSES ...172
ENGINE MOUNTING HARDWARE...172
ENGINE CRANKSHAFT END CLEARANCE ...173
TURBOCHARGER MOUNTING ...173
BATTERIES ...173
VISUAL INSPECTION...173
STATE OF CHARGE TEST...174
Specific Gravity Hydrometer Test...174
Stabilized Open Circuit Voltage Test...174
HYDRAULIC TANK OIL AND FILTERS ...175
HYDRAULIC TANK BREATHER ...176
PPC CIRCUIT STRAINER ...176
CAB AIR FILTER - IF EQUIPPED ...176
DRIVE AXLE OIL ...177
PARKING BRAKE DISC ...178
AIR DRYER - IF EQUIPPED ...178
ACCUMULATOR...179
COOLING SYSTEM...179
COOLANT RECOMMENDATIONS/SPECiFiCATlONS...179
CHANGING COOLANT AND FLUSHING SYSTEM...179
EVERY 6000 HOURS SERVICE ...181
FUEL PUMP ...181
FUEL INJECTORS ...181
ENGINE FAN HUB ...181
ENGINE IDLER PULLEY ...181
WATER PUMP ...181
TURBOCHARGER ...181
AIR COMPRESSOR ...181
ENGINE VIBRATION DAMPER ...181
SPECIFICATIONS -- SECTION 4...183
GENERAL SPECIFICATIONS ...184
OPERATING WEIGHT...184
PERFORMANCE...184
ENGINE...184
DIMENSIONS ...185
STANDARD TIGHTENING TORQUES ...188
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ...188
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS ...188
TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS ...189
