Komatsu Wheel Loaders WA180-3MC avance plus, WA180PT-3MC avance plus Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA180-3MC avance plus, WA180PT-3MC avance plus, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA180-3MC avance plus, WA180PT-3MC avance plus 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: 2,021 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM005002 - Wheel Loader WA180-3MC avance plus Shop Manual.pdf
CEBM005201 - Wheel Loader WA180PT-3MC avance plus Shop Manual.pdf
CEAM007501 - Wheel Loader WA180-3MC avance plus Operation & Maintenance Manual.pdf
CEAM007601 - Parallel Tool Carrier WA180-3MC avance plus Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM007501 - Wheel Loader WA180-3MC avance plus Operation & Maintenance Manual.....2
INTRODUCTION.....8
FOREWORD.....9
SAFETY INFORMATION.....9
INTRODUCTION.....11
INTENDED USE.....11
FEATURES.....11
BREAKING IN THE MACHINE.....11
LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR.....12
MACHINE SERIAL NO. PLATE POSITION.....12
ENGINE SERIAL NUMBER PLATE POSITION.....12
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR.....12
CONTENTS.....13
SAFETY.....22
GENERAL PRECAUTIONS.....23
SAFETY RULES.....23
SAFETY FEATURES.....23
UNAUTHORIZED MODIFICATION.....23
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....24
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....24
MOUNTING AND DISMOUNTING.....25
FIRE PREVENTION FOR FUEL AND OIL.....25
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.....26
ASBESTOS DUST HAZARD PREVENTION.....26
CRUSHING OR CUTTING PREVENTION.....26
FIRE EXTINGUISHER AND FIRST AID KIT.....27
PRECAUTIONS WHEN USING ROPS.....27
PRECAUTIONS FOR ATTACHMENTS.....27
PRECAUTION WHEN HANDLING ACCUMULATOR.....28
PRECAUTIONS DURING OPERATION.....29
BEFORE STARTING ENGINE.....29
SAFETY AT WORKSITE.....29
FIRE PREVENTION.....29
WALK AROUND CHECK.....29
IN OPERATOR'S CAB.....30
VENTILATION FOR ENCLOSED AREAS.....30
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS.....30
WHEN STARTING ENGINE.....31
AFTER STARTING ENGINE.....32
CHECKS AFTER STARTING ENGINE.....32
PRECAUTIONS WHEN MOVING.....32
CHECK WHEN CHANGING DIRECTION.....33
TRAVELING ON SLOPES.....34
PROHIBITED OPERATIONS.....34
PRECAUTIONS WHEN TRAVELING.....35
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....37
OPERATE CAREFULLY ON SNOW.....38
DO NOT HIT WORK EQUIPMENT.....38
WHEN USING THE BRAKE.....38
WHEN MAKING A DOWNHILL TRAVEL.....38
WORKING ON LOOSE GROUND.....39
PARKING THE MACHINE.....39
PRECAUTIONS IN COLD AREAS.....40
TRANSPORTATION.....41
LOADING AND UNLOADING.....41
SHIPPING.....41
BATTERY.....42
BATTERY HAZARD PREVENTION.....42
STARTING WITH BOOSTER CABLES.....43
CHARGING BATTERY.....44
TOWING.....45
WHEN TOWING.....45
PRECAUTIONS FOR MAINTENANCE.....46
BEFORE CARRYING OUT MAINTENANCE.....46
NOTIFICATION OF FAILURE.....46
WARNING TAGS.....46
CLEAN BEFORE INSPECTION AND MAINTENANCE.....46
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.....47
WORK EQUIPMENT SUPPORT.....47
PROPER TOOLS.....48
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....48
USE OF LIGHTING.....48
KEEP WORK PLACE CLEAN AND TIDY.....48
APPOINT A LEADER WHEN WORKING WITH OTHERS.....49
RADIATOR WATER LEVEL.....49
PREVENTION OF FIRE.....49
TURN E.C.S.S. SWITCH OFF.....49
DURING MAINTENANCE.....50
PERSONNEL.....50
ATTACHMENTS.....50
WORK UNDER THE MACHINE.....50
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE.....50
PRECAUTIONS WHEN USING HAMMER.....51
REPAIR WELDING.....51
PRECAUTIONS WITH BATTERY.....51
WHEN ABNORMALITY IS LOCATED.....51
RULES TO FOLLOW WHEN ADDING FUEL OR OIL.....51
ROTATING FAN AND BLADE.....52
HANDLING HIGH-PRESSURE HOSES.....52
PRECAUTION HIGH PRESSURE OIL.....52
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE.....52
TIRE MAINTENANCE.....53
CHECKS AFTER INSPECTION AND MAINTENANCE.....53
WASTE MATERIALS.....53
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED.....53
TIRES.....54
HANDLING TIRES.....54
STORING TIRES AFTER REMOVAL.....55
POSITION FOR ATTACHING SAFETY LABELS.....56
POSITION FOR ATTACHING SAFETY LABELS.....56
OPERATION.....62
GENERAL VIEW.....63
EXTERIOR VIEW OF MACHINE.....63
VIEW OF CONTROLS AND GAUGES.....64
EXPLANATION OF COMPONENTS.....66
METERS AND LAMPS.....66
SWITCHES.....71
CAB AND CANOPY.....71
CAB.....75
CONTROL LEVERS AND PEDALS.....77
MISCELLANEOUS.....84
FUEL CAP WITH LOCK.....84
SAFETY BAR.....84
TOWING PIN.....85
GREASE PUMP CLAMP AND RUBBER RING.....85
BACKUP ALARM.....85
FUSES.....86
FUSE CAPACITY AND NAME OF CIRCUIT.....86
SLOW-BLOW FUSES.....87
STORING THIS MANUAL.....87
AUXILIARY POWER SOURCE.....88
MACHINE AND ENGINE CHECKS.....90
CHECKS BEFORE STARTING ENGINE.....90
START-OF-DAY MACHINE CHECKS.....93
CHECKING AND ADDING COOLANT.....93
CHECKING THE DUST INDICATOR.....93
CHECKING THE BRAKE OIL TANK.....94
CHECKING AND ADDING ENGINE OIL.....94
DRAINING THE FUEL-WATER SEPARATOR.....95
DRAINING THE FUEL SEDIMENT STRAINER.....95
CHECKING THE ELECTRICAL WIRING.....96
CHECKING THE FUEL LEVEL.....96
INSPECTING THE TIRES.....97
INSPECTING THE RIMS.....97
CHECKING THE TIRE PRESSURE.....97
CHECKING THE MONITOR PANEL.....98
CHECKING THE PARKING BRAKE.....99
CHECKING THE WHEEL BRAKES.....99
CHECK SOUND OF HORN AND BACKUP ALARM.....99
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE.....99
CHECK ENGINE EXHAUST COLOR AND SOUND.....99
CHECK OPERATION OF GAUGES.....99
CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION.....99
CHECK THE REAR VIEW MIRROR.....99
CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB).....99
PRE-WORK SHIFT MACHINE CHECKS.....100
ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION).....100
ADJUSTING THE OPERATORS SEAT (OPTIONAL AIR-RIDE SEAT).....101
ADJUSTING THE SEAT BELT.....102
ADJUSTING THE REAR VIEW MIRRORS.....102
PRE-ENGINE START CHECKS.....103
STARTING THE ENGINE.....105
NORMAL STARTING PROCEDURES.....105
AFTER EXTENDED SHUTDOWN OR OIL CHANGE.....106
AFTER CHANGING FUEL FILTERS.....106
AFTER RUNNING OUT OF FUEL.....107
AFTER-STARTING CHECKS.....107
OPERATING THE MACHINE.....109
MOVING THE MACHINE.....109
CHANGING THE TRAVEL SPEED.....111
CHANGING DIRECTION.....112
AUTO-SHIFT TRANSMISSION.....112
TURNING THE MACHINE.....113
STOPPING THE MACHINE.....114
OPERATING THE WORK EQUIPMENT.....116
BUCKET (LEVER).....117
PARKING THE MACHINE.....118
CHECKS AFTER COMPLETION OF OPERATION.....120
STOPPING ENGINE.....120
CHECKS AFTER STOPPING ENGINE.....120
LOCKING THE MACHINE.....121
TRANSPORTING THE MACHINE.....122
LOADING AND UNLOADING.....122
PRECAUTIONS FOR LOADING.....123
PRECAUTIONS FOR LIFTING THE VEHICLE.....123
LIFTING POINT DECALS.....124
WEIGHT LIST.....124
LIFTING PROCEDURE.....125
TYPICAL WORK OPERATIONS.....126
DIGGING OPERATIONS WITH ROCK PILES.....126
DIGGING OPERATIONS ON LEVEL GROUND.....127
LEVELING OPERATIONS.....128
PUSHING OPERATIONS.....128
STANDARD LOADING OPERATIONS.....129
LOAD-AND-CARRY OPERATIONS.....130
PRECAUTIONS FOR OPERATION.....130
PERMISSIBLE WATER DEPTH.....130
IF WHEEL BRAKE DOES NOT WORK.....130
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....130
PRECAUTIONS WHEN DRIVING MACHINE.....131
ADJUSTING THE WORK EQUIPMENT POSTURE.....131
ADJUSTING THE BOOM KICKOUT.....131
ADJUSTING THE BUCKET POSITIONER.....132
BUCKET LEVEL INDICATOR.....132
COLD WEATHER OPERATIONS.....133
PRECAUTIONS DURING LOW AMBIENT TEMPERATURES.....133
FUEL AND LUBRICANTS.....133
COOLANT.....133
BATTERY.....134
AFTER COMPLETION OF WORK.....134
AFTER COLD WEATHER HAS PASSED.....134
LONG-TERM STORAGE.....135
BEFORE STORAGE.....135
DURING STORAGE.....135
AFTER STORAGE.....135
TROUBLESHOOTING.....136
MACHINE RUNS OUT OF FUEL.....136
TOWING THE MACHINE.....136
ENGINE STARTS.....137
ENGINE DOES NOT START.....137
DISCHARGED BATTERY.....138
BATTERY REMOVAL AND INSTALLATION.....139
BATTERY CHARGING PRECAUTIONS.....139
USING BOOSTER CABLES TO START THE ENGINE.....140
OTHER TROUBLE.....142
ELECTRICAL SYSTEM.....142
CHASSIS.....143
ENGINE.....145
MAINTENANCE.....148
GUIDES TO MAINTENANCE.....149
OUTLINES OF SERVICE.....151
OUTLINE OF OIL, FUEL, COOLANT.....151
OIL.....151
FUEL.....152
COOLANT.....152
GREASE.....153
STORING OIL AND FUEL.....153
FILTERS.....153
FUEL INJECTION PUMP.....153
OUTLINE OF ELECTRIC SYSTEM.....154
WEAR PARTS LIST.....155
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....156
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....156
ENGINE OIL SPECIFICATIONS.....157
NORMAL OPERATION.....157
ARCTIC OPERATION.....157
DIESEL FUEL SPECIFICATIONS.....158
COOLANT SPECIFICATIONS.....158
GENERAL.....158
WATER.....158
ANTIFREEZE.....159
INHIBITORS/CONDITIONERS.....160
MAINTENANCE OF COOLING SYSTEM INHIBITORS.....160
COOLANT TESTING FOR CONDITIONER CONCENTRATION.....160
REPLENISHING COOLANT CONDITIONER.....160
DCA4 UNIT MAINTENANCE GUIDE.....161
COOLING SYSTEM TEST KIT.....163
TOOLS.....164
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.....165
PERIODIC REPLACEMENT OF CRITICAL PARTS.....166
CRITICAL PARTS LIST.....166
MAINTENANCE SCHEDULE CHART.....169
MAINTENANCE SCHEDULE CHART.....169
SERVICE PROCEDURES.....172
INITIAL 250 HOURS SERVICE.....172
FUEL FILTERS.....172
TRANSMISSION OIL FILTER ELEMENT.....172
HYDRAULIC TANK FILTER ELEMENT.....172
WHEN REQUIRED.....173
CHECKING, CLEANING OR REPLACING THE AIR CLEANER ELEMENT.....173
CHECKING THE TRANSMISSION OIL LEVEL, ADDING OIL.....175
CHECKING THE AXLE OIL LEVEL, ADDING OIL.....176
CLEANING THE AXLE CASE BREATHER.....177
CLEANING THE RADIATOR FINS.....177
REPLACING THE BOLT-ON CUTTING EDGES.....178
REPLACING THE BUCKET TEETH (IF EQUIPPED).....179
CHECKING THE AIR CONDITIONER (IF EQUIPPED).....180
CLEANING THE AIR CONDITIONER CONDENSER (IF EQUIPPED).....181
CHECKING THE WINDOW WASHING FLUID.....181
CHECKING AND ADJUSTING THE PARKING BRAKE.....182
REPLACING A SLOW-BLOW FUSE.....183
CHECKING THE AIR INTAKE HEATER.....183
DRAINING WATER FROM THE FUEL-WATER SEPARATOR.....95
DRAINING SEDIMENT FROM THE FUEL-SEDIMENT STRAINER.....95
CHECKS BEFORE STARTING.....184
CHECK COOLANT LEVEL, ADD COOLANT.....93
CHECK FUEL LEVEL, ADD FUEL.....96
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.....94
CHECK AND REFILL OIL IN BRAKE OIL TANK.....94
CHECK DUST INDICATOR.....93
CHECK ELECTRIC WIRING.....96
CHECK EFFECT OF PARKING BRAKE.....99
CHECK EFFECT OF WHEEL BRAKES.....99
CHECK SOUND OF HORN AND BACKUP ALARM.....99
CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE.....99
CHECK ENGINE EXHAUST COLOR AND SOUND.....99
CHECK OPERATION OF GAUGES.....99
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.....99
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE.....99
CHECK LOCK OF CAB DOOR (MACHINE EQUIPED WITH CAB).....99
EVERY 50 HOURS SERVICE.....184
CHECKING THE TIRE INFLATION PRESSURE.....184
DRAINING WATER AND SEDIMENT FROM THE FUEL TANK.....184
EVERY 100 HOURS SERVICE.....185
CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK, ADDING OIL.....185
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT.....186
LUBRICATING.....187
EVERY 250 HOURS SERVICE.....188
CHANGING THE ENGINE OIL AND REPLACING THE ENGINE OIL FILTER.....188
CHECKING FOR LOOSE WHEEL HUB NUTS.....190
CLEANING THE AIR CONDITIONER RECIRCULATION FILTER ELEMENT.....190
CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION.....191
CHECKING THE BATTERY ELECTROLYTE LEVEL.....192
CHECKING THE AIR INTAKE SYSTEM.....192
LUBRICATING THE DUMP CYLINDER PIN, LIFT CYLINDE PIN, LIFT PIVOT PIN, TILT LEVER PIN AND STEERING CYLINDER PIN.....193
EVERY 500 HOURS SERVICE.....194
REPLACING THE FUEL FILTERS.....194
REPLACING THE TRANSMISSION OIL FILTER ELEMENT.....196
LUBRICATING THE CENTER HINGE PIN.....197
EVERY 1,000 HOURS SERVICE.....198
CHANGING THE TRANSMISSION CASE OIL.....198
CLEANING THE TRANSMISSION CASE BREATHER.....199
LUBRICATING THE FRONT, CENTER, AND REAR DRIVE SHAFTS.....199
ADJUSTING THE ENGINE VALVE LASH CLEARANCE.....200
CHANGING THE HYDRAULIC TANK OIL, REPLACING THE FILTER ELEMENT.....201
CHECKING THE FAN BELT TENSION.....203
CHECKING THE FAN BELT TENSIONER BEARING AND FAN HUB BEARING; INSPECTING THE FAN BELT.....203
EVERY 2,000 HOURS SERVICE.....205
REPLACING COOLANT, FLUSHING THE COOLING SYSTEM.....205
REPLACING THE HYDRAULIC TANK BREATHER ELEMENT.....208
CHANGING THE AXLE OIL.....208
CHECK BRAKE DISC WEAR.....209
CHECK THE ALTERNATOR.....209
CHECK THE STARTER MOTOR.....209
CHECKING THE VIBRATION DAMPER.....209
REPLACING THE AIR CONDITIONER RECIRCULATION AND FRESH AIR FILTER ELEMENTS.....209
SPECIFICATIONS.....210
WA180-3MC SPECIFICATIONS.....211
OPTIONS, ATTACHMENTS.....214
AVAILABLE ATTACHMENTS.....215
BUCKETS AND TIRES SELECTION.....216
AIR CONDITIONING.....217
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....217
FAN SWITCH.....217
AIR CONDITIONER SWITCH.....217
MODE SELECTOR SWITCH.....218
FRESH/RECIRC SELECTOR SWITCH.....218
TEMPERATURE CONTROL SWITCH.....218
METHOD OF OPERATION.....219
WHEN NOT USING THE AIR CONDITIONER REGU LARLY.....219
COOL BOX.....219
ECSS (ELECTRONICALLY-CONTROLLED SUSPENSION SYSTEM).....220
STRUCTURE AND FUNCTION OF ECSS.....220
METHOD OF OPERATING ECSS.....221
PRECAUTIONS WHEN OPERATING ECSS SWITCH.....221
ACCUMULATOR PRECAUTIONS.....222
RADIO.....223
OPERATING CONTROLS.....223
OPERATION.....224
SETTING THE CLOCK.....226
REMOTE CONTROL UNIT.....226
BATTERY REPLACEMENT.....227
PRECAUTIONS WHEN USING.....227
CEAM007601 - Parallel Tool Carrier WA180-3MC avance plus Operation & Maintenance Manual.....230
COVER.....230
INTRODUCTION.....236
FORWARD.....237
SAFETY INFORMATION.....238
INTRODUCTION.....239
INTENDED USE.....239
FEATURES.....239
BREAKING IN A NEW MACHINE.....239
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....240
MACHINE SERIAL NO. PLATE POSITION.....240
ENGINE SERIAL NO. PLATE POSITION.....240
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....240
CONTENTS.....241
SAFETY.....248
GENERAL PRECAUTIONS.....249
SAFETY RULES.....249
SAFETY FEATURES.....249
UNAUTHORIZED MODIFICATION.....249
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....250
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....250
MOUNTING AND DISMOUNTING.....251
FIRE PREVENTION FOR FUEL AND OIL.....251
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.....252
ASBESTOS DUST HAZARD PREVENTION.....252
CRUSHING OR CUTTING PREVENTION.....252
FIRE EXTINGUISHER AND FIRST AID KIT.....253
PRECAUTIONS WHEN USING ROPS.....253
PRECAUTIONS FOR ATTACHMENTS.....253
PRECAUTION WHEN HANDLING ACCUMULATOR.....254
PRECAUTIONS DURING OPERATION.....255
BEFORE STARTING ENGINE.....255
SAFETY AT WORKSITE.....255
FIRE PREVENTION.....255
WALK AROUND CHECK.....255
IN OPERATOR'S CAB.....256
VENTILATION FOR ENCLOSED AREAS.....256
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS.....256
WHEN STARTING ENGINE.....257
AFTER STARTING ENGINE.....258
CHECKS AFTER STARTING ENGINE.....258
PRECAUTIONS WHEN MOVING.....258
CHECK WHEN CHANGING DIRECTION.....259
PRECAUTIONS WHEN TRAVELING.....260
TRAVELING ON SLOPES.....261
PROHIBITED OPERATIONS.....261
PRECAUTIONS WHEN TRAVELING.....262
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....263
ENSURE GOOD VISIBILITY.....264
OPERATE CAREFULLY ON SNOW.....264
DO NOT HIT WORK EQUIPMENT.....264
WHEN USING THE BRAKE.....264
WHEN MAKING A DOWNHILL TRAVEL.....264
WORKING ON LOOSE GROUND.....265
PARKING THE MACHINE.....265
PRECAUTIONS IN COLD AREAS.....266
TRANSPORTATION.....267
LOADING AND UNLOADING.....267
SHIPPING.....267
BATTERY.....268
BATTERY HAZARD PREVENTION.....268
STARTING WITH BOOSTER CABLES.....269
CHARGING BATTERY.....270
TOWING.....271
WHEN TOWING.....271
PRECAUTIONS FOR MAINTENANCE.....272
BEFORE CARRYING OUT MAINTENANCE.....272
NOTIFICATION OF FAILURE.....272
WARNING TAGS.....272
CLEAN BEFORE INSPECTION AND MAINTENANCE.....272
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.....273
WORK EQUIPMENT SUPPORT.....273
PROPER TOOLS.....274
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....274
USE OF LIGHTING.....274
KEEP WORK PLACE CLEAN AND TIDY.....274
APPOINT A LEADER WHEN WORKING WITH OTHERS.....275
RADIATOR WATER LEVEL.....275
PREVENTION OF FIRE.....275
TURN ECSS SWITCH OFF.....275
DURING MAINTENANCE.....276
PERSONNEL.....276
ATTACHMENTS.....276
WORK UNDER THE MACHINE.....276
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE.....276
PRECAUTIONS WHEN USING HAMMER.....277
REPAIR WELDING.....277
PRECAUTIONS WITH BATTERY.....277
WHEN ABNORMALITY IS LOCATED.....277
RULES TO FOLLOW WHEN ADDING FUEL OR OIL.....277
ROTATING FAN AND BLADE.....278
HANDLING HIGH-PRESSURE HOSES.....278
PRECAUTION HIGH PRESSURE OIL.....278
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE.....278
TIRE MAINTENANCE.....279
CHECKS AFTER INSPECTION AND MAINTENANCE.....279
WASTE MATERIALS.....279
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED.....279
TIRES.....280
HANDLING TIRES.....280
STORING TIRES AFTER REMOVAL.....281
SAFETY LABELS.....282
SAFETY LABEL LOCATIONS.....282
OPERATION.....288
GENERAL VIEW.....289
EXTERIOR VIEW OF MACHINE.....289
VIEW OF CONTROLS AND GAUGES.....290
EXPLANATION OF COMPONENTS.....292
METERS AND LAMPS.....292
SWITCHES (ALL MODELS).....297
SWITCHES (MODELS WITH CAB).....302
CONTROL LEVERS AND PEDALS.....304
MISCELLANEOUS.....311
FUEL CAP WITH LOCK.....311
SAFETY BAR.....311
TOWING PIN.....312
GREASE PUMP CLAMP AND RUBBER RING.....312
BACKUP ALARM.....312
FUSES.....313
FUSE CAPACITY AND NAME OF CIRCUIT.....313
SLOW-BLOW FUSES.....314
STORING THIS MANUAL.....314
AUXILIARY POWER SOURCE.....315
WALK-AROUND CHECK.....316
STARTING ENGINE PRE-CHECK.....319
CHECK COOLANT LEVEL, ADD COOLANT.....319
CHECK FUEL LEVEL, ADD FUEL.....319
CHECK DUST INDICATOR.....320
CHECK THE BRAKE OIL TANK.....320
CHECK AND ADD ENGINE OIL.....320
DRAIN THE FUEL-WATER SEPARATOR.....321
DRAIN THE FUEL SEDIMENT STRAINER.....321
CHECK THE ELECTRICAL WIRING.....322
HANDLING TIRES.....323
INSPECTING RIMS.....323
CHECKING TIRE PRESSURE.....323
PRECAUTION WITH LOAD-AND-CARRY OPERATIONS.....324
CHECK MONITOR PANEL.....324
CHECK EFFECT PARKING BRAKE.....325
CHECK WHEEL BRAKES.....325
CHECK SOUND OF HORN AND BACKUP ALARM.....325
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE.....325
CHECK ENGINE EXHAUST COLOR AND SOUND.....325
CHECK OPERATION OF GAUGES.....325
CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION.....325
CHECK REAR VIEW MIRROR.....325
CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB).....325
OPERATORS SEAT.....326
ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION).....326
ADJUSTING THE OPERATORS SEAT (OPTIONAL AIR-RIDE SEAT).....327
ADJUSTING THE SEAT BELT.....328
ADJUSTING THE REAR VIEW MIRRORS.....328
BEFORE STARTING ENGINE CHECK.....329
STARTING ENGINE CHECK.....331
NORMAL STARTING PROCEDURES (IN COLD AND WARM CONDITIONS).....331
STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE.....333
STARTING PROCEDURES AFTER CHANGING FUEL FILTERS.....333
STARTING PROCEDURES AFTER RUNNING OUT OF FUEL.....333
AFTER STARTING ENGINE OPERATION CHECKS.....334
OPERATING THE MACHINE.....335
MOVING THE MACHINE.....335
CHANGING GEAR SPEED.....337
CHANGING DIRECTION (FORWARD-REVERSE).....338
AUTO-SHIFT TRANSMISSION.....338
TURNING THE MACHINE.....339
OPERATING THE WORK EQUIPMENT (WITH BUCKET TOOL).....340
LIFT ARM (LEVER).....340
BUCKET (LEVER).....340
OPERATING THE WORK EQUIPMENT (WITH FORK TOOL).....341
LIFT ARM OPERATION (LEVER).....341
FORK OPERATION (LEVER).....341
OPERATION OF WORK EQUIPMENT (WITH MULTI-PURPOSE BUCKET).....343
LIFT ARM OPERATION (LEVER).....343
BUCKET OPERATION (LEVER).....343
AUXILIARY OPERATION (LEVER).....344
OPEN (A).....344
HOLD (B).....344
CLOSE (C).....345
POSITION INDICATOR.....345
OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM).....346
LIFT ARM OPERATION (LEVER).....346
HYDRAULIC QUICK COUPLER.....347
COUPLING THE ATTACHMENT.....347
UNCOUPLING FROM THE ATTACHMENT.....348
TYPICAL WORK OPERATIONS.....350
DIGGING OPERATIONS WITH ROCK PILES.....350
DIGGING OPERATIONS ON LEVEL GROUND.....351
LEVELING OPERATION.....352
PUSHING OPERATIONS.....352
LOAD AND CARRY OPERATIONS.....352
LOADING OPERATIONS.....353
MULTI-PURPOSE BUCKET.....354
IN SCRAPER POSITION.....354
DIGGING, CLEARING AND LEVELING.....355
IMPROPER USE OF THE MULTI-PURPOSE BUCKET.....357
PALLET FORKS.....359
GENERAL.....359
LOADING.....359
TRANSPORTING.....360
UNLOADING.....361
MATERIAL HANDLING ARM.....362
PRECAUTIONS FOR OPERATION.....363
PERMISSIBLE WATER DEPTH.....363
IF WHEEL BRAKE DOES NOT WORK.....363
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....363
PRECAUTIONS WHEN DRIVING MACHINE.....364
ADJUSTING WORK EQUIPMENT POSTURE.....365
ADJUSTING BOOM KICKOUT POSITIONER.....365
ADJUSTING BUCKET / FORK POSITIONER.....366
STOPPING AND PARKING MACHINE.....368
CHECKS AFTER COMPLETION OF OPERATION.....370
STOPPING ENGINE.....370
CHECKS AFTER STOPPING ENGINE.....370
LOCKING THE MACHINE.....371
TRANSPORTING THE MACHINE.....372
LOADING AND UNLOADING.....372
PRECAUTIONS FOR LOADING.....373
PRECAUTIONS FOR LIFTING THE VEHICLE.....373
LIFTING POINT DECALS.....374
WEIGHT LIST.....374
LIFTING PROCEDURE.....375
COLD WEATHER OPERATIONS.....376
PRECAUTIONS FOR LOW TEMPERATURE.....376
FUEL AND LUBRICANTS.....376
COOLANT.....376
BATTERY.....377
PRECAUTIONS AFTER COMPLETION OF WORK.....377
AFTER COLD WEATHER.....377
LONG-TERM STORAGE.....378
BEFORE STORAGE.....378
DURING STORAGE.....378
AFTER STORAGE.....378
TROUBLESHOOTING.....379
MACHINE RUNS OUT OF FUEL.....379
TOWING THE MACHINE.....379
WHEN ENGINE CAN BE USED.....380
WHEN ENGINE CAN NOT BE USED.....380
IF BATTERY IS DISCHARGED.....381
REMOVAL AND INSTALLATION OF BATTERY.....382
PRECAUTIONS FOR CHARGING BATTERY.....382
STARTING ENGINE WITH BOOSTER CABLES.....383
OTHER TROUBLE.....385
ELECTRICAL SYSTEM.....385
CHASSIS.....386
ENGINE.....388
MAINTENANCE.....390
GUIDES TO MAINTENANCE.....391
OUTLINES OF SERVICE.....393
OUTLINE OF OIL, FUEL, COOLANT.....393
OIL.....393
FUEL.....394
COOLANT.....394
GREASE.....394
STORING OIL AND FUEL.....395
FILTERS.....395
FUEL INJECTION PUMP.....395
OUTLINE OF ELECTRIC SYSTEM.....395
WEAR PARTS LIST.....396
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....397
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....397
ENGINE OIL SPECIFICATIONS.....398
NORMAL OPERATION.....398
ARCTIC OPERATION.....399
DIESEL FUEL SPECIFICATIONS.....399
COOLANT SPECIFICATIONS.....400
GENERAL.....400
WATER.....400
ANTIFREEZE.....400
INHIBITORS/CONDITIONERS.....401
MAINTENANCE OF COOLING SYSTEM INHIBITORS.....401
COOLANT TESTING FOR CONDITIONER CONCENTRATION.....402
REPLENISHING COOLANT CONDITIONER.....402
DCA4 UNIT MAINTENANCE GUIDE.....403
COOLING SYSTEM TEST KIT.....405
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.....406
INTRODUCTION OF NECESSARY TOOLS.....406
TORQUE LIST.....407
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....409
SAFETY CRITICAL PARTS.....410
MAINTENANCE SCHEDULE CHART.....413
MAINTENANCE SCHEDULE CHART.....413
SERVICE PROCEDURES.....416
INITIAL 250 HOURS SERVICE.....416
REPLACE FUEL FILTERS.....416
REPLACE TRANSMISSION OIL FILTER ELEMENT.....416
REPLACE HYDRAULIC TANK FILTER ELEMENT.....416
WHEN REQUIRED.....417
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT.....417
CHECK TRANSMISSION OIL LEVEL, ADD OIL.....419
CHECK AXLE OIL LEVEL, ADD OIL.....420
CLEAN THE AXLE CASE BREATHER.....421
CLEAN RADIATOR FINS.....421
REPLACE THE BOLT-ON CUTTING EDGES.....422
REPLACE BUCKET TEETH (IF EQUIPPED).....422
CHECK AIR CONDITIONER (IF EQUIPPED).....423
CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).....424
CHECK WINDOW WASHING FLUID.....424
ADJUST PARKING BRAKE.....425
REPLACE SLOW BLOW FUSE.....426
CHECK AIR INTAKE HEATER.....426
DRAIN WATER FROM THE FUEL-WATER SEPARATOR.....321
DRAIN SEDIMENT FROM THE FUEL-SEDIMENT STRAINER.....321
CHECK BEFORE STARTING.....427
CHECK COOLANT LEVEL, ADD COOLANT.....319
CHECK FUEL LEVEL, ADD FUEL.....319
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.....320
CHECK AND REFILL OIL IN BRAKE OIL TANK.....320
CHECK DUST INDICATOR.....320
CHECK ELECTRIC WIRING.....322
DRAIN WATER FROM FUEL WATER SEPARATOR.....321
INSPECTION OF TIRES.....323
CHECK EFFECT OF PARKING BRAKE.....325
CHECK EFFECT OF WHEEL BRAKES.....325
CHECK SOUND OF HORN AND BACKUP ALARM.....325
CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE.....325
CHECK ENGINE EXHAUST COLOR AND SOUND.....325
CHECK OPERATION OF GAUGES.....325
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.....325
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE.....325
CHECK LOCK OF CAB DOOR (MACHINE EQUIPPED WITH CAB).....325
EVERY 50 HOURS SERVICE.....427
CHECK THE TIRE INFLATION PRESSURE.....427
DRAIN WATER, SEDIMENT FROM FUEL TANK.....427
EVERY 100 HOURS SERVICE.....428
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....428
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.....429
LUBRICATING.....429
REAR AXLE PIVOT PIN (2 PLACES).....429
BUCKET/FORK LINK PIN (2 PLACES).....430
BUCKET/FORK HINGE PIN (2 PLACES).....430
EVERY 250 HOURS SERVICE.....431
CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER.....431
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN.....432
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.....433
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....433
CHECK BATTERY ELECTROLYTE LEVEL.....434
CHECK AIR INTAKE SYSTEM.....434
LUBRICATING.....435
TILT CYLINDER PIN (4-PLACES).....435
LOADER LINK PIN (10 PLACES).....435
LIFT CYLINDER PIN (4 PLACES).....435
LIFT ARM PIVOT PIN (2 PLACES).....435
STEERING CYLINDER PIN (4 PLACES).....435
EVERY 500 HOURS SERVICE.....436
REPLACE FUEL FILTERS.....436
REPLACE TRANSMISSION OIL FILTER ELEMENT.....438
LUBRICATE THE FOLLOWING:.....439
CENTER HINGE PIN (2 PLACES).....415
EVERY 1000 HOURS SERVICE.....440
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER.....440
CLEAN TRANSMISSION CASE BREATHER.....441
LUBRICATE (FRONT, CENTER, AND REAR DRIVE SHAFTS).....441
CENTER HINGE PIN (2 PLACES).....441
FRONT DRIVE SHAFT (1 PLACE).....441
DRIVE SHAFT CENTER SUPPORT (1 PLACE).....442
CENTER DRIVE SHAFT (2 PLACES).....442
REAR DRIVE SHAFT (2 PLACES).....442
ADJUST ENGINE VALVE LASH CLEARANCE.....442
CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT.....443
CHECK FAN BELT TENSION.....445
CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT.....445
EVERY 2000 HOURS SERVICE.....447
REPLACE HYDRAULIC TANK BREATHER ELEMENT.....447
COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM.....447
RADIATOR CAP GENERAL INFORMATION.....448
CHANGE AXLE OIL.....450
CHECK BRAKE DISC WEAR.....450
CHECK ALTERNATOR.....450
CHECK STARTER MOTOR.....450
CHECK VIBRATION DAMPER.....451
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AND FRESH AIR FILTER.....451
ADJUST ENGINE VALVE LASH CLEARANCE.....451
CLEAN PPC CIRCUIT STRAINER.....452
CHECK ACCUMULATOR GAS PRESSURE.....452
SPECIFICATIONS.....454
WA180PT-3MC WITH BUCKET ATTACHMENT.....455
WA180PT-3MC WITH FORK ATTACHMENT.....457
WA180PT-3MC WITH MATERIAL HANDLING ARM.....459
OPTIONS, ATTACHMENTS.....462
AVAILABLE ATTACHMENTS.....463
BUCKETS AND TIRES SELECTION.....464
AIR CONDITIONING.....465
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....465
FAN SWITCH.....465
AIR CONDITIONER SWITCH.....465
MODE SELECTOR SWITCH.....466
FRESH/RECIRC SELECTOR SWITCH.....466
TEMPERATURE CONTROL SWITCH.....466
METHOD OF OPERATION.....467
WHEN NOT USING THE AIR CONDITIONER REGULARLY.....467
COOL BOX.....467
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM).....468
STRUCTURE AND FUNCTION OF ECSS.....468
METHOD OF OPERATING ECSS.....469
PRECAUTIONS WHEN OPERATING ECSS SWITCH.....469
ACCUMULATOR PRECAUTIONS.....470
RADIO.....471
OPERATING CONTROLS.....471
OPERATION.....472
SETTING THE CLOCK.....474
REMOTE CONTROL UNIT.....474
BATTERY REPLACEMENT.....475
PRECAUTIONS WHEN USING.....475
CEBM005002 - Wheel Loader WA180-3MC avance plus Shop Manual.....478
COVER.....478
CONTENTS.....479
00 FORWARD.....488
HOW TO READ THE SHOP MANUAL.....491
VOLUMES.....491
DISTRIBUTION AND UPDATING.....491
FILING METHOD.....491
REVISED EDITION MARK.....491
REVISIONS.....491
SYMBOLS.....491
HOISTING INSTRUCTIONS.....492
HOISTING.....492
WIRE ROPES.....492
COATING MATERIALS.....493
STANDARD TIGHTENING TORQUE.....495
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.....495
TIGHTENING TORQUE OF HOSE NUTS.....496
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.....496
TIGHTENING TORQUE FOR FLARED NUTS.....496
ELECTRIC WIRE CODE.....497
CLASSIFICATION BY THICKNESS.....497
CLASSIFICATION BY COLOR AND CODE.....497
CONVERSION TABLES.....498
METHOD OF USING THE CONVERSION TABLE.....498
SAFETY.....488
SAFETY NOTICE.....488
IMPORTANT SAFETY NOTICE.....488
GENERAL PRECAUTIONS.....488
PREPARATIONS FOR WORK.....488
PRECAUTIONS DURING WORK.....488
01 GENERAL.....504
SPECIFICATION DRAWING.....505
SPECIFICATIONS.....506
LIST OF LUBRICANT AND WATER.....511
ENGINE OIL SPECIFICATIONS.....512
NORMAL OPERATION.....512
ARCTIC OPERATION.....512
DIESEL FUEL SPECIFICATIONS.....513
COOLANT SPECIFICATIONS.....513
GENERAL.....513
WATER.....513
ANTIFREEZE.....514
INHIBITORS/CONDITIONERS.....515
10 STRUCTURE AND FUNCTION.....520
POWER TRAIN.....524
OUTLINE.....524
POWER TRAIN SYSTEM.....525
OUTLINE.....526
TORQUE CONVERTER, TRANSMISSION PIPING.....527
OUTLINE.....527
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.....529
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND.....529
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.....530
ENGINE STOPPED.....530
TORQUE CONVERTER.....531
TORQUE CONVERTER OIL FILTER.....533
TRANSMISSION.....535
CLUTCH.....537
REVERSE 1ST CLUTCH.....537
FORWARD, 2ND CLUTCH.....538
3RD, 4TH CLUTCH.....538
FORWARD 1ST.....540
FORWARD 2ND.....541
FORWARD 3RD.....542
FORWARD 4TH.....543
REVERSE 1ST.....544
TRANSMISSION CONTROL VALVE.....545
UPPER VALVE.....546
LOWER VALVE.....547
TRANSMISSION SOLENOID VALVE.....548
TORQUE CONVERTER OUTLET PORT VALVE.....549
PILOT REDUCING VALVE.....550
TRANSMISSION SOLENOID VALVE.....551
PRIORITY VALVE.....552
MAIN REGULATOR VALVE.....553
QUICK RETURN VALVE.....554
MODULATION FILL VALVE.....558
DIRECTIONAL SELECTOR SPOOL.....560
EMERGENCY MANUAL SPOOL.....561
OPERATION OF FORWARD 1ST.....563
ACCUMULATOR VALVE.....565
TRANSMISSION CONTROL.....567
DRIVE SHAFT.....568
AXLE.....569
FRONT AXLE.....569
FRONT DIFFERENTIAL.....570
REAR AXLE.....571
REAR DIFFERENTIAL.....572
TORQUE PROPORTIONING DIFFERENTIAL.....574
FINAL DRIVE.....575
AXLE MOUNT.....577
CENTER HINGE PIN.....579
STEERING PIPING.....580
STEERING COLUMN.....581
PRIORITY VALVE.....582
CUSHION VALVE.....585
STEERING VALVE (ORBIT-ROLL).....587
CONNECTION BETWEEN HAND PUMP AND SLEEVE.....593
BRAKE.....595
BRAKE PIPING.....595
BRAKE CONTROL.....596
BRAKE BOOSTER.....597
BRAKE.....600
PARKING BRAKE CONTROL.....602
PARKING BRAKE.....603
HYDRAULIC.....605
HYDRAULIC PIPING.....605
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....607
ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD".....607
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....608
HYDRAULIC TANK.....610
OIL FILTER BYPASS VALVE.....611
BREATHER.....612
PPC VALVE.....613
PPC RELIEF VALVE.....619
ACCUMULATOR.....620
FOR PPC VALVE.....620
MAIN CONTROL VALVE.....621
2-SPOOL.....621
3-SPOOL.....623
RELIEF VALVE.....625
SAFETY VALVE (WITH SUCTION).....626
SUCTION VALVE.....627
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION.....628
BOOM SPOOL AT RAISE POSITION.....629
BOOM SPOOL AT LOWER POSITION.....630
BOOM SPOOL AT FLOAT POSITION.....631
BUCKET SPOOL AT TILT BACK POSITION.....632
BUCKET SPOOL AT DUMP POSITION.....633
WORK EQUIPMENT.....634
WORK EQUIPMENT LVER LINKAGE.....634
WORK EQUIPMENT LINKAGE.....635
BUCKET.....637
BUCKET POSITIONER AND BOOM KICK-OUT.....638
BUCKET POSITIONER.....639
BOOM KICK-OUT.....639
PROXIMITY SWITCH.....640
ROPS CAB.....642
AIR CONDITIONER.....643
AIR CONDITIONER AND HEATER PIPING.....643
ECSS.....644
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM.....645
OPERATION.....646
CENTRAL PANEL.....647
SENSORS.....648
ENGINE OIL PRESSURE.....648
BRAKE OIL LEVEL.....648
ENGINE SPEED SENSOR.....649
ENGINE.....650
ENGINE STARTING CIRCUIT.....650
ENGINE STOP CIRCUIT.....651
AUTOMATIC PREHEATING CIRCUIT.....652
QUICK HEATING SYSTEM (QHS).....652
QHS CONTROLLER.....654
HEATER RELAY.....654
RIBBON HEATER.....655
QHS WATER TEMPERATURE SENSOR.....655
TRANSMISSION AUTO-SHIFT CONTROL.....656
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.....657
SHIFT CONTROL SYSTEM FUNCTION.....658
INPUT SIGNALS.....658
OUTPUT SIGNALS.....659
SHIFT CHARACTERISTICS.....660
SAFETY FUNCTION.....664
TROUBLESHOOTING.....664
TRANSMISSION CONTROLLER.....665
CONNECTOR SIGNALS.....665
COMBINATION SWITCH.....666
TRANSMISSION CUT-OFF FUNCTION.....667
PARKING BRAKE FUNCTION.....669
KICK-DOWN SWITCH.....670
KICK-DOWN ELECTRICAL CIRCUIT.....671
KICK-DOWN SWITCH OPERATED.....672
KICK-DOWN SWITCH ACTUATION - CANCELED (1).....673
KICK-DOWN SWITCH ACTUATION - CANCELED (2).....674
ELECTRICAL WIRING ILLUSTRATION.....676
ELECTRICAL WIRING DIAGRAM (1/5).....678
ELECTRICAL WIRING DIAGRAM (2/5).....680
ELECTRICAL WIRING DIAGRAM (3/5).....682
ELECTRICAL WIRING DIAGRAM (4/5).....684
ELECTRICAL WIRING DIAGRAM (5/5).....686
20 TESTING, ADJUSTING AND TROUBLESHOOTING.....690
STANDARD VALUE TABLE.....694
ENGINE TABLE - IN CHASSIS.....694
CHASSIS TABLE.....695
SERVICE TOOLS TABLE.....701
ENGINE COMPONENTS.....703
ADJUSTING ENGINE STOP MOTOR CABLE.....703
ADJUSTING ENGINE STOP SOLENOID.....703
MEASURING AND ADJUSTING VALVE CLEARANCE.....703
MEASURING BLOW-BY PRESSURE.....703
MEASURING COMPRESSION PRESSURE.....703
MEASURING COOLANT TEMPERATURE.....703
MEASURING ENGINE LUBRICATING OIL PRESSURE.....703
MEASURING ENGINE SPEEDS.....703
MEASURING EXHAUST COLOR.....703
MEASURING EXHAUST GAS TEMPERATURE.....703
MEASURING FUEL FILTER INLET RESTRICTION.....703
TEST AND ADJUSTING FAN BELT TENSION.....703
TEST AND ADJUSTING FUEL INJECTION TIMING.....703
ACCELERATOR PEDAL.....704
OPERATING FORCE.....704
OPERATING ANGLE.....705
SPEED LEVER.....706
OPERATING FORCE.....706
TRAVEL.....706
STALL SPEEDS.....707
TORQUE CONVERTER STALL SPEED.....707
HYDRAULIC STALL SPEED.....708
FULL STALL SPEED.....708
TORQUE CONVERTER OIL PRESSURE.....709
TRANSMISSION OIL PRESSURE.....709
EMERGENCY MANUAL SPOOL.....711
OPERATION.....711
STEERING WHEEL.....713
PLAY.....713
OPERATING FORCE.....713
OPERATING TIME.....714
STEERING OIL PRESSURE.....715
METHOD OF MEASURING MAIN RELIEF PRESSURE.....715
METHOD OF ADJUSTING MAIN RELIEF PRESSURE.....716
BRAKE.....717
BRAKE PEDAL.....717
OPERATING FORCE.....717
TRAVEL.....717
BRAKE PEDAL LINKAGE.....718
TESTING.....718
ADJUSTING.....718
BRAKE PERFORMANCE.....720
BRAKE OIL PRESSURE.....721
BRAKE DISC WEAR.....722
BLEEDING AIR.....723
PARKING BRAKE.....724
PARKING BRAKE PERFORMANCE.....724
PARKING BRAKE LINKAGE.....725
DISC WEAR.....726
TESTING.....726
MEASURING.....727
WORK EQUIPMENT.....728
CONTROL LEVER.....728
PPC VALVE.....729
MEASURING PRESSURE.....729
WORK EQUIPMENT HYDRAULIC PRESSURE.....731
WORK EQUIPMENT MEASUREMENT.....733
HYDRAULIC DRIFT WORK EQUIPMENT.....734
BUCKET POSITIONER.....735
TESTING.....735
ADJUSTING.....735
BOOM KICK-OUT (IF EQUIPPED).....736
TESTING.....736
ADJUSTING.....736
PROXIMITY SWITCH ACTUATION PILOT LAMP (RED).....737
TROUBLESHOOTING GENERAL.....738
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....740
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....742
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....743
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.....743
HANDLING CONTROL BOX.....748
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.....749
CHECKS BEFORE TROUBLESHOOTING.....751
JUDGEMENT OF POWER TRAIN.....752
PRECAUTIONS WHEN TROUBLESHOOTING.....753
SAFETY.....753
METHODS FOR TROUBLESHOOTING.....753
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....755
PREVENTING RECURRENCE OF TROUBLE.....756
HYDRAULIC EQUIPMENT.....756
OIL CHECKS.....756
CLEANING FRAGMENTS OF DAMAGED PARTS.....756
METHOD OF USING TROUBLESHOOTING CHARTS.....757
CATEGORY OF TROUBLESHOOTING CODE NUMBER.....757
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.....757
METHOD OF USING MATRIX TROUBLESHOOTING TABLES.....759
METHOD OF USING ENGINE RELATED CHARTS.....761
TROUBLESHOOTING ELECTRICAL CONNECTORS.....766
CONNECTOR TYPES.....767
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....770
ELECTRICAL CIRCUIT DIAGRAMS.....778
ENGINE START, STOP SYSTEM.....778
PREHEATING SYSTEM.....779
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE).....780
OUTLINE.....781
FUNCTION.....781
TROUBLESHOOTING.....781
FAILURE CODE TABLE.....781
TABLE OF TROUBLESHOOTING MODES AND CAUSES.....782
A-1 TROUBLESHOOTING CODE [12].....783
F SOLENOID SIGNAL SYSTEM.....783
A-2 TROUBLESHOOTING CODE [13].....784
R SOLENOID SIGNAL SYSTEM.....784
A-3 TROUBLESHOOTING CODE [14].....785
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM.....785
A-4 TROUBLESHOOTING CODE [16].....786
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.....786
A-5 TROUBLESHOOTING CODE [20].....787
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM.....787
A-6 TROUBLESHOOTING CODE [21].....788
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.....788
A-7 TROUBLESHOOTING CODE [22].....789
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM.....789
A-8 TROUBLESHOOTING CODE [23].....790
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM.....790
A-10 KICK-DOWN SWITCH SYSTEM.....791
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM.....792
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM.....793
A-13 BUZZER SIGNAL SYSTEM.....794
A-15 CONTROLLER POWER SOURCE SYSTEM.....795
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTM (D-MODE) ECSS.....796
ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC.....1214
ECSS - WORKING CHART.....797
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL.....798
INSPECTION / ADJUSTMENT.....798
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE).....780
E-1 ENGINE DOES NOT START.....781
A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.....801
B. CHECK FUEL SHUT-OFF SOLENOID.....803
E-2 ENGINE DOES NOT STOP.....774
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR......805
E-10 PREHEATING IS NOT CARRIED OUT.....807
E-11 PREHEATING REMAINS ACTUATED.....809
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE).....812
S1 STARTING PERFORMANCE IS POOR.....814
S2 ENGINE DOES NOT START.....815
(1) ENGINE DOES NOT TURN.....815
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT.....816
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START.....817
S-3 ENGINE DOES NOT PICK UP SMOOTHLY.....818
S-4 ENGINE STOPS DURING OPERATIONS.....819
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....820
S-6 ENGINE LACKS OUTPUT (NO POWER).....821
S-7 EXHAUST GAS IS BLACK.....822
S-8 OIL CONSUMPTION IS EXCESSIVE.....823
S-9 OIL BECOMES CONTAMINATED QUICKLY.....824
S-10 FUEL CONSUMPTION IS EXCESSIVE.....825
S-11 OIL IN COOLING WATER.....826
S-12 OIL PRESSURE LAMP LIGHTS UP.....827
S-13 OIL LEVEL RISES.....828
S-14 WATER TEMPERATURE BECOMES TOO HIGH.....829
S-15 ABNORMAL NOISE IS MADE.....830
S-16 VIBRATION IS EXCESSIVE.....831
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE).....832
T-1 MACHINE DOES NOT START.....834
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.....835
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS.....837
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEARS.....838
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....839
T-6 STEERING WHEEL DOES NOT TURN.....840
T-7 STEERING IS HEAVY.....841
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK.....842
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.....842
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT.....843
T-11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT.....843
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.....844
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS.....845
T-14 BOOM DOES NOT RISE.....846
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.....847
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.....848
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).....848
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM.....848
T-19 BOOM SHAKES DURING OPERATION.....849
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.....849
T-21 BUCKET DOES NOT TILT BACK.....850
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER.....851
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.....852
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.....852
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.....852
T-26 BUCKET SHAKES DURING LOADING OPERATION.....853
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.....853
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES NOT MOVE SMOOTHLY.....854
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER.....856
SERVICE TOOLS.....858
GAUGE MANIFOLD.....858
STRUCTURE AND HANDLING OF GAUGE MANIFOLD.....859
CHARGING HOSES.....861
GAS LEAK DETECTOR.....862
HALIDE TORCH LEAK DETECTOR.....862
ELECTRIC LEAK TESTER.....864
VALVE FOR SERVICE CANS.....866
MAINTENANCE PROCEDURE.....867
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING.....867
PROHIBITED WORK.....867
OTHER PRECAUTIONS.....867
BLEEDING AIR FROM REFRIGERATION CIRCUIT.....869
PURPOSE.....869
CONNECTING GAUGE MANIFOLD.....869
EVACUATION.....870
AIR-TIGHTNESS CHECK.....870
GAS-LEAK CHECK.....871
EVACUATION (REPEATING).....871
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT.....872
CHARGING FROM THE HIGH-PRESSURE SIDE.....872
CHARGING FROM THE LOW PRESSURE SIDE.....873
WHEN THE AMBIENT TEMPERATURE IS LOW.....874
WHEN THE AMBIENT TEMPERATURE IS HIGH.....874
REPLACING SERVICE CANS.....875
CHECKING THE AMOUNT OF REFRIGERANT.....875
REMOVAL OF GAUGE MANIFOLD.....877
DISCHARGING THE REFRIGERANT.....877
DAILY CHECKS.....878
CHECK REFRIGERANT LEVEL.....878
CLEANING THE CONDENSER.....878
CHECKING THE V-BELT.....878
CHECKING OIL LEVEL.....879
PROCEDURE FOR CHECKING.....879
PROCEDURE FOR CHECKING OIL LEVEL.....879
ADDING AND REMOVING OIL.....880
ADDING OIL BY EVACUATION.....880
TROUBLESHOOTING.....881
VISUAL AND ACOUSTICAL CHECKS.....881
DEFECTIVE COOLING.....882
TROUBLESHOOTING TABLE.....884
DEFECTIVE HEATING.....886
TROUBLESHOOTING USING GAUGE MANIFOLD.....887
PREPARATIONS BEFORE MEASURING.....887
INSUFFICIENT REFRIGERANT.....887
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER.....888
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 COMPRESSION BY COMPRESSOR.....893
30 DISASSEMBLY AND ASSEMBLY.....894
METHOD OF USING MANUAL.....898
PRECAUTIONS DURING OPERATION.....899
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.....899
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.....900
PRECAUTIONS WHEN COMPLETING THE OPERATIONS.....901
OTHER PRECAUTIONS.....901
SPECIAL TOOL LIST.....902
ENGINE COMPONENTS.....904
ALTERNATOR ASSEMBLY.....904
CYLINDER HEAD ASSEMBLY.....904
ENGINE OIL COOLER ASSEMBLY.....904
FUEL INJECTION PUMP ASSEMBLY.....904
NOZZLE HOLDER ASSEMBLY.....904
STARTING MOTOR ASSEMBLY.....904
THERMOSTAT ASSEMBLY.....904
TURBOCHARGER ASSEMBLY.....904
WATER PUMP ASSEMBLY.....904
COVERS AND LADDER.....905
REMOVAL.....905
INSTALLATION.....906
ENGINE HOOD.....907
REMOVAL.....907
INSTALLATION.....908
RADIATOR.....909
REMOVAL.....909
INSTALLATION.....912
ENGINE.....913
REMOVAL.....913
INSTALLATION.....920
EXHAUST MUFFLER.....921
REMOVAL.....921
INSTALLATION.....921
AIR CLEANER.....922
REMOVAL.....922
INSTALLATION.....922
TORQUE CONVERTER CHARGING PUMP.....923
REMOVAL.....923
INSTALLATION.....923
TORQUE CONVERTER, TRANSMISSION.....924
REMOVAL.....924
INSTALLATION.....931
TORQUE CONVERTER.....933
DISASSEMBLY.....933
ASSEMBLY.....935
TRANSMISSION.....937
DISASSEMBLY.....937
DISASSEMBLY OF PARKING BRAKE.....946
ASSEMBLY OF PARKING BRAKE.....948
ASSEMBLY.....951
TRANSMISSION CLUTCH PACK.....963
DISASSEMBLY.....963
1ST, REVERSE CLUTCH.....963
FORWARD, 2ND CLUTCH PACK.....965
3RD, 4TH CLUTCH PACK.....967
ASSEMBLY.....969
1ST, REVERSE CLUTCH.....969
FORWARD, 2ND CLUTCH.....974
3RD, 4TH CLUTCH.....978
TRANSMISSION CONTROL VALVE.....983
REMOVAL.....983
INSTALLATION.....985
DISASSEMBLY.....987
ASSEMBLY.....989
TRANSMISSION SOLENOID VALVE.....992
DISASSEMBLY.....992
ASSEMBLY.....993
TRANSMISSION ACCUMULATOR VALVE.....994
DISASSEMBLY.....994
ASSEMBLY.....995
DRIVE SHAFT.....996
DISASSEMBLY.....996
ASSEMBLY.....997
FRONT AXLE.....998
REMOVAL.....998
INSTALLATION.....999
REAR AXLE.....1000
REMOVAL.....1000
INSTALLATION.....1004
DIFFERENTIAL.....1009
DISASSEMBLY.....1009
ASSEMBLY.....1013
AXLE HOUSING.....1023
DISASSEMBLY.....1023
ASSEMBLY.....1028
CENTER HINGE PIN.....1036
REMOVAL.....1036
INSTALLATION.....1044
PRIORITY VALVE.....1053
REMOVAL.....1053
INSTALLATION.....1054
STEERING VALVE.....1055
REMOVAL.....1055
INSTALLATION.....1057
DISASSEMBLY.....1058
DISASSEMBLY OF ROTOR.....1058
DISASSEMBLY OF CONTROL SIDE.....1059
ASSEMBLY.....1061
ASSEMBLY OF CONTROL SIDE.....1061
ASSEMBLY OF ROTOR.....1063
MAIN CONTROL VALVE.....1066
REMOVAL.....1066
INSTALLATION.....1068
DISASSEMBLY.....1069
ASSEMBLY.....1071
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES.....1073
PPC VALVE.....1075
REMOVAL.....1075
INSTALLATION.....1076
STEERING CYLINDER.....1077
REMOVAL.....1077
INSTALLATION.....1079
BRAKE BOOSTER.....1080
REMOVAL.....1080
INSTALLATION.....1082
DISASSEMBLY.....1083
ASSEMBLY.....1086
PARKING BRAKE.....1091
REMOVAL.....1091
INSTALLATION.....1093
HYDRAULIC TANK.....1095
REMOVAL.....1095
INSTALLATION.....1096
HYDRAULIC FILTER.....1097
REMOVAL.....1097
INSTALLATION.....1097
STEERING PUMP.....1098
REMOVAL.....1098
INSTALLATION.....1099
BUCKET CYLINDER.....1100
REMOVAL.....1100
INSTALLATION.....1101
BOOM CYLINDER.....1102
REMOVAL.....1102
INSTALLATION.....1103
HYDRAULIC CYLINDER.....1104
DISASSEMBLY.....1104
ASSEMBLY.....1106
ECSS SYSTEM.....1109
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL.....1109
ECSS SOLENOID VALVE.....1110
REMOVAL.....1110
INSTALLATION.....1110
ECSS CONTROL VALVE.....1111
REMOVAL.....1111
INSTALLATION.....1111
WORK EQUIPMENT.....1112
REMOVAL.....1112
INSTALLATION.....1115
FUEL TANK.....1118
REMOVAL.....1118
INSTALLATION.....1119
COUNTERWEIGHT.....1120
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS.....1120
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS.....1120
REMOVAL OF REAR COUNTERWEIGHT.....1120
INSTALLATION OF REAR COUNTERWEIGHT.....1121
INSTRUMENT PANEL.....1122
REMOVAL.....1122
INSTALLATION.....1122
AIR CONDITIONING.....1123
AIR CONDITIONER UNIT.....1123
REMOVAL.....1123
INSTALLATION.....1129
AIR CONDITIONER CONDENSER.....1130
REMOVAL.....1130
INSTALLATION.....1131
DRYER RECEIVER.....1133
REMOVAL.....1133
INSTALLATION.....1133
AIR CONDITIONER COMPRESSOR.....1135
REMOVAL.....1135
INSTALLATION.....1136
40 MAINTENANCE STANDARD.....1139
ENGINE MOUNT, TRANSMISSION MOUNT.....1140
TORQUE CONVERTER CHARGING PUMP.....1142
TORQUE CONVERTER.....1144
TRANSMISSION.....1146
TRANSMISSION (1/3).....1146
TRANSMISSION (2/3).....1150
TRANSMISSION (3/3).....1154
REVERSE, 1ST CLUTCH.....1156
FORWARD, 2ND CLUTCH.....1158
3RD, 4TH CLUTCH.....1160
TRANSMISSION CONTROL VALVE.....1162
UPPER VALVE.....1162
LOWER VALVE.....1164
SOLENOID VALVE.....1166
ACCUMULATOR VALVE.....1168
DRIVE SHAFT.....1170
DIFFERENTIAL.....1172
DIFERENTIAL (1/2).....1172
DIFFERENTIAL (2/2).....1174
FINAL DRIVE.....1176
AXLE MOUNT.....1178
ADDITIONAL COUNTERWEIGHT.....1180
CENTER HINGE PIN.....1182
STEERING COLUMN.....1184
PRIORITY VALVE.....1186
STEERING CYLINDER MOUNT.....1187
BRAKE BOOSTER.....1188
BRAKE.....1190
PARKING BRAKE.....1191
HYDRAULIC PUMP (SAL40+14+8).....1192
MAIN CONTROL VALVE.....1193
2-SPOOL VALVE.....1193
3-SPOOL VALVE.....1196
HYDRAULIC CYLINDER.....1199
WORK EQUIPMENT LINKAGE.....1200
BUCKET.....1202
BUCKET POSITIONER AND BOOM KICK-OUT.....1204
90 OTHERS.....1207
ELECTRICAL WIRING DIAGRAM (1/5).....1209
ELECTRICAL WIRING DIAGRAM (2/5).....1211
ELECTRICAL WIRING DIAGRAM (3/5).....1213
ELECTRICAL WIRING DIAGRAM (4/5).....1215
ELECTRICAL WIRING DIAGRAM (5/5).....1217
CEBM005201 - Wheel Loader WA180PT-3MC avance plus Shop Manual.....1221
COVER.....1221
CONTENTS.....1222
FOREWORD.....1233
SAFETY.....1233
SAFETY NOTICE.....1233
IMPORTANT SAFETY NOTICE.....1233
GENERAL PRECAUTIONS.....1233
PREPARATIONS FOR WORK.....1233
PRECAUTIONS DURING WORK.....1233
GENERAL.....1235
HOW TO READ THE SHOP MANUAL.....1236
VOLUMES.....1236
DISTRIBUTION AND UPDATING.....1236
FILING METHOD.....1236
REVISED EDITION MARK.....1236
REVISIONS.....1236
SYMBOLS.....1236
HOISTING INSTRUCTIONS.....1237
HOISTING.....1237
WIRE ROPES.....1237
COATING MATERIALS.....1238
STANDARD TIGHTENING TORQUE.....1240
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.....1240
TIGHTENING TORQUE OF HOSE NUTS.....1241
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.....1241
TIGHTENING TORQUE FOR FLARED NUTS.....1241
ELECTRIC WIRE CODE.....1242
CLASSIFICATION BY THICKNESS.....1242
CLASSIFICATION BY COLOR AND CODE.....1242
CONVERSION TABLES.....1243
METHOD OF USING THE CONVERSION TABLE.....1243
01 GENERAL.....1249
SPECIFICATION DRAWINGS.....1250
BUCKET ATTACHMENT.....1250
DIMENSIONS FOR BUCKET ATTACHMENT.....1251
FORK ATTACHMENT.....1252
DIMENSIONS FOR FORK ATTACHMENT.....1253
MATERIAL HANDLING ARM ATTACHEMNT.....1254
DIMENSIONS FOR MATERIAL HANDLING ARM ATTACHMENT.....1255
SPECIFICATION.....1256
WEIGHT TABLE.....1259
LIST OF LUBRICANT AND WATER.....1261
ENGINE OIL SPECIFICATIONS.....1262
NORMAL OPERATION.....1262
ARCTIC OPERATION.....1262
DIESEL FUEL SPECIFICATIONS.....1263
COOLANT SPECIFICATIONS.....1263
GENERAL.....1263
WATER.....1263
ANTIFREEZE.....1264
INHIBITORS/CONDITIONERS.....1265
10 STRUCTURE AND FUNCTION.....1269
POWER TRAIN.....1273
PATH OF POWER TRANSMISSION.....1274
TORQUE CONVERTER, TRANSMISSION PIPING.....1276
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.....1278
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND.....1278
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.....1279
ENGINE STOPPED.....1279
TORQUE CONVERTER.....1280
TORQUE CONVERTER OIL FILTER.....1282
TRANSMISSION.....1284
CLUTCH.....1286
REVERSE 1ST CLUTCH.....1286
FORWARD, 2ND CLUTCH.....1287
3RD, 4TH CLUTCH.....1287
FORWARD 1ST.....1289
FORWARD 2ND.....1290
FORWARD 3RD.....1291
FORWARD 4TH.....1292
REVERSE 1ST.....1293
TRANSMISSION CONTROL VALVE.....1294
UPPER VALVE.....1295
LOWER VALVE.....1296
TRANSMISSION SOLENOID VALVE.....1297
TORQUE CONVERTER OUTLET PORT VALVE.....1298
PILOT REDUCING VALVE.....1299
TRANSMISSION SOLENOID VALVE.....1300
PRIORITY VALVE.....1301
MAIN REGULATOR VALVE.....1302
QUICK RETURN VALVE.....1303
MODULATION FILL VALVE.....1307
DIRECTIONAL SELECTOR SPOOL.....1309
EMERGENCY MANUAL SPOOL.....1310
OPERATION OF FORWARD 1ST.....1312
ACCUMULATOR VALVE.....1314
TRANSMISSION CONTROL.....1316
DRIVE SHAFT.....1317
AXLE.....1318
FRONT AXLE.....1318
FRONT DIFFERENTIAL.....1319
REAR AXLE.....1320
REAR DIFFERENTIAL.....1321
TORQUE PROPORTIONING DIFFERENTIAL.....1323
FINAL DRIVE.....1324
AXLE MOUNT.....1326
CENTER HINGE PIN.....1328
STEERING PIPING.....1329
STEERING COLUMN.....1330
PRIORITY VALVE.....1331
CUSHION VALVE.....1334
STEERING VALVE (ORBIT-ROLL).....1336
CONNECTION BETWEEN HAND PUMP AND SLEEVE.....1342
BRAKE.....1344
BRAKE PIPING.....1344
BRAKE CONTROL.....1345
BRAKE BOOSTER.....1346
BRAKE.....1349
PARKING BRAKE CONTROL.....1351
PARKING BRAKE.....1352
HYDRAULIC.....1354
HYDRAULIC PIPING.....1354
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....1356
ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD".....1356
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....1358
HYDRAULIC TANK.....1360
OIL FILTER BYPASS VALVE.....1361
BREATHER.....1362
PPC VALVE.....1364
PPC RELIEF VALVE.....1370
ACCUMULATOR.....1371
FOR PPC VALVE.....1371
MAIN CONTROL VALVE.....1372
3-SPOOL.....1372
RELIEF VALVE.....1374
SAFETY VALVE (WITH SUCTION).....1375
SUCTION VALVE.....1376
BOOM, BUCKET AND ATTACHMENT SPOOL AT NEUTRAL POSITION.....1377
BOOM SPOOL AT RAISE POSITION.....1378
BOOM SPOOL AT LOWER POSITION.....1379
BOOM SPOOL AT FLOAT POSITION.....1380
BUCKET / FORK SPOOL AT TILT ROLL BACK POSITION.....1381
BUCKET / FORK SPOOL AT DUMP POSITION - SLOW SPEED.....1382
BUCKET / FORK SPOOL AT DUMP POSITION - FAST SPEED.....1383
COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED.....1384
COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL.....1385
AUXILIARY ATTACHMENT PPC VALVE IN CLOSED POSITION.....1386
AUXILIARY ATTACHMENT PPC VALVE IN OPEN POSITION.....1387
PILOT SOLENOID VALVE.....1388
WORK EQUIPMENT.....1391
WORK EQUIPMENT LEVER HYDRAULIC CONNECTIONS.....1391
WORK EQUIPMENT LINKAGE.....1392
BUCKET.....1394
BUCKET POSITIONER AND BOOM KICK-OUT.....1395
BUCKET POSITIONER.....1396
BOOM KICK-OUT.....1396
PROXIMITY SWITCH.....1398
ROPS CAB.....1401
AIR CONDITIONER.....1402
AIR CONDITIONER AND HEATER PIPING.....1402
ECSS.....1403
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM.....1404
CENTRAL PANEL.....1406
SENSORS.....1407
ENGINE OIL PRESSURE.....1407
BRAKE OIL LEVEL.....1407
ENGINE SPEED SENSOR.....1408
ENGINE.....1409
ENGINE STARTING CIRCUIT.....1409
ENGINE STOP CIRCUIT.....1410
AUTOMATIC PREHEATING CIRCUIT.....1411
QUICK HEATING SYSTEM (QHS).....1411
QHS CONTROLLER.....1413
HEATER RELAY.....1413
RIBBON HEATER.....1414
QHS WATER TEMPERATURE SENSOR.....1414
TRANSMISSION AUTO-SHIFT CONTROL.....1415
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.....1416
SHIFT CONTROL SYSTEM FUNCTION.....1417
INPUT SIGNALS.....1417
OUTPUT SIGNALS.....1418
SHIFT CHARACTERISTICS.....1419
SAFETY FUNCTION.....1423
TROUBLESHOOTING.....1423
TRANSMISSION CONTROLLER.....1424
CONNECTOR SIGNALS.....1424
COMBINATION SWITCH.....1425
TRANSMISSION CUT-OFF FUNCTION.....1426
PARKING BRAKE FUNCTION.....1428
KICK-DOWN SWITCH.....1429
KICK-DOWN ELECTRICAL CIRCUIT.....1430
KICK-DOWN SWITCH OPERATED.....1431
KICK-DOWN SWITCH ACTUATION - CANCELED (1).....1432
KICK-DOWN SWITCH ACTUATION - CANCELED (2).....1433
DUMP SPEED SWITCH.....1434
QUICK COUPLER SWITCH.....1435
ELECTRICAL WIRING ILLUSTRATION.....1436
ELECTRICAL WIRING DIAGRAM (1/6).....1437
ELECTRICAL WIRING DIAGRAM (2/6).....1439
ELECTRICAL WIRING DIAGRAM (3/6).....1441
ELECTRICAL WIRING DIAGRAM (4/6).....1443
ELECTRICAL WIRING DIAGRAM (5/6).....1445
ELECTRICAL WIRING DIAGRAM (6/6).....1447
20 TESTING, ADJUSTING AND TROUBLESHOOTING.....1449
STANDARD VALUE TABLE.....1453
ENGINE TABLE - IN CHASSIS.....1453
CHASSIS TABLE.....1454
SERVICE TOOLS TABLE.....1459
ENGINE.....1461
ADJUSTING ENGINE STOP MOTOR CABLE.....1461
ADJUSTING ENGINE STOP SOLENOID.....1461
MEASURING AND ADJUSTING VALVE CLEARANCE.....1461
MEASURING BLOW-BY PRESSURE.....1461
MEASURING COMPRESSION PRESSURE.....1461
MEASURING COOLANT TEMPERATURE.....1461
MEASURING ENGINE LUBRICATING OIL PRESSURE.....1461
MEASURING ENGINE SPEEDS.....1461
MEASURING EXHAUST COLOR.....1461
MEASURING EXHAUST GAS TEMPRERATURE.....1461
MEASURING FUEL FILTER INLET RESTRICTION.....1461
TEST AND ADJUSTING FAN BELT TENSION.....1461
TEST AND ADJUSTING FUE IN JECTIO TIMING.....1461
ACCELERATOR PEDAL.....1462
OPERATING FORCE.....1462
OPERATING ANGLE.....1463
SHIFT LEVER.....1464
OPERATING FORCE.....1464
TRAVEL.....1464
STALL SPEEDS.....1465
TORQUE COVERTER STALL SPEED.....1465
HYDRAULIC STALL SPEED .....1466
FULL STALL SPEED.....1466
TORQUE CONVERTER.....1467
TRANSMISSION OIL PRESSURE.....1467
EMERGENCY MANUAL SPOOL.....1469
OPERATION.....1469
STEERING WHEEL.....1471
PLAY.....1471
OPERATING FORCE.....1471
OPERATING TIME.....1472
STEERING OIL PRESSURE.....1473
METHOD OF MEASURING MAIN RELIF PRESSURE.....1473
METHOD OF ADJUSTING MAIN RELIEF PRESSURE.....1474
BRAKE.....1475
BRAKE PEDAL.....1475
OPERATING EFFORT.....1475
TRAVEL.....1475
BRAKE PEDAL LINKAGE.....1476
TESTING.....1476
ADJUSTING.....1476
BRAKE PERFORMANCE.....1478
BRAKE OIL PRESSURE.....1479
BRAKE DISC WEAR.....1480
BLEEDING AIR.....1481
PARKING BRAKE.....1482
PARKING BRAKE PERFORMANCE.....1482
PARKING BRAKE LINKAGE.....1483
PARKING BRAKE PISTION STROKE.....1484
PARKING BRAKE DISC WEAR.....1485
TESTING.....1485
MEASURING.....1486
WORK EQUIPMENT.....1487
PPC VALVE.....1487
MEASURING PRESSURE.....1487
HYDRAULIC PRESSURE.....1489
MEASUREMENT.....1492
HYDRAULIC DRIFT.....1493
BOOM KICK-OUT.....1494
BUCKET/FORK POSITIONER.....1495
FUEL LEVEL SENSOR.....1497
CHECKING FOR ABNORMALITY.....1497
TROUBLESHOOTING GENERAL.....1499
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....1501
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....1503
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....1504
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.....1504
HANDLING CONTROL BOX.....1509
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.....1510
CHECKS BEFORE TROUBLESHOOTING.....1512
JUDGEMENT OF POWER TRAIN.....1513
PRECAUTIONS WHEN TROUBLESHOOTING.....1514
SAFETY.....1514
METHODS FOR TROUBLESHOOTING.....1514
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....1516
PREVENTING RECURRENCE OF TROUBLE.....1517
HYDRAULIC EQUIPMENT.....1517
OIL CHECKS.....1517
CLEANING FRAGMENTS OF DAMAGED PARTS.....1517
METHOD OF USING TROUBLESHOOTING CHARTS.....1518
CATEGORY OF TROUBLESHOOTING CODE NUMBER.....1518
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.....1518
METHOD OF USING MATRIX TROUBLESHOOTING TABLES.....1520
METHOD OF USING ENGINE RELATED CHARTS.....1522
TROUBLESHOOTING ELECTRICAL CONNECTORS.....1527
CONNECTOR TYPES.....1528
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....1531
ELECTRICAL CIRCUIT DIAGRAMS.....1539
ENGINE START, STOP SYSTEM.....1539
PREHEATING SYSTEM.....1540
WORK EQUIPMENT DUMP SPEED AND QUICK COUPLER SYSTEM.....1541
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE).....1543
OUTLINE.....1544
FUNCTION.....1544
TROUBLESHOOTING.....1544
FAILURE CODE TABLE.....1544
TABLE OF TROUBLESHOOTING MODES AND CAUSES.....1545
A-1 TROUBLESHOOTING CODE [12].....1546
F SOLENOID SIGNAL SYSTEM.....1546
A-2 TROUBLESHOOTING CODE [13].....1547
R SOLENOID SIGNAL SYSTEM.....1547
A-3 TROUBLESHOOTING CODE [14].....1548
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM.....1548
A-4 TROUBLESHOOTING CODE [16].....1549
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.....1549
A-5 TROUBLESHOOTING CODE [20].....1550
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM.....1550
A-6 TROUBLESHOOTING CODE [21].....1551
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.....1551
A-7 TROUBLESHOOTING CODE [22].....1552
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM.....1552
A-8 TROUBLESHOOTING CODE [23].....1553
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM.....1553
A-10 KICK-DOWN SWITCH SYSTEM.....1554
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM.....1555
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM.....1556
A-13 BUZZER SIGNAL SYSTEM.....1557
A-15 CONTROLLER POWER SOURCE SYSTEM.....1558
TROUBLESHOOTING ELECTRICALLY CONTROLLED SUSPENSION SYSTEM (D MODE - ECSS).....1559
ECSS - ELECTRICAL/HYDRAULIC SCHEMATIC.....1560
ECSS - WORKING CHART.....1560
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL .....1561
INSPECTION/ADJUSTMENT.....1561
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).....1563
E-1 ENGINE DOES NOT START.....1564
A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.....1564
B. CHECK FUEL SHUT-OFF SOLENOID.....1566
E-2 ENGINE DOES NOT STOP.....1567
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR......1568
E-10 PREHEATING IS NOT CARRIED OUT.....1570
E-11 PREHEATING REMAINS ACTUATED.....1572
E-12 ABNORMALITY IN QUICK COUPLER SYSTEM.....1574
E-13 ABNORMALITY IN TILT CYLINDER OPERATION.....1575
A. ONLY SLOW DUMP SPEED IS AVAILABLE.....1575
B. DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE.....1576
C. TILT BACK IS NOT AVAILABLE.....1577
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE).....1579
S-1 STARTING PERFORMANCE IS POOR.....1581
S-2 ENGINE DOES NOT START.....1582
A. ENGINE DOES NOT TURN.....1564
B. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT.....1583
C. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START.....1584
S-3 ENGINE DOES NOT PICK UP SMOOTHLY.....1585
S-4 ENGINE STOPS DURING OPERATIONS.....1586
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....1587
S-6 ENGINE LACKS OUTPUT (NO POWER).....1588
S-7 EXHAUST GAS IS BLACK.....1589
S-8 OIL CONSUMPTION IS EXCESSIVE.....1590
S-9 OIL BECOMES CONTAMINATED QUICKLY.....1591
S-10 FUEL CONSUMPTION IS EXCESSIVE.....1592
S-11 OIL IN COOLING WATER.....1593
S-12 OIL PRESSURE LAMP LIGHTS UP.....1594
S-13 OIL LEVEL RISES.....1595
S-14 WATER TEMPERATURE BECOMES TOO HIGH.....1596
S-15 ABNORMAL NOISE IS MADE.....1597
S-16 VIBRATION IS EXCESSIVE.....1598
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE).....1599
POWER TRAIN.....1601
T-1 MACHINE DOES NOT START.....1601
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.....1602
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.....1604
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.....1605
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....1606
STEERING SYSTEM.....1607
T-6 STEERING WHEEL DOES NOT TURN.....1607
T-7 STEERING IS HEAVY.....1608
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK.....1609
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.....1609
BRAKE SYSTEM.....1610
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.....1610
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS.....1611
WORK EQUIPMENT.....1612
T-12 BOOM DOES NOT RISE.....1612
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.....1613
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.....1614
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).....1614
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM.....1614
T-17 BOOM SHAKES DURING OPERATION.....1615
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.....1615
T-19 BUCKET DOES NOT TILT BACK.....1616
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER.....1617
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.....1618
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.....1618
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.....1618
T-24 BUCKET SHAKES DURING LOADING OPERATION.....1619
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.....1619
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY.....1620
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER.....1621
SERVICE TOOLS.....1623
GAUGE MANIFOLD.....1623
STRUCTURE AND HANDLING OF GAUGE MANIFOLD.....1624
CHARGING HOSES.....1626
GAS LEAK DETECTOR.....1627
HALIDE TORCH LEAK DETECTOR.....1627
ELECTRIC LEAK TESTER.....1629
VALVE FOR SERVICE CANS.....1631
MAINTENANCE PROCEDURE.....1632
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING.....1632
PROHIBITED WORK.....1632
OTHER PRECAUTIONS.....1632
BLEEDING AIR FROM REFRIGERATION CIRCUIT.....1634
PURPOSE.....1634
CONNECTING GAUGE MANIFOLD.....1634
EVACUATION.....1635
AIR-TIGHTNESS CHECK.....1635
GAS-LEAK CHECK.....1636
EVACUATION (REPEATING).....1636
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT.....1637
CHARGING FROM THE HIGH-PRESSURE SIDE.....1637
CHARGING FROM THE LOW PRESSURE SIDE.....1638
WHEN THE AMBIENT TEMPERATURE IS LOW.....1639
WHEN THE AMBIENT TEMPERATURE IS HIGH.....1639
REPLACING SERVICE CANS.....1640
CHECKING THE AMOUNT OF REFRIGERANT.....1640
REMOVAL OF GAUGE MANIFOLD.....1642
DISCHARGING THE REFRIGERANT.....1642
DAILY CHECKS.....1643
CHECK REFRIGERANT LEVEL.....1643
CLEANING THE CONDENSER.....1643
CHECKING THE V-BELT.....1643
CHECKING OIL LEVEL.....1644
PROCEDURE FOR CHECKING.....1644
PROCEDURE FOR CHECKING OIL LEVEL.....1644
ADDING AND REMOVING OIL.....1645
ADDING OIL BY EVACUATION.....1645
TROUBLESHOOTING.....1646
VISUAL AND ACOUSTICAL CHECKS.....1646
DEFECTIVE COOLING.....1647
TROUBLESHOOTING TABLE.....1649
DEFECTIVE HEATING.....1651
TROUBLESHOOTING USING GAUGE MANIFOLD.....1652
PREPARATIONS BEFORE MEASURING.....1652
INSUFFICIENT REFRIGERANT.....1652
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER.....1653
AIR INSIDE REFRIGERATION SYSTEM.....1654
MOISTURE IN REFRIGERATING SYSTEM.....1655
REFRIGERANT DOES NOT CIRCULATE.....1656
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE.....1657
DEFECTIVE COMPRESSION BY COMPRESSOR.....1658
30 DISASSEMBLY AND ASSEMBLY.....1659
METHOD OF USING MANUAL.....1663
PRECAUTIONS DURING OPERATION.....1664
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.....1664
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.....1665
PRECAUTIONS WHEN COMPLETING THE OPERATIONS.....1666
OTHER PRECAUTIONS.....1666
SPECIAL TOOL LIST.....1667
ENGINE COMPONENTS.....1669
ALTERNATOR ASSEMBLY.....1669
CYLINDER HEAD ASSEMBLY.....1669
ENGINE OIL COOLER ASSEMBLY.....1669
FUEL INJECTION PUMP ASSEMBLY.....1669
NOZZLE HOLDER ASSEMBLY.....1669
STARTING MOTOR ASSEMBLY.....1669
THERMOSTAT ASSEMBLY.....1669
TURBOCHARGER ASSEMBLY.....1669
WATER PUMP ASSEMBLY.....1669
COVERS AND LADDER.....1670
REMOVAL.....1670
INSTALLATION.....1671
ENGINE HOOD.....1672
REMOVAL.....1672
INSTALLATION.....1673
RADIATOR.....1674
REMOVAL.....1674
INSTALLATION.....1677
ENGINE.....1678
REMOVAL.....1678
INSTALLATION.....1685
EXHAUST MUFFLER.....1686
REMOVAL.....1686
INSTALLATION.....1686
AIR CLEANER.....1687
REMOVAL.....1687
INSTALLATION.....1687
TORQUE CONVERTER CHARGING PUMP.....1688
REMOVAL.....1688
INSTALLATION.....1688
TORQUE CONVERTER, TRANSMISSION.....1689
REMOVAL.....1689
INSTALLATION.....1696
TORQUE CONVERTER.....1698
DISASSEMBLY.....1698
ASSEMBLY.....1700
TRANSMISSION.....1702
DISASSEMBLY.....1702
DISASSEMBLY OF PARKING BRAKE.....1711
ASSEMBLY OF PARKING BRAKE.....1713
ASSEMBLY.....1716
TRANSMISSION CLUTCH PACK.....1728
DISASSEMBLY.....1728
1ST, REVERSE CLUTCH.....1728
FORWARD, 2ND CLUTCH PACK.....1730
3RD, 4TH CLUTCH PACK.....1732
ASSEMBLY.....1734
1ST, REVERSE CLUTCH.....1734
FORWARD, 2ND CLUTCH.....1739
3RD, 4TH CLUTCH.....1743
TRANSMISSION CONTROL VALVE.....1748
REMOVAL.....1748
INSTALLATION.....1750
DISASSEMBLY.....1751
ASSEMBLY.....1753
TRANSMISSION SOLENOID VALVE.....1756
DISASSEMBLY.....1756
ASSEMBLY.....1757
TRANSMISSION ACCUMULATOR VALVE.....1758
DISASSEMBLY.....1758
ASSEMBLY.....1759
DRIVE SHAFT.....1760
DISASSEMBLY.....1760
ASSEMBLY.....1761
FRONT AXLE.....1762
REMOVAL.....1762
INSTALLATION.....1763
REAR AXLE.....1764
REMOVAL.....1764
INSTALLATION.....1768
DIFFERENTIAL.....1773
DISASSEMBLY.....1773
ASSEMBLY.....1777
AXLE HOUSING.....1787
DISASSEMBLY.....1787
ASSEMBLY.....1792
CENTER HINGE PIN.....1800
REMOVAL.....1800
INSTALLATION.....1808
PILOT SOLENOID VALVE.....1817
REMOVAL.....1817
INSTALLATION.....1817
DISASSEMBLY OF SOLENOID VALVE.....1818
ASSEMBLY OF SOLENOID VALVE.....1819
DISASSEMBLY OF PILOT VALVE.....1820
ASSEMBLY OF PILOT VALVE.....1821
PRIORITY VALVE.....1822
REMOVAL.....1822
INSTALLATION.....1823
STEERING VALVE.....1824
REMOVAL.....1824
INSTALLATION.....1826
DISASSEMBLY.....1827
DISASSEMBLY OF ROTOR.....1827
DISASSEMBLY OF CONTROL SIDE.....1828
ASSEMBLY.....1830
ASSEMBLY OF CONTROL SIDE.....1830
ASSEMBLY OF ROTOR.....1832
MAIN CONTROL VALVE.....1835
REMOVAL.....1835
INSTALLATION.....1837
SEPARATION OF SPOOLS.....1838
ASSEMBLY OF SPOOLS.....1838
ATTACHMENT SPOOL ASSEMBLY.....1839
DISASSEMBLY.....1839
ASSEMBLY.....1841
BUCKET DUMP SPOOL ASSEMBLY.....1843
DISASSEMBLY.....1843
ASSEMBLY.....1844
BOOM LIFT SPOOL.....1846
DISASSEMBLY.....1846
ASSEMBLY.....1847
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES.....1849
PPC VALVE.....1851
REMOVAL.....1851
INSTALLATION.....1852
STEERING CYLINDER.....1853
REMOVAL.....1853
INSTALLATION.....1855
BRAKE BOOSTER.....1856
REMOVAL.....1856
INSTALLATION.....1858
DISASSEMBLY.....1859
ASSEMBLY.....1862
PARKING BRAKE.....1867
REMOVAL.....1867
INSTALLATION.....1869
HYDRAULIC TANK.....1871
REMOVAL.....1871
INSTALLATION.....1872
HYDRAULIC FILTER.....1873
REMOVAL.....1873
INSTALLATION.....1873
STEERING PUMP.....1874
REMOVAL.....1874
INSTALLATION.....1875
BUCKET/FORK (TILT) CYLINDERS.....1876
REMOVAL.....1876
INSTALLATION.....1877
BOOM (LIFT) CYLINDERS.....1878
REMOVAL.....1878
INSTALLATION.....1880
HYDRAULIC CYLINDER.....1881
DISASSEMBLY.....1881
ASSEMBLY.....1883
ECSS SYSTEM.....1886
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL.....1886
ECSS SOLENOID VALVE.....1887
REMOVAL.....1887
INSTALLATION.....1887
ECSS CONTROL VALVE.....1888
REMOVAL.....1888
INSTALLATION.....1888
BOOM AND PARALLEL TOOL LINKAGE.....1889
REMOVAL.....1889
INSTALLATION.....1897
FUEL TANK.....1900
REMOVAL.....1900
INSTALLATION.....1901
COUNTERWEIGHT.....1902
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS.....1902
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS.....1902
REMOVAL OF REAR COUNTERWEIGHT.....1902
INSTALLATION OF REAR COUNTERWEIGHT.....1903
INSTRUMENT PANEL.....1904
REMOVAL.....1904
INSTALLATION.....1904
AIR CONDITIONING.....1905
AIR CONDITIONER UNIT.....1905
REMOVAL.....1905
INSTALLATION.....1911
AIR CONDITIONER CONDENSER.....1912
REMOVAL.....1912
INSTALLATION.....1913
DRYER RECEIVER.....1915
REMOVAL.....1915
INSTALLATION.....1915
AIR CONDITIONER COMPRESSOR.....1917
REMOVAL.....1917
INSTALLATION.....1918
40 MAINTENANCE STANDARD.....1919
ENGINE MOUNT, TRANSMISSION MOUNT.....1920
TORQUE CONVERTER CHARGING PUMP.....1922
TORQUE CONVERTER.....1924
TRANSMISSION.....1926
TRANSMISSION (1/3).....1926
TRANSMISSION (2/3).....1930
TRANSMISSION (3/3).....1934
REVERSE, 1ST CLUTCH.....1936
FORWARD, 2ND CLUTCH.....1938
3RD, 4TH CLUTCH.....1940
TRANSMISSION CONTROL VALVE.....1942
UPPER VALVE.....1942
LOWER VALVE.....1944
SOLENOID VALVE.....1946
ACCUMULATOR VALVE.....1948
DRIVE SHAFT.....1950
DIFFERENTIAL.....1952
DIFERENTIAL (1/2).....1952
DIFFERENTIAL (2/2).....1954
FINAL DRIVE.....1956
AXLE MOUNT.....1958
ADDITIONAL COUNTERWEIGHT.....1960
CENTER HINGE PIN.....1962
STEERING COLUMN.....1964
PRIORITY VALVE.....1966
STEERING CYLINDER MOUNT.....1967
BRAKE BOOSTER.....1968
BRAKE.....1970
PARKING BRAKE.....1971
HYDRAULIC PUMP (SAL40+14+8).....1972
MAIN CONTROL VALVE.....1973
3-SPOOL VALVE.....1973
HYDRAULIC CYLINDER.....1976
PPC VALVE.....1978
PILOT SOLENOID VALVE.....1980
WORK EQUIPMENT LINKAGE.....1982
BUCKET POSITIONER AND BOOM KICK-OUT.....1986
90 OTHERS.....1989
HYDRAULIC.....1991
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....1991
BOOM, BUCKET AND ATTACHMENT SPOOL IN NEUTRAL POSITION.....1993
BOOM SPOOL IN RAISE POSITION.....1995
BOOM SPOOL IN LOWER POSITION.....1997
BOOM SPOOL IN FLOAT POSITION.....1999
BUCKET / FORK SPOOL IN TILT/ROLL BACK POSITION.....2001
BUCKET / FORK SPOOL IN DUMP POSITION - SLOW SPEED.....2003
BUCKET / FORK SPOOL IN DUMP POSITION - FAST SPEED.....2005
COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED.....2007
COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL.....2009
AUXILIARY ATTACHMENT IN CLOSE POSITION.....2011
AUXILIARY ATTACHMENT IN OPEN POSITION.....2013
ELECTRICAL WIRING DIAGRAM.....2015
DIAGRAM (1/6).....2015
DIAGRAM (2/6).....2017
DIAGRAM (3/6).....2019
DIAGRAM (4/6).....2021
DIAGRAM (5/6).....2023
DIAGRAM (6/6).....2025
