Komatsu Wheel Loader WA380, WA380Z-series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA380-, WA380Z-series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA380-, WA380Z-series 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: 32,564 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
VEBM440101 WA380-6...1
00 Index and foreword...3
Composition of shop manual...4
Table of contents...6
Index and foreword...17
Safety notice...18
How to read the shop manual...23
Explanation of terms for maintenance standard...25
Handling electric equipment and hydraulic component...27
How to read electric wire code...39
Precautions when carrying out operation...42
Method of disassembling and connecting push-pull type coupler...45
Standard tightening torque table...48
Conversion table...52
01 Specification...57
Specification and technical data...59
Specification dimension drawing...59
Specifications...60
Weight table...64
Table of fuel, coolant and lubricants...66
10 Structure, function and maintenance standard...67
Engine and cooling system...68
Engine mount and transmission mount...68
Cooling system...69
Cooling fan pump...70
Cooling fan motor...78
Power train...87
Power train...87
Power train system diagram...88
Drive shaft...90
Power train piping diagram...91
Torque converter...92
Transmission...100
Flow control valve...117
Valve assembly...118
ECMV...119
Main relief valve and torque converter relief valve...126
Axle...128
Differential...130
Limited slip differential...135
Final drive...142
Steering system...146
Steering piping diagram...146
Steering column...147
Steering pump...148
Steering valve...159
Orbit-roll valve...174
Stop valve...178
Steering relief valve...179
Steering cylinder...180
Emergency steering motor...182
Emergency steering pump...183
Brake system...186
Brake piping diagram...186
Charge valve...187
Brake valve...194
Accumulator (for brake)...199
Brake...200
Parking brake control...205
Parking brake...206
Parking brake solenoid valve...208
Emergency parking brake release valve...210
Undercarriage and frame...212
Axle mount and center hinge pin...212
Tires...216
Hydraulic system, Part 1...218
Hydraulic piping diagram...218
Work equipment control lever linkage...221
Hydraulic tank...222
Power train pump...224
Work equipment pump...225
Work equipment control valve...236
CLSS...250
Each function and operation of each valve...254
Hydraulic system, Part 2...278
PPC valve...278
Stabilizer valve...284
Accumulator (for PPC circuit)...289
Accumulator (for ECSS)...290
Work equipment...292
Work equipment linkage...292
Bucket...294
Bucket positioner and boom kick-out...295
Work equipment cylinder...301
Cab and its attachments...305
Cab...305
Air conditioner...306
Electrical system, Part 1...320
Machine monitor system...320
Machine monitor...325
Electrical system, Part 2...348
Electrical system (Transmission controller system)...348
Transmission controller...382
Electrical system, Part 3...386
Electric transmission control...386
Kickdown switch and hold switch...390
KOMTRAX terminal system...392
Engine starting circuit...394
Engine stopping circuit...396
Preheating circuit...397
Engine power mode selector circuit...398
Engine output derating function...399
Automatic warm-up function...399
Parking brake circuit...400
Sensor...402
Standard service value table...412
Standard service value table for engine...412
Standard service value table for chassis...413
20 Standard value table...411
Standard service value table...412
30 Testing and adjusting...421
Testing and adjusting, Part 1...423
Tools for testing, adjusting, and troubleshooting...423
Measuring engine speed...426
Measuring exhaust gas color...428
Adjusting valve clearance...430
Measuring compression pressure...432
Measuring blow-by pressure...435
Measuring engine oil pressure...436
Measuring intake air (boost) pressure...437
Handling fuel system equipment...438
Releasing residual pressure in fuel system...438
Measuring fuel pressure...439
Measuring fuel return rate and leakage...441
Bleeding air from fuel circuit...444
Testing leakage in fuel system...446
Handling reduced cylinder mode operation...447
Handling no-injection cranking operation...447
Handling controller voltage circuit...448
Testing and adjusting air conditioner compressor belt tension...449
Adjusting transmission speed sensor...450
Measuring directional lever...451
Measuring and adjusting power train oil pressure...452
Procedure for flushing torque converter and transmission hydraulic circuit...467
Method of moving machine when transmission valve is broken...468
Testing and adjusting steering stop valve...470
Testing and adjusting steering wheel...472
Testing steering oil pressure...474
Bleeding air from steering circuit...477
Testing and adjusting, Part 2...481
Testing hydraulic drive fan...481
Bleeding air from hydraulic drive fan circuit...483
Measuring brake pedal...485
Measuring brake performance...486
Testing and adjusting accumulator charge pressure...487
Testing wheel brake oil pressure...488
Measuring wear of wheel brake disc...490
Bleeding air from wheel brake circuit...491
Releasing residual pressure in brake accumulator circuit...492
Testing parking brake performance...493
Measuring parking brake oil pressure...494
Testing wear of parking brake disc...496
Method of releasing parking brake manually...497
Measuring and adjusting work equipment control lever...498
Measuring and adjusting work equipment PPC oil pressure...499
Measuring and adjusting work equipment oil pressure...502
Bleeding air from work equipment circuit...506
Releasing residual pressure in work equipment circuit...507
Testing and adjusting bucket positioner...508
Testing and adjusting boom kick- out...510
Checking proximity switch operation pilot lamp...511
Procedure for testing diodes...512
Preparation work for troubleshooting for electric system...513
How to start operation of KOMTRAX terminal...518
Lamp display of KOMTRAX terminal...523
Adjusting machine monitor...526
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...527
Testing and adjusting, Part 3...530
Special functions of machine monitor (EMMS)...530
Pm-click inspection table...589
40 Troubleshooting...591
General information on troubleshooting...592
Points to remember when troubleshooting...592
Sequence of events in troubleshooting...593
Testing before troubleshooting...594
Classification and procedures of troubleshooting...595
Connection table for connector pin numbers...598
T-branch box and T-branch adapter table...621
Troubleshooting by failure code (Display of code), Part 1...627
Failure codes list...627
Before carrying out troubleshooting for electrical system...634
Information contained troubleshooting table...637
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...639
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...640
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...642
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...644
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...646
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...648
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...650
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...652
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...654
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...656
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...658
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...660
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...662
Failure code [2F00MA] (Parking brake: Malfunction)...664
Troubleshooting by failure code (Display of code), Part 2...670
Failure code [2G43ZG] (Accumulator: Low oil pressure)...670
Failure code [AA1ANX] (Air cleaner: Clogging)...672
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...674
Failure code [AB00MA] (Alternator: Malfunction)...676
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...678
Failure code [B@BAZK] (Engine oil: Low level)...679
Failure code [B@BCNS] (Coolant: Overheating)...680
Failure code [B@BCZK] (Coolant: Low level)...682
Failure code [B@C7NS] (Brake oil: Overheating)...684
Failure code [b@CENS] (Torque converter oil: Overheating)...686
Failure code [B@CENS] (Torque converter oil: Overheating)...688
Failure code [B@HANS] (Hydraulic oil: Overheating)...690
Failure code [CA111] (Abnormality in engine controller)...692
Failure code [CA115] (Engine Ne or Bkup speed sensor error)...693
Failure code [CA122] (Charge pressure sensor high error)...694
Failure code [CA123] (Charge pressure sensor low error)...696
Failure code [CA131] (Throttle sensor high error)...698
Failure code [CA132] (Throttle sensor low error)...700
Failure code [CA144] (Coolant sensor high error)...702
Failure code [CA145] (Coolant sensor low error)...704
Failure code [CA153] (Charge temperature sensor high error)...706
Failure code [CA154] (Charge temperature sensor low error)...708
Failure code [CA155] (Derating of speed by abnormally high charge temperature)...710
Failure code [CA187] (Sensor power supply 2 low error)...712
Failure code [CA221] (Atmospheric pressure sensor high error)...714
Failure code [CA222] (Atmospheric sensor low error)...716
Failure code [CA227] (Sensor power supply 2 high error)...718
Troubleshooting by failure code (Display of code), Part 3...721
Failure code [CA234] (Engine overspeed)...721
Failure code [CA238] (Ne speed sensor power supply error)...722
Failure code [CA271] (PCV1 Short circuit)...723
Failure code [CA272] (PCV1 Disconnection)...724
Failure code [CA322] (Injector #1 (L/B #1) open/short error)...726
Failure code [CA323] (Injector #5 (L/B #5) open/short error)...728
Failure code [CA324] (Injector #3 (L/B #3) open/short error)...730
Failure code [CA325] (Injector #6 (L/B #6) open/short error)...732
Failure code [CA331] (Injector #2 (L/B #2) open/short error)...734
Failure code [CA332] (Injector #4 (L/B #4) open/short error)...736
Failure code [CA342] (Calibration code inconsistency)...738
Failure code [CA351] (Injectors drive circuit error)...739
Failure code [CA352] (Sensor power supply 1 low error)...741
Failure code [CA386] (Sensor power supply 1 high error)...743
Failure code [CA428] (Abnormally high level in water sensor)...744
Failure code [CA429] (Abnormally low level in water sensor)...746
Failure code [CA431] (Idle validation switch error)...748
Failure code [CA432] (Idle validation action error)...750
Failure code [CA435] (Engine oil pressure switch error)...752
Failure code [CA441] (Battery voltage low error)...753
Failure code [CA442] (Battery voltage high error)...756
Failure code [CA449] Common rail pressure high error 2...758
Failure code [CA451] (Common rail pressure sensor high error)...759
Failure code [CA452] (Common rail pressure sensor low error)...761
Failure code [CA488] (Derating of torque by abnormally high charge temperature)...763
Failure code [CA553] (Common rail pressure high error 1)...764
Failure code [CA559] (Supply pump pressure very low error)...765
Failure code [CA689] (Engine Ne speed sensor error)...766
Failure code [CA731] (Engine Bkup speed sensor phase error)...768
Failure code [CA757] (All continuous data lost error)...769
Failure code [CA778] (Engine Bkup speed sensor error)...772
Failure code [CA1117] (Partial engine controller data loss error)...774
Failure code [CA1633] (KOMNET datalink timeout error)...777
Troubleshooting by failure code (Display of code), Part 4...781
Failure code [CA2185] (Throttle sensor supply voltage high error)...781
Failure code [CA2186] (Throttle sensor power supply low error)...782
Failure code [CA2249] (Supply pump pressure very low error 2)...783
Failure code [CA2311] (Abnormality in IMV solenoid)...784
Failure code [CA2555] (Intake heater relay disconnection error)...786
Failure code [CA2556] (Intake heater relay short circuit error)...788
Failure code [D150KA] (Emergency steering relay: Disconnection)...790
Failure code [D150KB] (Emergency steering relay: Short circuit)...792
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...794
Failure code [D160KA] (Backup lamp relay: Disconnection)...796
Failure code [D160KB] (Backup lamp relay: Short circuit)...798
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...800
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...802
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...804
Failure code [D192KA] (ECSS solenoid: Disconnection)...806
Failure code [D192KB] (ECSS solenoid: Short circuit)...807
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...808
Failure code [D5ZHKA] (Terminal C signal: Disconnection)...809
Failure code [D5ZHKB] (Terminal C signal: Short circuit)...813
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...817
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...820
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))...822
Failure code [DAF5KP] (Machine monitor: Low output voltage)...824
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))...827
Failure code [DAQ0KK] (Transmission controller: Low source voltage)...829
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...831
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))...832
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...834
Troubleshooting by failure code (Display of code), Part 5...837
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))...837
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...839
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...840
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...843
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system))...844
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...846
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time...848
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time...850
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...852
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...854
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...856
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...858
Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time...860
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...862
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...864
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...866
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...868
Troubleshooting by failure code (Display of code), Part 6...874
Failure code [DDK3KA] (Right FNR switch: Disconnection)...874
Failure code [DDK6KA] (FNR lever switch: Disconnection)...877
Failure code [DDK6KB] (FNR lever switch: Short circuit)...880
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...882
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...884
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...886
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...888
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...890
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...892
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...896
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...898
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...900
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...902
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...904
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...906
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...908
Troubleshooting by failure code (Display of code), Part 7...912
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...912
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...914
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...916
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...918
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...920
Troubleshooting by failure code (Display of code), Part 8...924
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...924
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...926
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...928
Failure code [DV00KB] (Alarm buzzer: Short circuit)...930
Troubleshooting by failure code (Display of code), Part 9...934
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...934
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...935
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...936
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...938
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...939
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...940
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...942
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...944
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...946
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...948
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...950
Troubleshooting by failure code (Display of code), Part 10...956
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...956
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...958
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...960
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...962
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...964
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...966
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...968
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...970
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...972
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...974
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...976
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...978
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...980
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...982
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...984
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...986
Troubleshooting of electrical system (E-mode)...991
Before carrying out troubleshooting for electrical system...991
Information in troubleshooting table...994
E-1 Engine does not start...995
E-2 Wiper does not operate...1002
E-3 Windshield washer does not operate...1006
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...1010
E-5 Working lamp does not light up or go off...1018
E-6 Turn signal lamp and hazard lamp do not light up or go off...1023
E-7 Brake lamp does not light or it keeps lighting up...1029
E-8 Backup lamp does not light or it keeps lighting up...1031
E-9 Backup buzzer does not sound or it keeps sounding...1033
E-10 Horn does not sound or it keeps sounding...1035
E-11 Alarm buzzer does not sound or it keeps sounding...1038
E-12 Air conditioner does not operate or stop...1040
E-13 The KOMTRAX system does not work properly...1043
Troubleshooting of hydraulic and mechanical system (H-mode)...1047
Method of using troubleshooting chart...1047
Table of failure modes and causes...1050
H-1 The machine does not start...1054
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...1056
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]...1057
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...1058
H-5 Shocks are large at the times of starting and shifting gear...1060
H-6 Time lag is large at the times of starting and shifting gear...1062
H-7 The torque converter oil temperature is high...1064
H-8 Steering does not turn...1065
H-9 Steering does not turn [Machine with joystick steering (if equipped)]...1066
H-10 Steering response is low...1067
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]...1068
H-12 Steering is heavy...1069
H-13 When machine turns, it shakes or makes large shocks...1070
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...1071
H-15 The wheel brake does not work or does not work well...1072
H-16 The wheel brake is not released or it drags...1073
H-17 The parking brake does not work or does not work well...1074
H-18 The parking brake is not released or it drags (including emergency release system)...1075
H-19 Lift arm does not rise...1076
H-20 Lift arm speed is low or rising force of lift arm is insufficient...1077
H-21 When rising, the lift arm comes to move slowly at specific height...1078
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...1078
H-23 Hydraulic drifts of the lift arm is large...1078
H-24 The lift arm wobbles during operation...1078
H-25 Bucket does not tilt back...1079
H-26 Bucket speed is low or tilting back force is insufficient...1080
H-27 The bucket comes to operate slowly in the midst of tilting-back...1081
H-28 The bucket cylinder cannot hold down the bucket...1081
H-29 Hydraulic drifts of the bucket is large...1081
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to ?HOLD?)...1081
H-31 Lift arm and bucket control levers do not move smoothly and are heavy...1082
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...1083
H-33 Large shock is made when work equipment starts and stops...1083
H-34 When work equipment circuit is relieved singly, other work equipment moves...1083
H-35 ECSS does not operate, and pitching, bouncing occur...1084
Troubleshooting of engine (S-mode)...1087
Method of using troubleshooting chart...1087
S-1 Engine does not start easily...1090
S-2 Engine does not start...1091
S-3 Engine does not pick up smoothly...1094
S-4 Engine stops during operations...1095
S-5 Engine does not rotate smoothly...1096
S-6 Engine lacks output (or lacks power)...1097
S-7 Exhaust smoke is black (Incomplete combustion)...1098
S-8 Oil consumption is excessive (or exhaust smoke is blue)...1099
S-9 Engine oil becomes contaminated quickly...1100
S-10 Fuel consumption is excessive...1101
S-11 Coolant contains oil (blows back or reduces)...1102
S-12 Oil pressure drops...1103
S-13 Oil level rises (Water, fuel in oil)...1104
S-14 Coolant temperature rises too high (Overheating)...1105
S-15 Abnormal noise is made...1106
S-16 Vibration is excessive...1107
50 Disassembly and assembly...1109
General information on disassembly and assembly...1110
How to read this manual...1110
Coating materials list...1112
Special tools list...1115
Engine and cooling system...1118
Removal and installation of fuel supply pump assembly...1118
Removal and installation of fuel injector assembly...1120
Removal and installation of cylinder head assembly...1125
Removal and installation of engine hood...1134
Removal and installation of radiator assembly...1136
Removal and installation of air aftercooler...1138
Removal and installation of hydraulic oil cooler assembly...1140
Removal and installation of engine assembly...1142
Removal and installation of cooling fan and fan motor assembly...1147
Removal and installation of fuel tank assembly...1150
Power train...1154
Removal and installation of torque converter and transmission assembly...1154
Disassembly and assembly of torque converter assembly (Standard specification)...1160
Disassembly and assembly of torque converter assembly (Lockup specification)...1164
Disassembly and assembly of transmission assembly...1170
Disassembly and assembly of transmission clutch pack assembly...1185
Disassembly and assembly of parking brake assembly...1201
Removal and installation of front axle assembly...1206
Removal and installation of rear axle assembly...1208
Disassembly and assembly of axle housing...1211
Disassembly and assembly of differential assembly...1220
Steering system...1234
Removal and installation of steering demand valve assembly...1234
Brake system...1238
Removal and installation of parking brake discs and plates...1238
Undercarriage and frame...1242
Removal and installation of center hinge pin...1242
Removal and installation of counterweight...1250
Hydraulic system...1254
Removal and installation of work equipment control valve assembly...1254
Removal and installation of power train pump and work equipment pump assembly...1256
Removal and installation of steering pump and cooling fan pump assembly...1257
Removal and installation of hydraulic tank assembly...1258
Work equipment...1262
Removal and installation of work equipment assembly...1262
Disassembly and assembly of hydraulic cylinder assembly...1266
Cab and its attachments...1276
Removal and installation of operator's cab and floor frame assembly...1276
Removal and installation of operator's cab glass (stuck glass)...1279
Removal and installation of air conditioner unit assembly...1287
Electrical system...1292
Removal and installation of engine controller assembly...1292
90 Diagrams and drawings...1293
Hydraulic diagrams and drawings...1293
Hydraulic diagrams and drawings...1294
Power train hydraulic circuit diagram...1294
Hydraulic circuit diagram...1297
Electrical diagrams and drawings...1301
Electrical circuit diagram (1/2)...1301
Electrical circuit diagram (2/2)...1302
Connector arrangement diagram...1303
