Service manual Komatsu WA600-1 10001 & Up | SEBM04260111

MAIN MENU
CONTENTS
10 ENGINE
– 12 TESTING AND ADJUSTING
— STANDARD VALUE TABLE
— TOOL LIST FOR TESTING AND ADJUSTING
— ADJUSTING VALVE CLEARANCE
— MEASURING COMPRESSION PRESSURE
— TESTING AND ADJUSTING FUEL INJECTION TIMING
— MEASURING BLOW-BY PRESSURE
— TESTING AND ADJUSTING ALTERNATOR DRIVE BELT TENSION
— MEASURING EXHAUST GAS COLOR
— MEASURING ENGINE OIL PRESSURE AND TEMPERATURE
— ADJUSTING FUEL CUT SOLENOID
— ADJUSTMENT OF ENGINE STOP MOTOR CABLE
— MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE
— MEASURING ACCELERATOR PEDAL
– 13 DISASSEMBLY AND ASSEMBLY
— STARTING MOTOR
— REMOVAL
— INSTALLATION
— ALTERNATOR
— REMOVAL
— INSTALLATION
— OIL COOLER
— REMOVAL
— INSTALLATION
— FUEL INJECTION PUMP
— REMOVAL
— INSTALLATION
— WATER PUMP
— REMOVAL
— INSTALLATION
— NOZZLE HOLDER
— REMOVAL
— INSTALLATION
— TURBOCHARGER
— REMOVAL
— INSTALLATION
— AIR COMPRESSOR
— ASSEMBLY
— INSTALLATION
— CYLINDER HEAD
— REMOVAL
— INSTALLATION
— RADIATOR
— REMOVAL
— INSTALLATION
— ENGINE
— REMOVAL
— INSTALLATION
— FUEL TANK
— REMOVAL
— INSTALLATION
20 POWER TRAIN
– 21 STRUCTURE AND FUNCTION
— GENERAL
— LOCATION OF COMPONENTS
— POWER TRAIN
— HYDRAULIC CIRCUIT SCHEMATICS FOR POWER TRAIN
— HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
— TRANSMISSION MOUNT
— TORQUE CONVERTER AND TRANSMISSION PIPING
— TORQUE CONVERTER OIL COOLER
— TORQUE CONVERTER OIL FILTER
— LUBRICATION BYPASS VALVE
— PILOT OIL FILTER
— TORQUE CONVERTER
— TORQUE CONVERTER REGULATOR VALVE
— TORQUE CONVERTER RELIEF VALVE
— TRANSMISSION
— TRANSMISSION CONTROL VALVE
— UPPER VALVE
— LOWER VALVE
— MAIN RELIEF VALVE
— PRIORITY VALVE
— MODULATING VALVE AND QUICK RETURN VALVE
— REDUCING VALVE
— ACCUMULATOR VALVE
— PILOT REDUCING VALVE
— TRANSMISSION SOLENOID VALVE
— EMERGENCY MANUAL SPOOL
— TRANSFER
— DRIVE SHAFT
— CENTER SUPPORT
— AXLE MOUNT
— AXLE AND DIFFERENTIAL
— FINAL DRIVE
— TIRE AND WHEEL
– 22 TESTING AND ADJUSTING
— STANDARD VALUE TABLE
— TOOL LIST FOR TESTING AND ADJUSTING
— MEASURING ENGINE STALL SPEED
— MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION
— MEASURING SPEED LEVER
— METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
— TIRE AND WHEEL
— TROUBLESHOOTING
— PRECAUTIONS WHEN TROUBLESHOOTING
— METHOD OF READING TROUBLESHOOTING TABLE
— PREVENTING RECURRENCE OF TROUBLE
— METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM
— TROUBLESHOOTING TABLE
—- 1. Machine does not move
—- 2. Machine lacks power or speed
—- 3. Excessive timing lag when starting machine or shifting gear
—- 4. Torque converter oil temperature too high
– 23 DISASSEMBLY AND ASSEMBLY
— HYDRAULIC PUMP
— REMOVAL
— INSTALLATION
— TORQUE CONVERTER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— TRANSMISSION
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— TRANSFER
— DISASSEMBLY
— ASSEMBLY
— TRANSMISSION CONTROL VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY AND ASSEMBLY
— FRONT DIFFERENTIAL
— REMOVAL
— INSTALLATION
— REAR DIFFERENTIAL
— REMOVAL
— INSTALLATION
— DIFFERENTIAL GEAR
— DISASSEMBLY
— ASSEMBLY
— FRONT AXLE
— REMOVAL
— INSTALLATION
— REAR AXLE
— REMOVAL
— INSTALLATION
— CENTER SUPPORT
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— DRIVE SHAFT
— DISASSEMBLY
— ASSEMBLY
— FINAL DRIVE
— DISASSEMBLY
— ASSEMBLY
– 24 POWER TRAIN
— ENGINE MOUNT
— TRANSMISSION MOUNT
— TORQUE CONVERTER
— TORQUE CONVERTER REGULATOR VALVE
— TRANSMISSION
— TRANSMISSION SOLENOID VALVE
— TRANSMISSION CONTROL VALVE
— Upper valve
— Lower valve
— TRANSFER
— DRIVE SHAFT
— CENTER SUPPORT
— AXLE MOUNT
— DIFFERENTIAL
— FINAL DRIVE
40 STEERING SYSTEM
– 41 STRUCTURE AND FUNCTION
— GENERAL
— STEERING COLUMN, GEAR BOX AND LINKAGE
— HYDRAULIC CIRCUIT FOR STEERING
— HYDRAULIC CIRCUIT SCHEMATICS
— HYDRAULIC CIRCUIT DIAGRAM
— STEERING CONTROL SYSTEM
— STEERING VALVE
— STEERING RELIEF VALVE
— SAFETY VALVE (with suction valve)
— OPERATION OF DEMAND SPOOL
— OPERATIONS OF STEERING VALVE
— TWO-WAY RESTRICTOR VALVE
— STEERING CYLINDER
— CENTER HINGE PIN
— EMERGENCY STEERING PIPING (If equipped)
— EMERGENCY STEERING PUMP (If equipped)
— DIVERTER VALVE (If equipped)
— STEERING DEMAND VALVE (MACHINE WITH JOYSTICK STEERING)
— STEERING UNIT (ORBIT-ROLL VALVE) (MACHINE WITH JOYSTICK STEERING)
– 42 TESTING AND ADJUSTING
— STANDARD VALUE TABLE
— TOOL LIST FOR TESTING AND ADJUSTING
— MEASURING PLAY OF STEERING WHEEL
— MEASURING OPERATING FORCE OF STEERING WHEEL
— MEASURING OPERATING TIME OF STEERING WHEEL
— TESTING AND ADJUSTING OF STEERING LINKAGE
— ADJUSTING STEERING LINKAGE
— MEASURING STEERING OIL PRESSURE
— ADJUSTING JOYSTICK STEERING
— TROUBLESHOOTING
— TROUBLESHOOTING TABLE
—- 1. Steering wheel does not turn.
—- 2. Steering wheel is sluggish.
—- 3. Steering wheel moves unsteadily or is subjected to large shock.
—- 4. Machine tends to turn naturally in one particular direction when traveling
—- 5. Left and right turning radii are different.
— TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYTEM (J MODE)
—- 1. FUNCTION
—- 2. TROUBLESHOOTING
—- 3. TABLE OF FAILURE CODES
—- 4. TABLE OF FAILURE MODES AND CAUSES
—- J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM
—- J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM
—- J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY SYSTEM
—- J-4 FAILURE CODE [19] ABNORMALITY IN CAUTION LAMP SYSTEM
—- J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R SIGNAL SYSTEM
—- J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING SOLENOID
—- J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID
—- J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L.H. STEERING SOLENOID
—- J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID
—- J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM
—- J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM
—- J-12 FAlLURE CODE [37] ABNORMALITY IN JOYSTICK STEERING LEVE 3 POTENTIOMETER
—- J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS
—- J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE
—- J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM
—- J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM
—- J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM
—- J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM
—- J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM
—- J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM
—- J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM
– 43 DISASSEMBLY AND ASSEMBLY
— STEERING GEAR [Serial No.10001 – 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— STEERING GEAR [Serial No. 10881 and up (Except D. spec.)]
— REMOVAL
— INSTALLATION
— STEERING BOX GEAR
— DISASSEMBLY
— ASSEMBLY
— STEERING VALVE
— REMOVAL
— INSTALLATION
— DISASSEMBLY AND ASSEMBLY
— STEERING CYLINDER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— CENTER HINGE PIN [Serial No. 10880 (Except D. spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— CENTER HINGE PIN [Serial No. 10881 and up (Except D spec.)]
— REMOVAL
— INSTALLATION
– 44 MAINTENANCE STANDARD
— STEERING COLUMN AND GEAR BOX
— CENTER HINGE PIN
— STEERING VALVE
— STEERING CYLINDER MOUNT
— STEERING CYLINDER
— DIVERTER VALVE
— EMERGENCY STEERING PUMP
50 BRAKE AND AIR SYSTEM
– 51 STRUCTURE AND FUNCTION
— GENERAL
— BRAKE AND AIR CIRCUIT DIAGRAM
— AIR GOVERNOR
— AIR TANK
— SAFETY VALVE
— BRAKE VALVE
— BRAKE ACTUATED
— OPERATING IN BALANCE
— BRAKE RELEASED
— TWO-WAY VALVE
— RELAY VALVE
— BRAKE CHAMBER
— SLACK ADJUSTER
— BRAKE
— PARKING BRAKE
— BRAKE CALIPER
— SPRING CYLINDER
— PARKING BRAKE SOLENOID VALVE
— HYDRAULIC TANK PRESSURIZING VALVE
– 52 TESTING AND ADJUSTING
— STANDARD VALUE TABLE
— TOOL LIST FOR TESTING AND ADJUSTING
— MEASURING BRAKE PEDAL
— MEASURING AIR PRESSURE
— TESTING BRAKE PERFORMANCE
— CHECKING BRAKE PISTON LEAKAGE
— MEASURING WEAR OF BRAKE DISC
— AIR BLEEDING FROM BRAKE LINE
— TESTING PARKING BRAKE PERFORMANCE
— CHECKING AND ADJUSTING PARKING BRAKE
— TROUBLESHOOTING
— TROUBLESHOOTING TABLE
—- 1. Air pressure does not rise at all.
—- 2. Air pressure does not rise to the specified range.
—- 3. Brake is ineffective or not very effective.
—- 4. Brake does not release, or drags.
—- 5. Parking brake does not release, or drags.
– 53 DISASSEMBLY AND ASSEMBLY
— BRAKE VALVE [Serial No. 10001 – 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— BRAKE VALVE [Serial No.10881 and up (Except D spec.)
— REMOVAL
— INSTALLATION
— BRAKE VALVE
— DISASSEMBLY
— ASSEMBLY
— BRAKE CHAMBER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— SLACK ADJUSTER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— BRAKE
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— SPRING CYLINDER
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— PARKING BRAKE
— REMOVAL
— INSTALLATION
— PARKING BRAKE PAD
— REMOVAL
— INSTALLATION
– 54 MAINTENANCE STANDARD
— BRAKE VALVE
— BRAKE CHAMBER
— SLACK ADJUSTER
— BRAKE
— PARKING BRAKE
— SPRING CYLINDER
60 WORK EQUIPMENT SYSTEM
– 61 STRUCTURE AND FUNCTION
— GENERAL
— WORK EQUIPMENT LEVER LINKAGE
— HYDRAULIC CIRCUIT SYSTEM
— HYDRAULIC CIRCUIT SCHEMATICS
— HYDRAULIC CIRCUIT DIAGRAM
— HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING)
— HYDRAULIC TANK
— OIL FILTER BYPASS VALVE
— BREATHER
— HYDRAULIC PUMP
— POC VALVE (Pilot Operated Control valve)
— PPC VALVE (Proportional Pressure Control Valve)
— POC RELIEF VALVE
— PPC RELIEF VALVE
— MAIN CONTROL VALVE
— RELIEF VALVE
— SAFETY VALVE (with suction valve)
— SUCTION VALVE
— FLOAT SELECTOR VALVE AND UNLOADER
— ACCUMULATOR
— OPERATION OF HYDRAULIC CIRCUIT
— HYDRAULIC CYLINDER
— BUCKET LINKAGE
— BUCKET POSITIONER AND BOOM KICK-OUT
– 62 TESTING AND ADJUSTING
— STANDARD VALUE TABLE
— TOOL LIST FOR TESTING AND ADJUSTING
— MEASURING DUMP AND LIFT CONTROL LEVERS
— ADJUSTING DUMP AND LIFT CONTROL LEVERS
— MEASURING AND ADJUSTING POC RELIEF VALVE PRESSURE
— MEASURING AND ADJUSTING PPC RELIEF VALVE PRESSURE
— MEASURING AND ADJUSTING WORK EQUIPMENT RELIEF VALVE PRESSURE
— MEASURING WORK EQUIPMENT
— MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT ’
— ADJUSTING BUCKET POSITIONER
— ADJUSTING BOOM KICK-OUT
— TROUBLESHOOTING
— TROUBLESHOOTING TABLE
—- 1. Lift arm does not rise.
—- 2. Lift arm moves slowly or does not have sufficient lifting power.
—- 3. Lift arm movement becomes slow after it reaches a certain height
—- 4. Bucket cannot be held down with lift arm cylinder
—- 5. Lift arm has large hydraulic drift.
—- 6. Lift arm movementis unsteady during work
—- 7. Lift arm lowers momentarily when control lever is shifted from “Hold” to “Raise”
—- 8. Bucket does not tilt back.
—- 9. Bucket moves slowly or has insufficient tilt back power
—- 10. Bucket movement becomes slow during tilt back
—- 11. Bucket cannot be held down by the bucket cylinder
—- 12. Bucket has large hydraulic drift. .
—- 13. Bucket moves unsteadily when machine travels under load. (Main control valve is in “Hold”).
—- 14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”.
—- 15. Control levers of lift arm and dump move stiffly and sluggishly.
– 63 DISASSEMBLY AND ASSEMBLY
— HYDRAULIC TANK [Serial No. 10001- 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— HYDRAULIC TANK [Serial No. 10881 and up (Except D spec.)]
— REMOVAL
— INSTALLATION
— HYDRAULIC FILTER [Serial No. 10001 – 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— HYDRAULIC FILTER [Serial No. 10881 and up (Except D spec.)]
— REMOVAL
— INSTALLATION
— WORK EQUIPMENT, STEERING, POC (PPC) PUMP
— REMOVAL
— INSTALLATION
— POC VALVE [Serial No. 10001 – 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— PPC VALVE [Serial No. 10881 and up (Except D spec.)]
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— ASSEMBLY
— MAIN CONTROL VALVE
— REMOVAL
— INSTALLATION
— MAIN CONTROL VALVE [Serial No. 10001 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]
— DISASSEMBLY
— ASSEMBLY
— MAIN CONTROL VALVE [Serial No. 10881 and up (Except D spec.)]
— DISASSEMBLY
— ASSEMBLY
— DUMP CYLINDER
— REMOVAL
— INSTALLATION
— LIFT CYLINDER
— REMOVAL
— INSTALLATION
— LIFT CYLINDER AND DUMP CYLINDER
— DISASSEMBLY
— ASSEMBLY
— WORK EQUIPMENT
— REMOVAL
— INSTALLATION
— COUNTERWEIGHT
— REMOVAL
— INSTALLATION
– 64 MAINTENANCE STANDARD
— BUCKET LINKAGE
— BUCKET
— BUCKET POSITIONER AND BOOM KICK-OUT
— HYDRAULIC PUMP
— MAIN CONTROL VALVE
— POC VALVE
— PPC VALVE
— DUMP CYLINDER
— LIFT CYLINDER
80 ELECTRIC AND ELECTRONIC SYSTEM
– 81 STRUCTURE AND FUNCTION
— ELECTRICAL WIRING DIAGRAM CIRCUIT
— ENGINE STARTING CIRCUIT
— ENGINE STOP CIRCUIT
— ELECTRICAL TRANSMISSION CONTROL
— COMBINATION SWITCH
— TRANSMISSION CUT-OFF SWITCH
— TRANSMISSION CUT-OFF SELECTOR SWITCH
— NEUTRALIZER RELAY
— KICK-DOWN SWITCH
— KICK-DOWN ELECTRIC CIRCUIT
— ELECTRICAL PARKING BRAKE CONTROL
— PROXIMITY SWITCH
— AUTO PRIMING SYSTEM (APS)
— ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
— MONITOR PANEL
— INDICATION ON MONITOR PANEL
— WIRING HARNESS
— CONTROLLER
— SENSORS
– 82 TESTING AND ADJUSTING
— STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
— ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR
— TROUBLESHOOTING
— CHECK BEFORE TROUBLESHOOTING
— METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
— CONNECTOR TERMINAL NUMBERS
— PRECAUTION WHEN HANDLING CONNECTOR
— ELECTRICAL WIRING DIAGRAM AND LOCATION OF CONNECTORS
— ELECTRICAL CIRCUIT SYSTEM
— TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM
—- CONNECTOR TYPES AND LOCATION OF COMPONENTS
—- ENGINE STARTING AND STOP CIRCUIT
—– E-1. ENGINE DOES NOT START.
—– E-2. ENGINE DOES NOT STOP.
—– E-3. ENGINE STOPS WHEN TRAVELING.
—- PARKING BRAKE CIRCUIT
—– E-4a. PARKING BRAKE DOES NOT WORK. (PARKING BRAKE SWITCH ON)
—– E-4b. PARKING BRAKE DOES NOT WORK. (AIR PRESSURE LESS THAN 2.0 KG/CM2)
—– E-5. PARKING BRAKE IS NOT RELEASED.
—– E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON.
—– E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.
—- TRANSMISSION CONTROL CIRCUIT [SERIAL NO. 10001 AND UP (D SPEC.) SERIAL NO. 10001-10880 (EXCEPT D SPEC.)]
—– E-8. MACHINE DOES NOT TRAVEL FORWARD.
—– E-9. MACHINE DOES NOT TRAVEL REVERSE.
—– E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).
—– E-11. MACHINE DOES NOT WHEN TRANSMISSION SELECTOR SWITCH ON.
—– E-12. TRANSMISSION CANNOT BE CUT-OFF.
—– E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL.
—- TRANSMISSION CONTROL CIRCUIT [SERIAL NO. 10881 AND UP (EXCEPT D SPEC.)]
—– E-8. TRANSMISSION DOES NOT WORK NORMALLY.
—– E-9. KICK-DOWN SWITCH DOES NOT WORK (1/2)
—– E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.
—– E-11. KICK-DOWN OPERATION IS NOT CANCELED.
—– E-12. KICK-DOWN WORKS MISTAKE WHEN TRAVELING IN F2.
—– E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.
—- PREHEATING CIRCUIT
—– E-14. PREHEATING IS NOT CARRIED OUT.
—– E-15. PREHEATING DISPLAY DOES NOT GO OUT.
—– E-15A. PREHEATING STAY ON
—– E-16. AFTERHEATING DOES NOT DISPLAY.
—– E-17. AFTERHEATING DISPLAY DOES NOT GO OUT.
— TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM
—- Serial No. 10001-10494
—– M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING …
—— a) BRAKE OIL LEVEL
—— b) ENGINE OIL
—— c) COOLANT LEVEL
—– M-2. WHEN STARTING SWITCH IS TURNED ON (AT ENGINE RUNNING), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES.
—— a) BATTERY CHARGE
—— b) FUEL LEVEL
—— c) AFTERHEATING LIGHTS UP.
—— d) AFTERHEATING DOES NOT LIGHT UP.
—— e) CLOGGING IN TRANSMISSION OIL FILTER FLASHES.
—– M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASH ES.
—— a) FAILURE IN BRAKE LINE FLASHES.
—— b) ENGINE OIL PRESSURE FLASHES.
—— c) COOLANT LEVEL FLASHES.
—— d) DROP IN AIR PRESSURE FLASHES.
—— e) COOLANT TEMPERATURE FLASHES.
—— f) TORQUE CONVERTER OIL TEMPERATURE FLASHES.
—– M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP …
—— a) PARKING BRAKE DISPLAY DOES NOT GO OUT.
—— b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP.
—— c) WORKING LAMP DISPLAY DOES NOT GO OUT.
—— d) WORKING LAMP DISPLAY DOES NOT LIGHT UP.
—— e) PREHEATING LIGHTS UP.
—— f) PREHEATING DOES NOT LIGHT UP.
—— g) FAILURE IN MAIN STEERING LIGHTS UP. (IF EQUIPPED)
—— h) FAILURE IN MAIN STEERING DOES NOT LIGHT UP. (IF EQUIPPED)
—— i) TRANSMISSION CUT-OFF LIGHTS UP.
—— j) TRANSMISSION CUT-OFF DOES NOT LIGHT UP.
—– M-5. TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT U-P.
—— a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP.
—— b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS up.
—— c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.
—— d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP.
—— e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP.
—— f) HIGH BEAM PILOT LAMP DOES NOT GO OUT.
—– M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
—– M-7. SERVICE METER DOES NOT WORK NORMALLY.
—– M-8. ABNORMALITY IN MONITOR PANEL.
—— a) NONE OF MONITOR PANEL WORKS.
—— b) PART OF MONITOR PANEL DOES NOT WORK.
—— c) EVEN WHEN ENGINE IS STOPPED, ENGINE 0iL PRESSURE FLASHES, CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP.
—— d) EVEN WHEN ENGINE STOPPED, BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP.
—— e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARGING SWITCH TO “ON”, ENGINE STOPPED.)
—— f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY.
—— g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.
—— h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY.
—— i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY.
—– M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR.
—— a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SIDE LAMP IN COMBINATION LAMP IS USED.
—— b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON.
—— c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP.
—— d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP.
—— e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP.
—– M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP.
—— a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND.
—— b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMPS DOES NOT FLASH.
—– M-11. ABNORMALITY IN GAUGE.
—— a) FUEL GAUGE
—— b) AIR PRESSURE GAUGE
—— c) COOLANT TEMPERATURE GAUGE
—— d) TORQUE CONVERTER OIL TEMPERATURE GAUGE
—- Serial No. 10495-and up (D Spec.) & Serial No. 10495-10880 (except D spec.)
—– CONNECTOR TYPES AND LOCATION OF COMPONENTS
—– M-1. BRAKE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED.
—– M-2. ENGINE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED.
—– M-3. RADIATOR WATER LEVEL FLASHES WHEN – ENGINE IS STOPPED.
—– M-4. BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING.
—– M-5. TRANSMISSION OIL FILTER CLOGGING WHEN ENGINE IS RUNNING.
—– M-6. FUEL LEVEL FLASHES WHEN ENGINE
—– M-7. BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING.
—– M-8. ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING.
—– M-9. RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS RUNNING.
—– M-10. DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING.
—– M-11. ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.
—– M-12. TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING.
—– M-13. PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
—— a) If stays lighted up
—— b) If does not light up
—– M-14. WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
—— a) If stays lighted up
—— b) If does not light up
—– M-15. PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP.
—— a) (Preheating) lights up
—— b) (Preheating) does not light up
—– M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP.
—— a) Lights up
—— b) Does not light up
—– M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP.
—— a) Turn signal (right) pilot display lights up
—— b) Turn signal (left) pilot display lights up
—— c) Turn signal (right) pilot display does not light up
—— d) Turn signal (left) pilot display does not light up
—— e) Hi beam pilot does not light up
—— f) Hi beam pilot stays lighted up
—– M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON.
—– M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
—– M-20. HOURMETER DOES NOT WORK NORMALLY.
—– M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS.
—— a) None of monitor panel lights up
—— b) Except for speedometer module, none of monitqr panel lights up
—— c) None of CAUTION items light up
—— d) Some other parts do not light up
—– M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT.
—– M-23. (ENGINE OIL PRESSURE) FLASHES (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED.
—— a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated.
—— b) (Battery charge) flashes, and warning lamp lights up
—– M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP.
—— a) Even when combination lamp is placed at SMALL, none of panel lighting lights up.
—— b) Even when working lamp is switched ON, none of monitor panel lights up
—— c) Even when starting switch is turned ON, none of monitor panel lights up
—— d) Part of panel does not light up
—– M-25. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS …
—– M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.
—– M-27. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.
—– M-28. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP.
—– M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at FULL
—– M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at maximum level
—– M-31. ABNORMALITY IN (ENGINE WATER C TEMPERATURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at minimum level
—– M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at minimum level
—- Serial No. 10881 and up (except D spec.)
—– CONNECTOR TYPES AND LOCATION OF COMPONENTS
—– M-1. (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.
—– M-2. (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.
—– M-3. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED.
—– M-4. (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING.
—– M-5. (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING.
—– M-6. (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING.
—– M-7. (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING.
—– M-8. (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING.
—– M-9. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING.
—– M-10. (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING.
—– M-11. (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING.
—– M-12. (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING.
—– M-13. (PARKING BRAKE) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
—— a) If stays lighted up
—— b) If does not light up
—– M-14. (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
—— a) If stays lighted up
—— b) If does not light up
—– M-15. (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP.
—— a) (Preheating) lights up
—— b) (Preheating) does not light up
—– M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP.
—— a) Lights up
—— b) Does not light up
—– M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP.
—— a) Turn signal (right) pilot display lights up
—— b) Turn signal (left) pilot display lights up
—— c) Turn signal (right) pilot display does not light up
—— d) Turn signal (left) pilot display does not light up
—— e) Hi beam pilot does not light up
—— f) Hi beam pilot stays lighted up
—– M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON.
—– M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
—– M-20. HOURMETER DOES NOT WORK NORMALLY.
—– M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS.
—— a) None of monitor panel lights up
—— b) Except for speedometer module, none of monitor panel lights up
—— c) None of CAUTION items light up
—— d) Some other parts do not light up
—– M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT.
—– M-23. (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED.
—— a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated.
—— b) (Battery charge) flashes, and warning lamp lights up
—– M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP.
—— a) Even when combination lamp is placed at SMALL, none of panel lighting lights up.
—— b) Even when working lamp is switched ON, none of monitor panel lights up
—— c) Even when starting switch is turned ON, none of monitor panel lights up
—— d) Part of panel does not light up
—– M-25. WHEN STARTING SWITCH IS TURNED TO ON POSlTlON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS …
—– M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.
—– M-27. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM…
—– M-28 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP.
—– M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at FULL
—– M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at maximum level
—– M-31. ABNORMALITY IN (ENGINE WATER TEMPERATURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at minimum level
—– M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM
—— a) If nothing is displayed in display area
—— b) If indicator remains at minimum level
– 83 DISASSEMBLY AND ASSEMBLY
— MACHINE MONITOR
— REMOVAL
— INSTALLATION
90 OTHERS
– 91 OTHERS
— CAB
— AIR CONDITIONER
— AIR CONDITIONER WIRING DIAGRAM
— AIR CONDITIONER ELECTRIC CIRCUIT
— AIR CONDITIONER UNIT
— COMPRESSOR
— CONDENSOR
— DRY RESERVOIR
– 93 DISASSEMBLY AND ASSEMBLY
— CAB
— REMOVAL
— INSTALLATION
— AIR CONDITIONER UNIT (For DAIKIN air conditioner)
— REMOVAL
— INSTALLATION
— AIR CONDITIONER UNIT (For DENS0 air conditioner)
— REMOVAL
— INSTALLATION
— AIR CONDITIONER CONDENSER
— REMOVAL
— INSTALLATION
— DRY RESERVOIR
— REMOVAL
— INSTALLATION
— COMPRESSOR FOR AIR CONDITIONER (For DAI KIN air conditioner)
— REMOVAL
— INSTALLATION
— COMPRESSOR FOR AIR CONDITIONER (For DENS0 air conditioner)
— REMOVAL
— INSTALLATION
– 97 GEAR PUMP
— GENERAL
— PRINCIPLE OF OPERATION
— PRESSURE LOADED TYPE GEAR PUMP
— FIXED SIDE PLATE TYPE GEAR PUMP