Komatsu WA320-5 Wheel Loader Shop Manual SEBM034610 – PDF DOWNLOAD

Komatsu WA320-5 Wheel Loader Shop Manual SEBM034610 – PDF DOWNLOAD

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Komatsu WA320-5 Wheel Loader Shop Manual SEBM034610 – PDF DOWNLOAD

Language : English
Pages : 870
Downloadable : Yes
File Type : PDF
Size: 86.9 MB

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Komatsu WA320-5 Wheel Loader Shop Manual SEBM034610 – PDF DOWNLOAD

Machine model Serial number
WA320-5 60001 and up

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.• Always wear safety glasses when hitting parts with a hammer.• Always wear safety glasses when grinding parts with a grinder, etc.3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

• 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
• 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
• 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
• 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu WA320-5 Wheel Loader Shop Manual SEBM034610 – PDF DOWNLOAD

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
01 GENERAL 27
GENERAL ASSEMBLY DRAWINGS 28
SPECIFICATIONS 29
WEIGHT TABLE 33
LIST OF LUBRICANT AND COOLANT 35
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD 37
ENGINE MOUNT AND TRANSFER MOUNT 38
DAMPER 39
COOLING SYSTEM 40
POWER TRAIN 43
POWER TRAIN SYSTEM DIAGRAM 44
DRIVE SHAFT (PROPELLER SHAFT) 46
HST HYDRAULIC PIPING DIAGRAM 47
HST PUMP 48
HIGH-PRESSURE RELIEF VALVE 50
LOW-PRESSURE RELIEF VALVE 52
HST CHARGE PUMP 53
SPEED-RELATED VALVE (DA VALVE) 54
HIGH-PRESSURE CUT-OFF VALVE 55
HST MOTOR 56
EP SERVO VALVE 59
HA SERVO VALVE 60
FORWARD-REVERSE SHUTTLE VALVE 61
TRANSFER 62
CLUTCH SOLENOID VALVE 73
AXLE 74
DIFFERENTIAL 76
LIMITED-SLIP DIFFERENTIAL 84
FINAL DRIVE 88
AXLE MOUNTING AND CENTER HINGE PIN 90
STEERING PIPING 99
STEERING COLUMN 100
PRIORITY VALVE 101
ORBIT-ROLL VALVE 104
CUSHION VALVE 112
STEERING CYLINDER 113
EMERGENCY STEERING PIPING 115
EMERGENCY STEERING VALVE 116
BRAKE PIPING 119
BRAKE VALVE 120
INCHING VALVE 124
CHARGE VALVE 126
ACCUMULATOR (FOR BRAKE) 130
SLACK ADJUSTER 132
BRAKE 134
PARKING BRAKE CONTROL 136
PARKING BRAKE 137
HYDRAULIC PIPING 138
WORK EQUIPMENT LEVEL LINKAGE 140
HYDRAULIC TANK 142
4-GEAR PUMP UNIT 144
ACCUMULATOR (FOR PPC CIRCUIT) 146
LOCK VALVE 147
E C S S VALVE 148
ACCUMULATOR (FOR E C S S ) 150
HYDRAULIC PIPING OF COOLING SYSTEM 151
COOLING FAN MOTOR 152
WORK EQUIPMENT CONTROL VALVE 155
WORK EQUIPMENT PPC VALVE 176
ATTACHMENT PPC VALVE 188
WORK EQUIPMENT LINKAGE 192
BUCKET 194
BUCKET POSITIONER AND BOOM KICK-OUT 196
WORK EQUIPMENT CYLINDER 202
AIR CONDITIONER 203
MACHINE MONITORING SYSTEM 204
MACHINE MONITOR 214
LIST OF ITEMS DISPLAYED ON MONITOR 215
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM) 241
HST CONTROLLER 245
KOMTRAX SYSTEM 246
ENGINE START CIRCUIT 248
ENGINE STOP CIRCUIT 250
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM) 251
PARKING BRAKE CIRCUIT 252
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM 255
SENSORS 256
20 TESTING AND ADJUSTING 265
STANDARD VALUE TABLE FOR ENGINE 266
STANDARD VALUE TABLE FOR CHASSIS 267
TESTING AND ADJUSTING 271
TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING 272
MEASURING ENGINE SPEED 274
MEASURING EXHAUST GAS COLOR 275
ADJUSTING VALVE CLEARANCE 277
MEASURING COMPRESSION PRESSURE 278
MEASURING BLOW-BY PRESSURE 279
TESTING AND ADJUSTING FUEL INJECTION TIMING 280
MEASURING ENGINE OIL PRESSURE 281
MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL 282
ADJUSTING ENGINE STOP SOLENOID 284
ADJUSTING ENGINE SPEED SENSOR 285
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 285
MEASURING DIRECTIONAL LEVER 286
TESTING AND ADJUSTING HST OIL PRESSURE 286
MEASURING CLUTCH CONTROL PRESSURE 291
TESTING AND ADJUSTING STEERING WHEEL 292
TESTING AND ADJUSTING STEERING OIL PRESSURE 293
BLEEDING AIR FROM STEERING CIRCUIT 294
TESTING HYDRAULIC FAN 295
MEASURING BRAKE PEDAL 296
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 297
MEASURING BRAKE PERFORMANCE 298
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 299
MEASURING BRAKE OIL PRESSURE 300
MEASURING WEAR OF BRAKE DISC 302
BLEEDING AIR FROM BRAKE CIRCUIT 303
MEASURING PARKING BRAKE PERFORMANCE 304
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 305
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER 306
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 307
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE 308
BLEEDING AIR 310
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 311
TESTING AND ADJUSTING BUCKET POSITIONER 311
TESTING AND ADJUSTING OF BOOM KICK-OUT 313
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP 314
PROCEDURE FOR CHECKING DIODE 315
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER 316
STARTING KOMTRAX TERMINAL OPERATIONS 317
INDICATOR LAMPS OF KOMTRAX TERMINAL 321
SPECIAL FUNCTIONS OF MACHINE MONITOR 325
FLOW OF MODES AND FUNCTIONS 326
FAILURE CODE TABLE 334
PM CLINIC INSPECTION CHART 344
TROUBLESHOOTING 347
POINTS TO REMEMBER WHEN TROUBLESHOOTING 348
SEQUENCE OF EVENTS IN TROUBLESHOOTING 349
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 350
CHECKS BEFORE TROUBLESHOOTING 358
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 359
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO 360
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 363
T-ADAPTER TABLE 386
CONNECTOR TYPES AND MOUNTING LOCATIONS 389
CONNECTOR LAYOUT DRAWING 396
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 401
BEFORE TROUBLESHOOTING CODE DISPLAY 402
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM 404
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 405
FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00)) 407
FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX)) 408
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC)) 410
FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ)) 412
FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)) 414
FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)) 416
TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION)) 418
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED) 420
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED 424
TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN “1ST” POSITION) 426
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED) 428
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE) 429
RELATED ELECTRICAL CIRCUIT DIAGRAM 430
ECSS-1 MALFUNCTION OF TRAVEL DAMPER 431
TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE) 437
BEFORE TROUBLESHOOTING CODE DISPLAY 440
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM 442
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 443
FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX)) 445
FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG)) 446
FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO)) 447
FAILURE CODE [989FN1] (HST OVERRUNNING (N1)) 448
FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX)) 450
FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6)) 452
FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA)) 453
FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG)) 454
FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK) 455
FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS)) 456
FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK)) 457
FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS)) 458
FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS)) 459
FAILURE CODE [D5ZHL6] (STARTING SWITCH “C”(IGN”C”)INPUT FAILURE(L6)) 460
FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT)) 462
FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR)) 464
FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD)) 466
FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD) 467
FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD) 468
FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD) 469
FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB)) 470
FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6)) 472
FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX)) 473
FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)) 474
FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)) 475
FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA)) 476
FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)) 477
FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6)) 478
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON) 480
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON) 484
TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE ) 485
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE ) 486
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE ) 487
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON) 488
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON) 489
TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON) 490
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)) 491
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)) 492
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)) 493
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)) 494
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP) 496
TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP 498
TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP) 500
TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION 502
TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY) 502
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 503
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM 504
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 505
TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START) 508
TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP) 514
TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT) 516
TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION) 520
TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION) 526
TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION) 530
TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION) 533
TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY) 534
TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION) 540
TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION) 546
TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY) 550
TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND) 562
TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER) 564
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE) 577
METHOD OF USING TROUBLESHOOTING CHART 578
FAILURE CODE AND CAUSE TABLE 580
H-1 THE MACHINE DOES NOT START 582
H-2 THE TRAVEL SPEED IS SLOW 583
H-3 THE THRUSTING FORCE IS WEAK 584
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY 585
H-5 THE GEAR IS NOT SHIFTED 586
H-6 THE STEERING WHEEL DOES NOT TURN 587
H-7 THE STEERING WHEEL IS HEAVY 588
H-8 STEERING WHEEL SHAKES OR JERKS 589
H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL 590
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED 591
H-12 THE LIFT ARM DOES NOT RISE OR LOWER 592
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 593
H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT 594
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR) 594
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN 594
H-17 THE LIFT ARM WOBBLES DURING OPERATION 594
H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM “HOLD” TO “RAISE”, THE LIFT ARM FALLS TEMPORARILY 595
H-19 THE BUCKET DOES NOT TILT BACK 596
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 597
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK 598
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 598
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 598
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 599
H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM “HOLD”TO “TILT”,THE BUCKET FALLS TEMPORARILY 599
H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 599
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES 600
TROUBLESHOOTING OF ENGINE (S MODE) 601
METHOD OF USING TROUBLESHOOTING CHARTS 602
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME) 606
S-2 ENGINE DOES NOT START 608
(1)ENGINE DOES NOT TURN 608
(2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 609
(3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 610
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR) 611
S-4 ENGINE STOPS DURING OPERATIONS 612
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) 613
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER) 614
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION) 615
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 616
S-9 OIL BECOMES CONTAMINATED QUICKLY 617
S-10 FUEL CONSUMPTION IS EXCESSIVE 618
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN 619
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE) 620
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) 621
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) 622
S-15 ABNORMAL NOISE IS MADE 623
S-16 VIBRATION IS EXCESSIVE 624
30 DISASSEMBLY AND ASSEMBLY 625
HOW TO READ THIS MANUAL 626
PRECAUTIONS WHEN CARRYING OUT OPERATION 628
SPECIAL TOOL LIST 630
SKETCH OF SPECIAL TOOLS 633
REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 640
REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY 644
REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY 646
REMOVAL,INSTALLATION OF ENGINE ASSEMBLY 654
REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY 661
REMOVAL,INSTALLATION OF AIR AFTERCOOLER 662
REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 664
REMOVAL,INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY 666
REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY 668
REMOVAL,INSTALLATION OF TRANSFER 670
DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY 672
REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY 692
DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY 694
REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY 699
REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY 701
DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY 704
DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY 717
REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY 741
REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY 744
REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY 746
REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY 748
REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY(IF EQUIPPED) 750
REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY 752
REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY 754
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY 761
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY 788
DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 804
REMOVAL,INSTALLATION OF OPERATOR’S CAB ASSEMBLY 811
REMOVAL,INSTALLATION OF OPERATOR’S CAB GLASS(STUCK GLASS) 817
REMOVAL,INSTALLATION OF CENTER HINGE PIN 825
REMOVAL,INSTALLATION OF COUNTERWEIGHT 838
REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 840
REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 843
REMOVAL,INSTALLATION OF MONITOR PANEL 844
REMOVAL,INSTALLATION OF HST CONTROLLER ASSEMBLY 848
90 OTHERS 849
HYDRAULIC CIRCUIT DIAGRAM 851
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4) 853
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4) 855
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4) 857
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4) 859
ELECTRICAL CIRCUIT DIAGRAM 2/4 861
ELECTRICAL CIRCUIT DIAGRAM 3/4 863
ELECTRICAL CIRCUIT DIAGRAM 4/4 865
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) 867
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) 869

IMAGES PREVIEW OF THE MANUAL: