Komatsu WA500-1 Wheel Loader Service Repair Shop Manual (10001 and up) - SEBM04250107

This Complete Service Repair Workshop Manual PDF Download for the WA500-1 Komatsu Wheel Loader (SN: 10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA500-1 Wheel Loader
Serial Numbers : 10001 and up


TABLE OF CONTENTS :

10 ENGINE
20 POWER TRAIN
40 STEERING SYSTEM
50 BRAKE AND AIR SYSTEM
60 WORK EQUIPMENT SYSTEM
80 ELECTRIC AND ELECTRONIC SYSTEM
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM04250107
Total Pages : 933


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
CONTENTS

10 ENGINE
11 STRUCTURE AND FUNCTION
ENGINE MOUNT
RADIATOR
FUEL TANK AND PIPING
ENGINE CONTROL
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 BELT TENSION
MEASURING EXHAUST GAS COLOR
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE
ADJUSTING FUEL CUT SOLENOID
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE
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
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
14 MAINTENANCE STANDARD
ENGINE MOUNT

20 POWER TRAIN
21 STRUCTURE AND FUNCTION
GENERAL
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
DAMPER
TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER
TRANSMISSION MOUNT
TORQUE CONVERTER RELIEF VALVE
TRANSMISSION
TRANSMISSION CONTROL VALVE
UPPER VALVE
LOWER VALVE
TRANSMISSION SOLENOID VALVE
EMERGENCY MANUAL SPOOL
FORWARD IST
PRIORITY VALVE
MODULATING VALVE AND QUICK RETURN VALVE
ACCUMULATOR VALVE
PILOT REDUCING VALVE
MAIN RELIEF VALVE
REDUCING VALVE
LUBRICATION BYPASS VALVE
PILOT OIL FILTER
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 SHIFT LEVER
METHOD FOR OPERATION OF SPOOL EMERGENCY MANUAL
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 time lag when starting machine or shifting gear
4. Torque converter oil temperature too high
23 DISASSEMBLY AND ASSEMBLY
DAMPER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER CHARGING PUMP
REMOVAL
INSTALLATION
TORQUE CONVERTER AND TRANSMISSION
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
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 Serial No. 10001 - 10222
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT Serial No. 10223 and up
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
24 MAINTENANCE STANDARD
TRANSMISSION MOUNT
TORQUE CONVERTER CHARGING PUMP
DAMPER
TORQUE CONVERTER
TRANSMISSION
TRANSFER
DRIVE SHAFT
CENTER SUPPORT
DIFFERENTIAL
AXLE MOUNT
FINAL DRIVE

40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION
GENERAL
HYDRAULIC CIRCUIT FOR STEERING
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING
OPERATIONS OF STEERING VALVE
STEERING CONTROL SYSTEM
STEERING VALVE
STEERING RELIEF VALVE
SAFETY VALVE (with suction valve)
OPERATION OF DEMAND SPOOL
TWO-WAY RESTRICTOR VALVE
ROTOR SEAL
STEERING CYLINDER
STEERING COLUMN AND GEAR BOX
STEERING LINKAGE
STEERING PUMP
CENTER HINGE PIN
42 TESTING AND ADJUSTING
STANDARD VALUE TABLE
TOOL LIST FOR TESTING AND ADJUSTING
MEASURING STEERING WHEEL PLAY
MEASURING OPERATING FORCE OF STEERING WHEEL
OPERATING TIME OF STEERING WHEEL
TESTING STEERING LINKAGE
ADJUSTING STEERING LINKAGE
STEERING OIL PRESSURE
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.
42 DISASSEMBLY AND ASSEMBLY
STEERING GEAR BOX
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
STEERING PUMP AND POC PUMP
REMOVAL
INSTALLATION
STEERING CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
44 MAINTENANCE STANDARD
STEERING LINKAGE
STEERING COLUMN AND GEAR BOX
STEERING PUMP
STEERING VALVE
STEERING CYLINDER MOUNT
STEERING CYLINDER
CENTER HINGE PIN

50 BRAKE AND AIR SYSTEM
51 STRUCTURE AND FUNCTION
GENERAL
AIR TANK
SAFETY VALVE
BRAKE VALVE
BRAKE ACTUATED
OPERATING IN BALANCE
BRAKE RELEASED
AIR GOVERNOR
TWO-WAY VALVE
BRAKE CHAMBER
SLACK ADJUSTER
BRAKE
PARKING BRAKE
PARKING BRAKE SOLENOID VALVE
SPRING CYLINDER
BRAKE CALIPER
52 TESTING AND ADJUSTING
STANDARD VALUE TABLE
TOOL LIST FOR TESTING AND ADJUSTING
MEASURING BRAKE PEDAL
MEASURING AIR
BRAKE PERFORMANCE
CHECKING BRAKE PISTON LEAKAGE
MEASURING WEAR OF BRAKE DISC
AIR BLEEDING FROM BRAKE LINE
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. (Applies to machine equiped with air parking brake.)
53 DISASSEMBLY AND ASSEMBLY
AIR GOVERNOR
DISASSEMBLY
ASSEMBLY
BRAKE VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE CHAMBER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SLACK ADJUSTER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SPRING CYLINDER
REMOVAL
INSTALLATION
DISASSMBLY
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
HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULK TANK
OIL FILTER BYPASS VALVE
BREATHER
HYDRAULIC PUMPS
HYDRAULtC PUMP
SWtTCH PUMP
POC PUMP
POC VALVE
MAIN CONTROL VALVE
RELIEF VALVE
SAFETY VALVE
SUCTION VALVE
FLOAT SELECTOR VALVE AND UNLOADER VALVE
HYDRAULIC CYLINDER
BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET LINKAGE
BUCKET
ACCUMULATOR
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 HYDRAULIC PRESSURE OF WORK’EQUIPME,NT
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.
*** MISSING 2-7 (PGS 62-15 THROUGH 62-22)
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 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
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
HYDRAULIC FILTER
REMOVAL
INSTALLATION
SWITCH PUMP
REMOVAL
INSTALLATION
POC VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
DUMP CYLINDER
REMOVAL
INSTALLATION
LIFT CYLINDER
REMOVAL
INSTALLATION
LIFT AND DUMP CYLINDERS
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
64 MAINTENANCE STANDARD
MAIN CONTROL VALVE
DUMP CYLINDER
LIFT CYLINDER
BUCKET LINKAGE
BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET
HYDRAULIC AND SWlTCH PUMP
POC PUMP
POC VALVE

80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION
ELECTRIC AND ELECTRONIC SYSTEM
ELECTRICAL WIRING DIAGRAM CIRCUIT
ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
PREHEATING WITH STARTING SWITCH
AUTOMATIC PREHEATING
COMBINATION SWITCH
ELECTRICAL TRANSMISSION CONTROL
TRANSMISSION CUT-OFF SWITCH
TRANSMISSION CUT-OFF SELECTOR SWITCH
NEUTRALIZER RELAY
ELECTRICAL PARKING BRAKE CONTROL
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
MONITOR PANEL
INDICATION ON MONITOR PANEL
CONTROLLER
WIRING HARNESS
SENSORS
CONTACT SWITCH
OPERATION OF CONTACT SWITCH
82 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
CONNECTOR TERMINAL NUMBERS
PRECAUTION WHEN HANDLING CONNECTOR
ELECTRICAL WIRING DIAGRAM
ELETRICAL CIRCUIT SYSTEM
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-15)
E-1 ENGINE DOES NOT START
E-1A ENGINE DOES NOT START (STARTING MOTOR ROTATES)
E-2 ENGINE DOES NOT STOP
E-3 ENGINE STOPS WHEN TRAVELING
E-4 a)PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON)
b)PARKlNG BRAKE DOES NOT WORK. (AIR PRESSURE LESS THAN 2.0kg/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
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 TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON
E-12 TRANSMISSION CANNOT BE CUT-OFF.
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL
E-14 PREHEATING DISPLAY DOES NOT GO OUT
E-15 PREHATING DOES NOT WORK
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 to M-11)(Serial No. 10001-10662)
M-1 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ITEM
a) BRAKE OIL LEVEL FLASHES
b) ENGINE OIL LEVEL FLASHES
c) COOLANT LEVEL FLASHES.
M-2 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES
a) BATTERY CHARGE FLASHES.
b) FUEL LEVEL FLASHES
c) CLOGGING IN TRANsMlSSl0N OIL FILTER FLASHES
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASHES
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 ABNORM
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) PREHEAT DISPLAY LIGHTS UP
f) PREHEAT DISPLAY DOES NOT LIGHT UP
g) FAILURE IN MAIN STEERING DISPLAY LIGHTS UP (IF EQUIPPED)
h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)
i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED)
i) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)
k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP
I) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP
M-5 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT UP.
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
*** MISSING "b)..." (PG 82-79 & 82-80)
c) EVEN WHEN ENGINE IS STOPPED (ENGINE OIL PRESSURE) FLASHES, CAUTION BUZZER SOUNDS AND WARNING
d) EVEN WHEN ENGINE STOPPED, I- (BATTERY CHARGE) L-J 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 SMALL LAMP IN COMBINATION LAMP IS USED
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS
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 LAMP DOES NOT FLASH
M-11 ABNORMALITY IN GAUGE.
a) FUEL GAUGE
b) AIR PRESSURE GUAGE
c) COOLANT TEMPERATURE GAUGE
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (Electronic vehicle monitoring system)(Serial No. 10663 and UP)
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 parking brake stays lighted up
b) If parking brake does not light up
M-14 WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP
a) if working lamp stays lighted up
b) If working lamp 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) Transmission cut-off lights up
b) Transmission cut-off 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 POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND.
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 IS FLASHING BUT WARNING LAMP DOES NOT FLASH.
M-28 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNIGN 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 TEMPERRATURE GUAGE 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
MONITOR MACHINE
Serial No. 10001-10662
REMOVAL
INSTALLATION
Serial No. 10663 and up
REMOVAL
INSTALLATION

90 OTHERS
91 OTHERS
CAB
AIR CONDITIONER
PIPING
AIR CONDITIONER WIRING DIAGRAM
AIR CONDITIONER ELECTRIC CIRCUIT
AIR CONDITIONER UNIT
COMPRESSOR
CONDENSER
DRY RESERVOIR
93 DISASSEMBLY AND ASSEMBLY
CAB
REMOVAL
INSTALLATION
AIR CONDITIONER UNIT (If equipped)
REMOVAL
INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL
INSTALLATION
DRY RESERVOIR
REMOVAL
INSTALLATION
COMPRESSOR FOR AIR CONDITIONER
(For DAIKIN air conditioner)
REMOVAL
INSTALLATION
(For DENS0 air conditioner)
REMOVAL
INSTALLATION
97 GEAR PUMP SA SERIES
STRUCTURE
TESTING AND ADJUSTING
DISASSEMBLY
ASSEMBLY
MAINTENANCE STANDARD

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