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KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A81001 & UP) KOMATSU AVANCE PLUS WA180-3MC – PDF DOWNLOAD
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- KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A81001 & UP
- PUBLICATION NUMBER:CEBM005002
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KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A81001 & UP) KOMATSU AVANCE PLUS WA180-3MC
KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A81001 & UP) KOMATSU AVANCE PLUS WA180-3MC – PDF DOWNLOAD:
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KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A81001 & UP) KOMATSU AVANCE PLUS WA180-3MC
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - TESTING, ADJUSTING AND TROUBLESHOOTING
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 to Causes are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU AVANCE PLUS WA180-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A81001 & UP) KOMATSU AVANCE PLUS WA180-3MC
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 CONTENTS........................................................................................................ 2 00 FORWARD...................................................................................................... 11 HOW TO READ THE SHOP MANUAL................................................................................. 14 VOLUMES................................................................................................. 14 DISTRIBUTION AND UPDATING............................................................................... 14 FILING METHOD........................................................................................... 14 REVISED EDITION MARK.................................................................................... 14 REVISIONS............................................................................................... 14 SYMBOLS................................................................................................. 14 HOISTING INSTRUCTIONS....................................................................................... 15 HOISTING................................................................................................ 15 WIRE ROPES.............................................................................................. 15 COATING MATERIALS........................................................................................... 16 STANDARD TIGHTENING TORQUE.................................................................................. 18 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS............................................................ 18 TIGHTENING TORQUE OF HOSE NUTS.......................................................................... 19 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................. 19 TIGHTENING TORQUE FOR FLARED NUTS....................................................................... 19 ELECTRIC WIRE CODE.......................................................................................... 20 CLASSIFICATION BY THICKNESS............................................................................. 20 CLASSIFICATION BY COLOR AND CODE........................................................................ 20 CONVERSION TABLES........................................................................................... 21 METHOD OF USING THE CONVERSION TABLE.................................................................... 21 SAFETY...................................................................................................... 11 SAFETY NOTICE........................................................................................... 11 IMPORTANT SAFETY NOTICE............................................................................. 11 GENERAL PRECAUTIONS................................................................................. 11 PREPARATIONS FOR WORK............................................................................... 11 PRECAUTIONS DURING WORK............................................................................. 11 01 GENERAL...................................................................................................... 27 SPECIFICATION DRAWING....................................................................................... 28 SPECIFICATIONS.............................................................................................. 29 LIST OF LUBRICANT AND WATER................................................................................. 34 ENGINE OIL SPECIFICATIONS................................................................................... 35 NORMAL OPERATION........................................................................................ 35 ARCTIC OPERATION........................................................................................ 35 DIESEL FUEL SPECIFICATIONS.................................................................................. 36 COOLANT SPECIFICATIONS...................................................................................... 36 GENERAL................................................................................................. 36 WATER................................................................................................... 36 ANTIFREEZE.............................................................................................. 37 INHIBITORS/CONDITIONERS................................................................................. 38 10 STRUCTURE AND FUNCTION....................................................................................... 43 POWER TRAIN................................................................................................. 47 OUTLINE................................................................................................. 47 POWER TRAIN SYSTEM.......................................................................................... 48 OUTLINE................................................................................................. 49 TORQUE CONVERTER, TRANSMISSION PIPING....................................................................... 50 OUTLINE................................................................................................. 50 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....................................................................... 52 ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND..................................... 52 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...................................................................... 53 ENGINE STOPPED.......................................................................................... 53 TORQUE CONVERTER............................................................................................ 54 TORQUE CONVERTER OIL FILTER................................................................................. 56 TRANSMISSION................................................................................................ 58 CLUTCH.................................................................................................. 60 REVERSE 1ST CLUTCH.................................................................................. 60 FORWARD, 2ND CLUTCH................................................................................. 61 3RD, 4TH CLUTCH..................................................................................... 61 FORWARD 1ST......................................................................................... 63 FORWARD 2ND......................................................................................... 64 FORWARD 3RD......................................................................................... 65 FORWARD 4TH......................................................................................... 66 REVERSE 1ST......................................................................................... 67 TRANSMISSION CONTROL VALVE.................................................................................. 68 UPPER VALVE............................................................................................. 69 LOWER VALVE............................................................................................. 70 TRANSMISSION SOLENOID VALVE............................................................................. 71 TORQUE CONVERTER OUTLET PORT VALVE...................................................................... 72 PILOT REDUCING VALVE.................................................................................... 73 TRANSMISSION SOLENOID VALVE............................................................................. 74 PRIORITY VALVE.......................................................................................... 75 MAIN REGULATOR VALVE.................................................................................... 76 QUICK RETURN VALVE...................................................................................... 77 MODULATION FILL VALVE................................................................................... 81 DIRECTIONAL SELECTOR SPOOL.............................................................................. 83 EMERGENCY MANUAL SPOOL.................................................................................. 84 OPERATION OF FORWARD 1ST................................................................................ 86 ACCUMULATOR VALVE....................................................................................... 88 TRANSMISSION CONTROL........................................................................................ 90 DRIVE SHAFT................................................................................................. 91 AXLE........................................................................................................ 92 FRONT AXLE.............................................................................................. 92 FRONT DIFFERENTIAL...................................................................................... 93 REAR AXLE............................................................................................... 94 REAR DIFFERENTIAL....................................................................................... 95 TORQUE PROPORTIONING DIFFERENTIAL....................................................................... 97 FINAL DRIVE................................................................................................. 98 AXLE MOUNT..................................................................................................100 CENTER HINGE PIN............................................................................................102 STEERING PIPING.............................................................................................103 STEERING COLUMN.............................................................................................104 PRIORITY VALVE..............................................................................................105 CUSHION VALVE...............................................................................................108 STEERING VALVE (ORBIT-ROLL).................................................................................110 CONNECTION BETWEEN HAND PUMP AND SLEEVE.................................................................116 BRAKE.......................................................................................................118 BRAKE PIPING............................................................................................118 BRAKE CONTROL...........................................................................................119 BRAKE BOOSTER...........................................................................................120 BRAKE...................................................................................................123 PARKING BRAKE CONTROL...................................................................................125 PARKING BRAKE...........................................................................................126 HYDRAULIC...................................................................................................128 HYDRAULIC PIPING........................................................................................128 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.................................................................130 ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD".........................................................130 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................131 HYDRAULIC TANK..........................................................................................133 OIL FILTER BYPASS VALVE.............................................................................134 BREATHER............................................................................................135 PPC VALVE...............................................................................................136 PPC RELIEF VALVE........................................................................................142 ACCUMULATOR.............................................................................................143 FOR PPC VALVE.......................................................................................143 MAIN CONTROL VALVE......................................................................................144 2-SPOOL.............................................................................................144 3-SPOOL.............................................................................................146 RELIEF VALVE........................................................................................148 SAFETY VALVE (WITH SUCTION).........................................................................149 SUCTION VALVE.......................................................................................150 BOOM AND BUCKET SPOOL AT NEUTRAL POSITION...........................................................151 BOOM SPOOL AT RAISE POSITION........................................................................152 BOOM SPOOL AT LOWER POSITION........................................................................153 BOOM SPOOL AT FLOAT POSITION........................................................................154 BUCKET SPOOL AT TILT BACK POSITION..................................................................155 BUCKET SPOOL AT DUMP POSITION.......................................................................156 WORK EQUIPMENT..............................................................................................157 WORK EQUIPMENT LVER LINKAGE.............................................................................157 WORK EQUIPMENT LINKAGE..................................................................................158 BUCKET..................................................................................................160 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................161 BUCKET POSITIONER...................................................................................162 BOOM KICK-OUT.......................................................................................162 PROXIMITY SWITCH....................................................................................163 ROPS CAB....................................................................................................165 AIR CONDITIONER.............................................................................................166 AIR CONDITIONER AND HEATER PIPING.......................................................................166 ECSS........................................................................................................167 ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM...........................................................168 OPERATION...............................................................................................169 CENTRAL PANEL...............................................................................................170 SENSORS.....................................................................................................171 ENGINE OIL PRESSURE.....................................................................................171 BRAKE OIL LEVEL.........................................................................................171 ENGINE SPEED SENSOR.....................................................................................172 ENGINE......................................................................................................173 ENGINE STARTING CIRCUIT.................................................................................173 ENGINE STOP CIRCUIT.....................................................................................174 AUTOMATIC PREHEATING CIRCUIT................................................................................175 QUICK HEATING SYSTEM (QHS)..............................................................................175 QHS CONTROLLER..........................................................................................177 HEATER RELAY............................................................................................177 RIBBON HEATER...........................................................................................178 QHS WATER TEMPERATURE SENSOR............................................................................178 TRANSMISSION AUTO-SHIFT CONTROL.............................................................................179 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM......................................................................180 SHIFT CONTROL SYSTEM FUNCTION...........................................................................181 INPUT SIGNALS.......................................................................................181 OUTPUT SIGNALS......................................................................................182 SHIFT CHARACTERISTICS...............................................................................183 SAFETY FUNCTION.....................................................................................187 TROUBLESHOOTING.........................................................................................187 TRANSMISSION CONTROLLER.................................................................................188 CONNECTOR SIGNALS...................................................................................188 COMBINATION SWITCH......................................................................................189 TRANSMISSION CUT-OFF FUNCTION...........................................................................190 PARKING BRAKE FUNCTION..................................................................................192 KICK-DOWN SWITCH........................................................................................193 KICK-DOWN ELECTRICAL CIRCUIT........................................................................194 KICK-DOWN SWITCH OPERATED...........................................................................195 KICK-DOWN SWITCH ACTUATION - CANCELED (1)...........................................................196 KICK-DOWN SWITCH ACTUATION - CANCELED (2)...........................................................197 ELECTRICAL WIRING ILLUSTRATION..............................................................................199 ELECTRICAL WIRING DIAGRAM (1/5).............................................................................201 ELECTRICAL WIRING DIAGRAM (2/5).............................................................................203 ELECTRICAL WIRING DIAGRAM (3/5).............................................................................205 ELECTRICAL WIRING DIAGRAM (4/5).............................................................................207 ELECTRICAL WIRING DIAGRAM (5/5).............................................................................209 20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................213 STANDARD VALUE TABLE........................................................................................217 ENGINE TABLE - IN CHASSIS...............................................................................217 CHASSIS TABLE...........................................................................................218 SERVICE TOOLS TABLE.........................................................................................224 ENGINE COMPONENTS...........................................................................................226 ADJUSTING ENGINE STOP MOTOR CABLE.......................................................................226 ADJUSTING ENGINE STOP SOLENOID..........................................................................226 MEASURING AND ADJUSTING VALVE CLEARANCE.................................................................226 MEASURING BLOW-BY PRESSURE..............................................................................226 MEASURING COMPRESSION PRESSURE..........................................................................226 MEASURING COOLANT TEMPERATURE...........................................................................226 MEASURING ENGINE LUBRICATING OIL PRESSURE...............................................................226 MEASURING ENGINE SPEEDS.................................................................................226 MEASURING EXHAUST COLOR.................................................................................226 MEASURING EXHAUST GAS TEMPERATURE.......................................................................226 MEASURING FUEL FILTER INLET RESTRICTION.................................................................226 TEST AND ADJUSTING FAN BELT TENSION.....................................................................226 TEST AND ADJUSTING FUEL INJECTION TIMING................................................................226 ACCELERATOR PEDAL...........................................................................................227 OPERATING FORCE.........................................................................................227 OPERATING ANGLE.........................................................................................228 SPEED LEVER.................................................................................................229 OPERATING FORCE.........................................................................................229 TRAVEL..................................................................................................229 STALL SPEEDS................................................................................................230 TORQUE CONVERTER STALL SPEED............................................................................230 HYDRAULIC STALL SPEED...................................................................................231 FULL STALL SPEED........................................................................................231 TORQUE CONVERTER OIL PRESSURE...............................................................................232 TRANSMISSION OIL PRESSURE...................................................................................232 EMERGENCY MANUAL SPOOL......................................................................................234 OPERATION...............................................................................................234 STEERING WHEEL..............................................................................................236 PLAY....................................................................................................236 OPERATING FORCE.........................................................................................236 OPERATING TIME..........................................................................................237 STEERING OIL PRESSURE.......................................................................................238 METHOD OF MEASURING MAIN RELIEF PRESSURE................................................................238 METHOD OF ADJUSTING MAIN RELIEF PRESSURE................................................................239 BRAKE.......................................................................................................240 BRAKE PEDAL.............................................................................................240 OPERATING FORCE.....................................................................................240 TRAVEL..............................................................................................240 BRAKE PEDAL LINKAGE.....................................................................................241 TESTING.............................................................................................241 ADJUSTING...........................................................................................241 BRAKE PERFORMANCE.......................................................................................243 BRAKE OIL PRESSURE......................................................................................244 BRAKE DISC WEAR.........................................................................................245 BLEEDING AIR............................................................................................246 PARKING BRAKE...............................................................................................247 PARKING BRAKE PERFORMANCE...............................................................................247 PARKING BRAKE LINKAGE...................................................................................248 DISC WEAR...............................................................................................249 TESTING.............................................................................................249 MEASURING...........................................................................................250 WORK EQUIPMENT..............................................................................................251 CONTROL LEVER...........................................................................................251 PPC VALVE...............................................................................................252 MEASURING PRESSURE..................................................................................252 WORK EQUIPMENT HYDRAULIC PRESSURE.......................................................................254 WORK EQUIPMENT MEASUREMENT..............................................................................256 HYDRAULIC DRIFT WORK EQUIPMENT......................................................................257 BUCKET POSITIONER.......................................................................................258 TESTING.............................................................................................258 ADJUSTING...........................................................................................258 BOOM KICK-OUT (IF EQUIPPED).............................................................................259 TESTING.............................................................................................259 ADJUSTING...........................................................................................259 PROXIMITY SWITCH ACTUATION PILOT LAMP (RED).............................................................260 TROUBLESHOOTING GENERAL.....................................................................................261 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................263 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................265 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...............................................................266 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT........................................................266 HANDLING CONTROL BOX................................................................................271 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT................................................272 CHECKS BEFORE TROUBLESHOOTING...........................................................................274 JUDGEMENT OF POWER TRAIN................................................................................275 PRECAUTIONS WHEN TROUBLESHOOTING........................................................................276 SAFETY..............................................................................................276 METHODS FOR TROUBLESHOOTING.........................................................................276 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....278 PREVENTING RECURRENCE OF TROUBLE........................................................................279 HYDRAULIC EQUIPMENT.................................................................................279 OIL CHECKS......................................................................................279 CLEANING FRAGMENTS OF DAMAGED PARTS.............................................................279 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................280 CATEGORY OF TROUBLESHOOTING CODE NUMBER.............................................................280 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.................................280 METHOD OF USING MATRIX TROUBLESHOOTING TABLES...........................................................282 METHOD OF USING ENGINE RELATED CHARTS...................................................................284 TROUBLESHOOTING ELECTRICAL CONNECTORS.......................................................................289 CONNECTOR TYPES.........................................................................................290 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..............................................................293 ELECTRICAL CIRCUIT DIAGRAMS.............................................................................301 ENGINE START, STOP SYSTEM...........................................................................301 PREHEATING SYSTEM...................................................................................302 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)..................................................303 OUTLINE.................................................................................................304 FUNCTION............................................................................................304 TROUBLESHOOTING.....................................................................................304 FAILURE CODE TABLE..................................................................................304 TABLE OF TROUBLESHOOTING MODES AND CAUSES...........................................................305 A-1 TROUBLESHOOTING CODE [12]...........................................................................306 F SOLENOID SIGNAL SYSTEM............................................................................306 A-2 TROUBLESHOOTING CODE [13]...........................................................................307 R SOLENOID SIGNAL SYSTEM............................................................................307 A-3 TROUBLESHOOTING CODE [14]...........................................................................308 ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...........................................................308 A-4 TROUBLESHOOTING CODE [16]...........................................................................309 ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.........................................................309 A-5 TROUBLESHOOTING CODE [20]...........................................................................310 ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM......................................................310 A-6 TROUBLESHOOTING CODE [21]...........................................................................311 ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM............................................................311 A-7 TROUBLESHOOTING CODE [22]...........................................................................312 ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...........................................................312 A-8 TROUBLESHOOTING CODE [23]...........................................................................313 ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM...........................................................313 A-10 KICK-DOWN SWITCH SYSTEM............................................................................314 A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM.................................................................315 A-12 NEUTRALIZER RELAY SIGNAL SYSTEM....................................................................316 A-13 BUZZER SIGNAL SYSTEM...............................................................................317 A-15 CONTROLLER POWER SOURCE SYSTEM.....................................................................318 TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTM (D-MODE) ECSS....................................319 ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC.................................................................737 ECSS - WORKING CHART....................................................................................320 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...............................................................321 INSPECTION / ADJUSTMENT.............................................................................321 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)..................................................303 E-1 ENGINE DOES NOT START...............................................................................304 A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.............................324 B. CHECK FUEL SHUT-OFF SOLENOID.....................................................................326 E-2 ENGINE DOES NOT STOP................................................................................297 E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR.......328 E-10 PREHEATING IS NOT CARRIED OUT......................................................................330 E-11 PREHEATING REMAINS ACTUATED........................................................................332 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...................................................................335 S1 STARTING PERFORMANCE IS POOR.........................................................................337 S2 ENGINE DOES NOT START................................................................................338 (1) ENGINE DOES NOT TURN............................................................................338 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT.......................................................339 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START.................................................340 S-3 ENGINE DOES NOT PICK UP SMOOTHLY....................................................................341 S-4 ENGINE STOPS DURING OPERATIONS......................................................................342 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................343 S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................344 S-7 EXHAUST GAS IS BLACK................................................................................345 S-8 OIL CONSUMPTION IS EXCESSIVE........................................................................346 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................347 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................348 S-11 OIL IN COOLING WATER...............................................................................349 S-12 OIL PRESSURE LAMP LIGHTS UP........................................................................350 S-13 OIL LEVEL RISES....................................................................................351 S-14 WATER TEMPERATURE BECOMES TOO HIGH.................................................................352 S-15 ABNORMAL NOISE IS MADE.............................................................................353 S-16 VIBRATION IS EXCESSIVE.............................................................................354 TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)..................................................355 T-1 MACHINE DOES NOT START..............................................................................357 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES................................358 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS.............................................360 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEARS..........................................361 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH............................................................362 T-6 STEERING WHEEL DOES NOT TURN........................................................................363 T-7 STEERING IS HEAVY...................................................................................364 T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK...................................................365 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...............................................365 T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT.................................................366 T-11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT....................366 T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.......................................................367 T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS.................................................................368 T-14 BOOM DOES NOT RISE.................................................................................369 T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER..................................................370 T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT...........................................371 T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).........................................371 T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM..................................................................371 T-19 BOOM SHAKES DURING OPERATION.......................................................................372 T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...........................372 T-21 BUCKET DOES NOT TILT BACK..........................................................................373 T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...................................................374 T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION............................................375 T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.......................................................375 T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET................................................................375 T-26 BUCKET SHAKES DURING LOADING OPERATION.............................................................376 T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT..........................376 T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES NOT MOVE SMOOTHLY....................................377 TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER......................................................379 SERVICE TOOLS...........................................................................................381 GAUGE MANIFOLD......................................................................................381 STRUCTURE AND HANDLING OF GAUGE MANIFOLD........................................................382 CHARGING HOSES..................................................................................384 GAS LEAK DETECTOR...................................................................................385 HALIDE TORCH LEAK DETECTOR......................................................................385 ELECTRIC LEAK TESTER............................................................................387 VALVE FOR SERVICE CANS..............................................................................389 MAINTENANCE PROCEDURE...................................................................................390 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING......................................................390 PROHIBITED WORK.................................................................................390 OTHER PRECAUTIONS...............................................................................390 BLEEDING AIR FROM REFRIGERATION CIRCUIT.............................................................392 PURPOSE.........................................................................................392 CONNECTING GAUGE MANIFOLD.......................................................................392 EVACUATION......................................................................................393 AIR-TIGHTNESS CHECK.............................................................................393 GAS-LEAK CHECK..................................................................................394 EVACUATION (REPEATING)..........................................................................394 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT.................................................395 CHARGING FROM THE HIGH-PRESSURE SIDE............................................................395 CHARGING FROM THE LOW PRESSURE SIDE.............................................................396 WHEN THE AMBIENT TEMPERATURE IS LOW.............................................................397 WHEN THE AMBIENT TEMPERATURE IS HIGH............................................................397 REPLACING SERVICE CANS..............................................................................398 CHECKING THE AMOUNT OF REFRIGERANT..................................................................398 REMOVAL OF GAUGE MANIFOLD...........................................................................400 DISCHARGING THE REFRIGERANT.........................................................................400 DAILY CHECKS........................................................................................401 CHECK REFRIGERANT LEVEL.........................................................................401 CLEANING THE CONDENSER..........................................................................401 CHECKING THE V-BELT.................................................................................401 CHECKING OIL LEVEL..................................................................................402 PROCEDURE FOR CHECKING..........................................................................402 PROCEDURE FOR CHECKING OIL LEVEL................................................................402 ADDING AND REMOVING OIL.........................................................................403 ADDING OIL BY EVACUATION........................................................................403 TROUBLESHOOTING.........................................................................................404 VISUAL AND ACOUSTICAL CHECKS........................................................................404 DEFECTIVE COOLING...................................................................................405 TROUBLESHOOTING TABLE...............................................................................407 DEFECTIVE HEATING...................................................................................409 TROUBLESHOOTING USING GAUGE MANIFOLD................................................................410 PREPARATIONS BEFORE MEASURING...................................................................410 INSUFFICIENT REFRIGERANT........................................................................410 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER......................................411 AIR INSIDE REFRIGERATION SYSTEM.................................................................412 MOISTURE IN REFRIGERATING SYSTEM................................................................413 REFRIGERANT DOES NOT CIRCULATE..................................................................414 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...............415 DEFECTIVE COMPRESSION BY COMPRESSOR.............................................................416 30 DISASSEMBLY AND ASSEMBLY.....................................................................................417 METHOD OF USING MANUAL......................................................................................421 PRECAUTIONS DURING OPERATION................................................................................422 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..............................................................422 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.........................................................423 PRECAUTIONS WHEN COMPLETING THE OPERATIONS..............................................................424 OTHER PRECAUTIONS.......................................................................................424 SPECIAL TOOL LIST...........................................................................................425 ENGINE COMPONENTS...........................................................................................427 ALTERNATOR ASSEMBLY.....................................................................................427 CYLINDER HEAD ASSEMBLY..................................................................................427 ENGINE OIL COOLER ASSEMBLY..............................................................................427 FUEL INJECTION PUMP ASSEMBLY............................................................................427 NOZZLE HOLDER ASSEMBLY..................................................................................427 STARTING MOTOR ASSEMBLY.................................................................................427 THERMOSTAT ASSEMBLY.....................................................................................427 TURBOCHARGER ASSEMBLY...................................................................................427 WATER PUMP ASSEMBLY.....................................................................................427 COVERS AND LADDER...........................................................................................428 REMOVAL.................................................................................................428 INSTALLATION............................................................................................429 ENGINE HOOD.................................................................................................430 REMOVAL.................................................................................................430 INSTALLATION............................................................................................431 RADIATOR....................................................................................................432 REMOVAL.................................................................................................432 INSTALLATION............................................................................................435 ENGINE......................................................................................................436 REMOVAL.................................................................................................436 INSTALLATION............................................................................................443 EXHAUST MUFFLER.............................................................................................444 REMOVAL.................................................................................................444 INSTALLATION............................................................................................444 AIR CLEANER.................................................................................................445 REMOVAL.................................................................................................445 INSTALLATION............................................................................................445 TORQUE CONVERTER CHARGING PUMP..............................................................................446 REMOVAL.................................................................................................446 INSTALLATION............................................................................................446 TORQUE CONVERTER, TRANSMISSION..............................................................................447 REMOVAL.................................................................................................447 INSTALLATION............................................................................................454 TORQUE CONVERTER............................................................................................456 DISASSEMBLY.............................................................................................456 ASSEMBLY................................................................................................458 TRANSMISSION................................................................................................460 DISASSEMBLY.............................................................................................460 DISASSEMBLY OF PARKING BRAKE........................................................................469 ASSEMBLY OF PARKING BRAKE...........................................................................471 ASSEMBLY................................................................................................474 TRANSMISSION CLUTCH PACK....................................................................................486 DISASSEMBLY.............................................................................................486 1ST, REVERSE CLUTCH.................................................................................486 FORWARD, 2ND CLUTCH PACK............................................................................488 3RD, 4TH CLUTCH PACK................................................................................490 ASSEMBLY................................................................................................492 1ST, REVERSE CLUTCH.................................................................................492 FORWARD, 2ND CLUTCH.................................................................................497 3RD, 4TH CLUTCH.....................................................................................501 TRANSMISSION CONTROL VALVE..................................................................................506 REMOVAL.................................................................................................506 INSTALLATION............................................................................................508 DISASSEMBLY.............................................................................................510 ASSEMBLY................................................................................................512 TRANSMISSION SOLENOID VALVE.................................................................................515 DISASSEMBLY.............................................................................................515 ASSEMBLY................................................................................................516 TRANSMISSION ACCUMULATOR VALVE..............................................................................517 DISASSEMBLY.............................................................................................517 ASSEMBLY................................................................................................518 DRIVE SHAFT.................................................................................................519 DISASSEMBLY.............................................................................................519 ASSEMBLY................................................................................................520 FRONT AXLE..................................................................................................521 REMOVAL.................................................................................................521 INSTALLATION............................................................................................522 REAR AXLE...................................................................................................523 REMOVAL.................................................................................................523 INSTALLATION............................................................................................527 DIFFERENTIAL................................................................................................532 DISASSEMBLY.............................................................................................532 ASSEMBLY................................................................................................536 AXLE HOUSING................................................................................................546 DISASSEMBLY.............................................................................................546 ASSEMBLY................................................................................................551 CENTER HINGE PIN............................................................................................559 REMOVAL.................................................................................................559 INSTALLATION............................................................................................567 PRIORITY VALVE..............................................................................................576 REMOVAL.................................................................................................576 INSTALLATION............................................................................................577 STEERING VALVE..............................................................................................578 REMOVAL.................................................................................................578 INSTALLATION............................................................................................580 DISASSEMBLY.............................................................................................581 DISASSEMBLY OF ROTOR................................................................................581 DISASSEMBLY OF CONTROL SIDE.........................................................................582 ASSEMBLY................................................................................................584 ASSEMBLY OF CONTROL SIDE............................................................................584 ASSEMBLY OF ROTOR...................................................................................586 MAIN CONTROL VALVE..........................................................................................589 REMOVAL.................................................................................................589 INSTALLATION............................................................................................591 DISASSEMBLY.............................................................................................592 ASSEMBLY................................................................................................594 PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES.............................................................596 PPC VALVE...................................................................................................598 REMOVAL.................................................................................................598 INSTALLATION............................................................................................599 STEERING CYLINDER...........................................................................................600 REMOVAL.................................................................................................600 INSTALLATION............................................................................................602 BRAKE BOOSTER...............................................................................................603 REMOVAL.................................................................................................603 INSTALLATION............................................................................................605 DISASSEMBLY.............................................................................................606 ASSEMBLY................................................................................................609 PARKING BRAKE...............................................................................................614 REMOVAL.................................................................................................614 INSTALLATION............................................................................................616 HYDRAULIC TANK..............................................................................................618 REMOVAL.................................................................................................618 INSTALLATION............................................................................................619 HYDRAULIC FILTER............................................................................................620 REMOVAL.................................................................................................620 INSTALLATION............................................................................................620 STEERING PUMP...............................................................................................621 REMOVAL.................................................................................................621 INSTALLATION............................................................................................622 BUCKET CYLINDER.............................................................................................623 REMOVAL.................................................................................................623 INSTALLATION............................................................................................624 BOOM CYLINDER...............................................................................................625 REMOVAL.................................................................................................625 INSTALLATION............................................................................................626 HYDRAULIC CYLINDER..........................................................................................627 DISASSEMBLY.............................................................................................627 ASSEMBLY................................................................................................629 ECSS SYSTEM.................................................................................................632 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...............................................................632 ECSS SOLENOID VALVE.....................................................................................633 REMOVAL.............................................................................................633 INSTALLATION........................................................................................633 ECSS CONTROL VALVE......................................................................................634 REMOVAL.............................................................................................634 INSTALLATION........................................................................................634 WORK EQUIPMENT..............................................................................................635 REMOVAL.................................................................................................635 INSTALLATION............................................................................................638 FUEL TANK...................................................................................................641 REMOVAL.................................................................................................641 INSTALLATION............................................................................................642 COUNTERWEIGHT...............................................................................................643 REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS................................................................643 INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS...........................................................643 REMOVAL OF REAR COUNTERWEIGHT...........................................................................643 INSTALLATION OF REAR COUNTERWEIGHT......................................................................644 INSTRUMENT PANEL............................................................................................645 REMOVAL.................................................................................................645 INSTALLATION............................................................................................645 AIR CONDITIONING............................................................................................646 AIR CONDITIONER UNIT....................................................................................646 REMOVAL.............................................................................................646 INSTALLATION........................................................................................652 AIR CONDITIONER CONDENSER...............................................................................653 REMOVAL.............................................................................................653 INSTALLATION........................................................................................654 DRYER RECEIVER..........................................................................................656 REMOVAL.............................................................................................656 INSTALLATION........................................................................................656 AIR CONDITIONER COMPRESSOR..............................................................................658 REMOVAL.............................................................................................658 INSTALLATION........................................................................................659 40 MAINTENANCE STANDARD.........................................................................................662 ENGINE MOUNT, TRANSMISSION MOUNT............................................................................663 TORQUE CONVERTER CHARGING PUMP..............................................................................665 TORQUE CONVERTER............................................................................................667 TRANSMISSION................................................................................................669 TRANSMISSION (1/3)......................................................................................669 TRANSMISSION (2/3)......................................................................................673 TRANSMISSION (3/3)......................................................................................677 REVERSE, 1ST CLUTCH.....................................................................................679 FORWARD, 2ND CLUTCH.....................................................................................681 3RD, 4TH CLUTCH.........................................................................................683 TRANSMISSION CONTROL VALVE..................................................................................685 UPPER VALVE.............................................................................................685 LOWER VALVE.............................................................................................687 SOLENOID VALVE..........................................................................................689 ACCUMULATOR VALVE...........................................................................................691 DRIVE SHAFT.................................................................................................693 DIFFERENTIAL................................................................................................695 DIFERENTIAL (1/2).......................................................................................695 DIFFERENTIAL (2/2)......................................................................................697 FINAL DRIVE.................................................................................................699 AXLE MOUNT..................................................................................................701 ADDITIONAL COUNTERWEIGHT....................................................................................703 CENTER HINGE PIN............................................................................................705 STEERING COLUMN.............................................................................................707 PRIORITY VALVE..............................................................................................709 STEERING CYLINDER MOUNT.....................................................................................710 BRAKE BOOSTER...............................................................................................711 BRAKE.......................................................................................................713 PARKING BRAKE...............................................................................................714 HYDRAULIC PUMP (SAL40+14+8).................................................................................715 MAIN CONTROL VALVE..........................................................................................716 2-SPOOL VALVE...........................................................................................716 3-SPOOL VALVE...........................................................................................719 HYDRAULIC CYLINDER..........................................................................................722 WORK EQUIPMENT LINKAGE......................................................................................723 BUCKET......................................................................................................725 BUCKET POSITIONER AND BOOM KICK-OUT.........................................................................727 90 OTHERS.......................................................................................................730 ELECTRICAL WIRING DIAGRAM (1/5).............................................................................732 ELECTRICAL WIRING DIAGRAM (2/5).............................................................................734 ELECTRICAL WIRING DIAGRAM (3/5).............................................................................736 ELECTRICAL WIRING DIAGRAM (4/5).............................................................................738 ELECTRICAL WIRING DIAGRAM (5/5).............................................................................740
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