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KOMATSU AVANCE PLUS WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU AVANCE PLUS WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM003602
- SERIAL NUMBERS WA450-3MC – A31001 and up,WA450-3MC – A35001 and up
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Description
KOMATSU AVANCE PLUS WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL
KOMATSU AVANCE PLUS WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU AVANCE PLUS WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL
- 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 WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL
MAIN MENU................................................................................................................................ 0 COVER.................................................................................................................................... 1 CONTENTS................................................................................................................................. 2 00 FOREWORD............................................................................................................................. 13 SAFETY............................................................................................................................... 14 GENERAL.............................................................................................................................. 16 HOW TO READ THE SHOP MANUAL.......................................................................................................... 17 HOISTING INSTRUCTIONS................................................................................................................ 18 COATING MATERIALS.................................................................................................................... 19 STANDARD TIGHTENING TORQUE........................................................................................................... 21 ELECTRIC WIRE CODE................................................................................................................... 24 CONVERSION TABLES.................................................................................................................... 25 01 GENERAL.............................................................................................................................. 31 SPECIFICATION DRAWING................................................................................................................ 32 SPECIFICATIONS....................................................................................................................... 34 WEIGHT TABLE......................................................................................................................... 36 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..................................................................................... 37 10 STRUCTURE AND FUNCTION............................................................................................................... 44 POWER TRAIN.......................................................................................................................... 45 POWER TRAIN SYSTEM................................................................................................................... 46 TORQUE CONVERTER, TRANSMISSION PIPING................................................................................................ 48 TRANSMISSION SYSTEM DIAGRAM.......................................................................................................... 49 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM............................................................................................... 50 TORQUE CONVERTER..................................................................................................................... 51 TORQUE CONVERTER OIL FILTER.......................................................................................................... 54 TRANSMISSION......................................................................................................................... 55 FORWARD AND 1ST CLUTCH........................................................................................................... 58 REVERSE AND 2ND CLUTCH........................................................................................................... 58 3RD AND 4TH CLUTCH............................................................................................................... 59 FORWARD 1ST...................................................................................................................... 60 FORWARD 2ND...................................................................................................................... 61 FORWARD 3RD...................................................................................................................... 62 FORWARD 4TH...................................................................................................................... 63 REVERSE 1ST...................................................................................................................... 64 TRANSMISSION CONTROL VALVE........................................................................................................... 65 UPPER VALVE...................................................................................................................... 66 LOWER VALVE...................................................................................................................... 67 TRANSMISSION SOLENOID VALVE...................................................................................................... 68 FLOW VALVE....................................................................................................................... 70 ACCUMULATOR VALVE................................................................................................................ 71 TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM......................................................................................... 73 DIRECTIONAL SELECTOR VALVE....................................................................................................... 74 EMERGENCY MANUAL SPOOL........................................................................................................... 75 PRIORITY VALVE................................................................................................................... 75 TORQUE CONVERTER OUTLET PORT VALVE............................................................................................... 77 PILOT REDUCING VALVE............................................................................................................. 78 PROPORTIONAL SOLENOID VALVE...................................................................................................... 79 TRANSMISSION SOLENOID VALVE...................................................................................................... 79 ELECTRONIC CONTROL MODULATION VALVE [ECMV]....................................................................................... 80 PILOT OIL FILTER................................................................................................................. 83 DRIVE SHAFT.......................................................................................................................... 84 FRONT AXLE........................................................................................................................... 85 REAR AXLE............................................................................................................................ 86 DIFFERENTIAL......................................................................................................................... 87 FRONT DIFFERENTIAL............................................................................................................... 87 REAR DIFFERENTIAL................................................................................................................ 88 TORQUE PROPORTIONING DIFFERENTIAL................................................................................................ 90 LIMITED SLIP DIFFERENTIAL............................................................................................................ 91 FINAL DRIVE.......................................................................................................................... 94 AXLE MOUNT, CENTER HINGE PIN......................................................................................................... 95 STEERING PIPING...................................................................................................................... 96 STEERING COLUMN...................................................................................................................... 97 STEERING VALVE....................................................................................................................... 98 OPERATION OF DEMAND VALVE........................................................................................................ 99 STEERING PILOT...................................................................................................................102 OPERATION OF STEERING VALVE......................................................................................................105 STEERING RELIEF VALVE............................................................................................................108 SAFETY VALVE.....................................................................................................................110 STEERING CONTROL VALVE...............................................................................................................112 CONNECTION BETWEEN HAND PUMP AND SLEEVE..........................................................................................114 STOP VALVE...........................................................................................................................116 GROUND DRIVEN STEERING PUMP..........................................................................................................117 DIVERTER VALVE.......................................................................................................................118 OPERATION........................................................................................................................119 BRAKE PIPING.........................................................................................................................121 BRAKE CIRCUIT DIAGRAM................................................................................................................122 BRAKE VALVE..........................................................................................................................123 RIGHT BRAKE VALVE................................................................................................................123 LEFT BRAKE VALVE.................................................................................................................124 OPERATION........................................................................................................................125 ACCUMULATOR CHARGE VALVE.............................................................................................................128 ACCUMULATOR..........................................................................................................................132 SLACK ADJUSTER.......................................................................................................................133 BRAKE................................................................................................................................135 PARKING BRAKE CONTROL................................................................................................................137 PARKING BRAKE........................................................................................................................138 PARKING BRAKE SOLENOID VALVE.........................................................................................................139 PARKING BRAKE VALVE..................................................................................................................140 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.......................................................................................141 HYDRAULIC PIPING.....................................................................................................................142 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM..............................................................................................144 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.............................................................................................145 WORK EQUIPMENT LEVER LINKAGE.....................................................................................................146 WORK EQUIPMENT LEVER LINKAGE.........................................................................................................146 HYDRAULIC TANK.......................................................................................................................147 BREATHER.........................................................................................................................148 PPC VALVE............................................................................................................................149 OPERATION OF PPC VALVE...........................................................................................................150 FUNCTION OF PPC VALVE............................................................................................................151 PPC RELIEF VALVE.....................................................................................................................153 PPC VALVE ACCUMULATOR................................................................................................................154 CUT OFF VALVE........................................................................................................................155 OPERATION........................................................................................................................156 MAIN CONTROL VALVE - TWO SPOOL [1/2].................................................................................................157 MAIN CONTROL VALVE [2/2].........................................................................................................158 MAIN CONTROL VALVE - THREE SPOOL [1/2]...............................................................................................159 MAIN CONTROL VALVE [2/2].........................................................................................................160 MAIN CONTROL VALVE...................................................................................................................161 RELIEF VALVE.....................................................................................................................161 SAFETY SUCTION VALVE.............................................................................................................162 SUCTION VALVE....................................................................................................................163 FLOAT SELECTOR VALVE AND UNLOAD VALVE............................................................................................164 BOOM AND BUCKET SPOOL HOLD POSITION..............................................................................................165 BOOM SPOOL AT RAISE POSITION.....................................................................................................166 BOOM SPOOL AT LOWER POSITION.....................................................................................................167 BOOM SPOOL AT FLOAT POSITION.....................................................................................................168 BUCKET SPOOL AT DUMP POSITION....................................................................................................169 BUCKET SPOOL AT TILT POSITION....................................................................................................170 WORK EQUIPMENT LINKAGE...............................................................................................................171 BUCKET...............................................................................................................................173 BUCKET POSITIONER AND BOOM KICK OUT..................................................................................................174 BUCKET POSITIONER................................................................................................................175 BOOM KICK OUT....................................................................................................................175 BOOM PROXIMITY SWITCH............................................................................................................176 BUCKET PROXIMITY SWITCH..........................................................................................................178 ROPS CAB.............................................................................................................................180 HEATER AND DEFROSTER.................................................................................................................181 AIR CONDITIONER......................................................................................................................182 ELECTRIC CIRCUIT DIAGRAM.............................................................................................................183 MACHINE MONITOR SYSTEM...............................................................................................................184 MAIN MONITOR.........................................................................................................................185 MAIN MONITOR DISPLAY FUNCTION....................................................................................................186 PREHEATING OUTPUT FUNCTION.......................................................................................................187 TROUBLE DATA DISPLAY MODE........................................................................................................188 MAINTENANCE MONITOR..................................................................................................................189 MAINTENANCE MONITOR DISPLAY FUNCTION.............................................................................................190 TRANSMISSION AUTO SHIFT..............................................................................................................191 SYSTEM STRUCTURE DIAGRAM.........................................................................................................191 SHIFT CONTROL SYSTEM FUNCTION....................................................................................................192 SAFETY FUNCTION..................................................................................................................194 TROUBLESHOOTING..................................................................................................................194 TRANSMISSION CONTROLLER..........................................................................................................195 LOAD METER SYSTEM....................................................................................................................196 ADJUSTING LOAD MEASUREMENT POINTS................................................................................................197 CALIBRATION, ADJUSTING 0 POINT...................................................................................................198 MEASURING........................................................................................................................199 SETTING TARGET AMOUNT IN REMAIN MODE.............................................................................................202 PRINTING DATA....................................................................................................................203 DELETING DATA FROM STORAGE DEVICE................................................................................................204 SETTING TIME ON CLOCK............................................................................................................205 REPLACING PRINTER PAPER..........................................................................................................206 TROUBLESHOOTING FUNCTION.........................................................................................................208 SPARE PARTS......................................................................................................................208 ECSS.................................................................................................................................209 SENSORS..............................................................................................................................213 ENGINE OIL LEVEL SENSOR..........................................................................................................214 RADIATOR COOLANT LEVEL SENSOR....................................................................................................214 ENGINE OIL PRESSURE SENSOR.......................................................................................................215 ENGINE WATER TEMPERATURE SENSOR..................................................................................................215 TORQUE CONVERTER OIL TEMPERATURE SENSOR..........................................................................................216 ENGINE SPEED SENSOR..............................................................................................................216 FUEL LEVEL SENSOR................................................................................................................217 ENGINE START CIRCUIT.................................................................................................................218 ENGINE STOP CIRCUIT..................................................................................................................219 PREHEATING CIRCUIT...................................................................................................................221 ELECTRIC TRANSMISSION CONTROL........................................................................................................223 COMBINATION SWITCH...............................................................................................................224 KICK DOWN, HOLD SWITCH...............................................................................................................226 KICK DOWN CIRCUIT DIAGRAM............................................................................................................227 TRANSMISSION CUT OFF SWITCH..........................................................................................................233 TRANSMISSION CUT OFF FUNCTION........................................................................................................234 ELECTRIC PARKING BRAKE CONTROL.......................................................................................................237 EMERGENCY BRAKE SWITCH...........................................................................................................239 PARKING BRAKE SAFETY RELAY NEUTRALIZER RELAY.....................................................................................239 OPERATION........................................................................................................................240 PARKING BRAKE SWITCH OFF.........................................................................................................244 PARKING BRAKE SWITCH ON..........................................................................................................247 WHEN MAIN BRAKE OIL PRESSURE DROPS...............................................................................................247 PARKING BRAKE EMERGENCY RELEASE..................................................................................................249 FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY......................................................................................250 20 TESTING AND ADJUSTING.................................................................................................................251 STANDARD VALUE TABLES FOR ENGINE.....................................................................................................252 STANDARD VALUE FOR CHASSIS...........................................................................................................253 STANDARD VALUE TABLES FOR ELECTRICAL PARTS...........................................................................................256 TESTING AND ADJUSTING................................................................................................................259 TOOLS FOR TESTING AND ADJUSTING..................................................................................................260 ENGINE SPEED.....................................................................................................................261 INTAKE AIR PRESSURE..............................................................................................................262 VALVE CLEARANCE..................................................................................................................263 EXHAUST COLOR....................................................................................................................264 EXHAUST TEMPERATURE..............................................................................................................265 BLOW BY PRESSURE.................................................................................................................266 COMPRESSION PRESSURE.............................................................................................................267 ENGINE OIL PRESSURE..............................................................................................................268 FUEL INJECTION TIMING............................................................................................................269 ENGINE STOP MOTOR CABLE..........................................................................................................272 FAN BELT TENSION.................................................................................................................274 ACCELERATOR PEDAL................................................................................................................275 SPEED CONTROL LEVER..............................................................................................................277 STALL SPEED......................................................................................................................278 POWER TRAIN OIL PRESSURE.........................................................................................................280 EMERGENCY MANUAL SPOOL...........................................................................................................281 TIRE AND WHEEL...................................................................................................................282 STEERING WHEEL...................................................................................................................283 STEERING CONTROL.................................................................................................................285 STEERING OIL PRESSURE............................................................................................................286 BRAKE PEDAL......................................................................................................................287 BRAKE OIL PRESSURE...............................................................................................................288 BRAKE PERFORMANCE................................................................................................................289 BRAKE DISC WEAR..................................................................................................................290 BLEED AIR FROM BRAKE SYSTEM......................................................................................................291 ACCUMULATOR CHARGE PRESSURE......................................................................................................292 PARKING BRAKE PERFORMANCE........................................................................................................293 MANUAL RELEASE OF PARKING BRAKE..................................................................................................294 WEAR OF PARKING BRAKE DISC.......................................................................................................295 WORK EQUIPMENT CONTROL LEVER.....................................................................................................296 WORK EQUIPMENT PRESSURE..........................................................................................................298 WORK EQUIPMENT...................................................................................................................302 BUCKET POSITIONER................................................................................................................304 BOOM KICK OUT....................................................................................................................305 LOAD METER.......................................................................................................................307 MAIN MONITOR.....................................................................................................................309 FUEL LEVEL SENSOR................................................................................................................310 TROUBLESHOOTING......................................................................................................................311 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................................................312 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................313 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.................................................................................314 CHECKS BEFORE TROUBLESHOOTING....................................................................................................322 METHOD OF USING CHARTS...........................................................................................................323 CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................................................330 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................334 TROUBLESHOOTING OF ENGINE SYSTEM S MODE.............................................................................................344 S-1 STARTING PERFORMANCE IS POOR...............................................................................................345 S-2 ENGINE DOES NOT START......................................................................................................346 S-3 ENGINE DOES NOT PICK UP SMOOTHLY...........................................................................................349 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................350 S-5 ENGINE DOES NOT ROTATE SMOOTHLY............................................................................................351 S-6 ENGINE LACKS POWER.........................................................................................................352 S-7 EXHAUST GAS IS BLACK.......................................................................................................353 S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST GAS IS BLUE........................................................................354 S-9 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................355 S-10 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................356 S-11 OIL IS IN COOLANT, COOLANT SPURTS OR COOLANT LEVEL GOES DOWN...............................................................357 S-12 OIL PRESSURE LAMP LIGHTS UP................................................................................................358 S-13 OIL LEVEL RISES............................................................................................................359 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH.......................................................................................360 S-15 ABNORMAL NOISE IS MADE.....................................................................................................361 S-16 VIBRATION IS EXCESSIVE.....................................................................................................362 TROUBLESHOOTING OF MAIN MONITOR SYSTEM M MODE.......................................................................................363 FAILURE CODE.....................................................................................................................364 M-1 MAIN MONITOR DOES NOT WORK.................................................................................................366 M-2 WHEN START SWITCH IS TURNED ON AND ENGINE IS STARTED, ALL LAMPS STAY LIT..................................................367 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.................................................................................368 M-4 ABNORMALITY IN SHIFT INDICATOR.............................................................................................369 M-5 HIGH BEAM DOES NOT LIGHT UP................................................................................................371 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP......................................................................................372 M-7 ABNORMALITY IN PARKING DISPLAY.............................................................................................373 M-8 ABNORMALITY IN PREHEATING SYSTEM...........................................................................................374 M-9 TAIL LIGHTS DO NOT ILLUMINATE..............................................................................................376 M-10 ABNORMALITY IN FRONT WORKING LAMP..........................................................................................377 M-11 ABNORMALITY IN REAR WORKING LAMP...........................................................................................379 M-12 ABNORMALITY IN TRANSMISSION CUT OFF........................................................................................380 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING..............................................................................381 M-14 WHEN PARKING BRAKE DRAG WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY OR THEY ARE NOT ACTUATED.......382 M-15 ABNORMALITY IN BUZZER......................................................................................................383 M-16 CONDITIONER OF MONITOR SWITCHES IS NOT STORED IN MEMORY....................................................................384 M-17 ABNORMALITY IN FAILURE DISPLAY MODE........................................................................................385 M-18 ABNORMALITY IN GROUND DRIVEN STEERING NORMAL DISPLAY.......................................................................386 M-19 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY....................................................................387 M-20 ABNORMALITY IN ECSS SYSTEM.................................................................................................388 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM K MODE................................................................................389 K-1 WHEN START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOE....390 K-2 WHEN START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR ILLUMINATE, BUT DO NOT GO OUT.............................390 K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT.........391 K-4 WHEN START SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.........................................................392 K-5 WHEN START SWITCH IS TURNED ON, ENGINE STARTED, CAUTION ITEMS FLASH........................................................393 K-6 CAUTION ITEMS ARE FLASHING, BUT ALARM BUZZER DOES NOT SOUND................................................................397 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS........................................................398 K-8 CHECK OR CAUTION ITEMS ARE FLASHING, BUT CHECK OR CAUTION LAMP DOES NOT LIGHT UP...........................................399 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY, BUT CHECK OR CAUTION LAMP LIGHTS UP................................400 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON.............................................................401 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF......................................................................402 K-12 SERVICE METER DOES NOT WORK................................................................................................403 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.......................................................................403 K-14 ABNORMALITY IN GAUGE ITEMS.................................................................................................404 TROUBLESHOOTING OF ELECTRICAL SYSTEM E MODE.........................................................................................407 E-1 ENGINE DOES NOT START......................................................................................................409 E-2 ENGINE DOES NOT STOP.......................................................................................................412 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.....................................................................................413 E-4 PARKING BRAKE DOES NOT WORK................................................................................................414 E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.........................................................................415 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON................................................................416 E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED......................................................416 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM A MODE............................................................................417 FUNCTION.........................................................................................................................418 WHEN CARRYING OUT TROUBLESHOOTING................................................................................................418 FAILURE CODE.....................................................................................................................418 TABLE OF FAILURE MODES AND CAUSES................................................................................................419 A-1 FAILURE CODE [10] MODULATION VALVE SOLENOID SYSTEM.........................................................................420 A-2 FAILURE CODE [11] SHORT CIRCUIT IN POWER SUPPLY FOR MODULATION VALVE SOLENOID SYSTEM.......................................421 A-3 FAILURE CODE [12] F SOLENOID SIGNAL SYSTEM.................................................................................422 A-4 FAILURE CODE [13] R SOLENOID SIGNAL SYSTEM.................................................................................423 A-5 FAILURE CODE [14] ABNORMALITY IN HI LO SOLENOID SIGNAL SYSTEM..............................................................424 A-6 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM..............................................................425 A-7 FAILURE CODE [17] BRAKE OUTPUT SIGNAL SYSTEM...............................................................................426 A-8 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...........................................................427 A-9 FAILURE CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.................................................................428 A-10 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM................................................................429 A-11 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL.......................................................................430 A-12 HOLD SWITCH SYSTEM.........................................................................................................431 A-13 KICK DOWN SWITCH SYSTEM....................................................................................................432 A-14 TRANSMISSION CUT OFF SIGNAL SYSTEM.........................................................................................433 A-15 NEUTRALIZER RELAY SIGNAL SYSTEM............................................................................................434 A-16 BUZZER SIGNAL SYSTEM.......................................................................................................435 A-17 NETWORK SIGNAL SYSTEM......................................................................................................436 A-18 CONTROLLER POWER SOURCE SYSTEM.............................................................................................437 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM T MODE...........................................................................438 T-1 MACHINE DOES NOT MOVE......................................................................................................439 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.......................................................440 T-3 EXCESIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS.....................................................................441 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR..................................................................442 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...................................................................................443 T-6 STEERING DOES NOT TURN.....................................................................................................444 T-7 STEERING WHEEL IS HEAVY....................................................................................................445 T-8 STEERING WHEEL SHAKES OR JERKS.............................................................................................446 T-9 MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING................................................................................446 T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT.........................................................................446 T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...............................................................................447 T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG.....................................................................................448 T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS...............................................................................449 T-14 BOOM DOES NOT RISE.........................................................................................................450 T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER..........................................................................451 T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT...................................................................452 T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDERS................................................................................452 T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM..........................................................................................452 T-19 BOOM SHAKES DURING OPERATION...............................................................................................452 T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...................................................452 T-21 BUCKET DOES NOT TILT BACK..................................................................................................453 T-22 BUCKET MOVEMENT IS SLOW OR TILT BACK LACKS POWER...........................................................................454 T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK OPERATION....................................................................455 T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...............................................................................455 T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET........................................................................................455 T-26 BUCKET SHAKES DURING LOADING OPERATION.....................................................................................455 T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT..................................................455 T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..............................................................456 TROUBLESHOOTING OF ECSS E MODE.....................................................................................................457 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.................................................................................458 D-1 ECSS DOES NOT WORK.........................................................................................................459 D-2 ECSS CANNOT BE CANCELED....................................................................................................464 D-3 OUTPUT IS TURNED ON, TRAVEL SPEED DOES NOT BECOME 5 KM/H (DEVIATES AT AROUND 5 KM/H).......................................465 D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST............................................................................465 D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH............................................................................466 D-6 CONTROLLER LED CODE IS NOT DISPLAYED.......................................................................................467 D-7 ECSS IS ABNORMAL, BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY........................................................467 30 DISASSEMBLY AND ASSEMBLY..............................................................................................................468 HOW TO USE THIS MANUAL...............................................................................................................472 When removing or installing unit assemblies......................................................................................472 PRECAUTIONS DURING OPERATION.........................................................................................................473 Precautions when carrying out removal work.......................................................................................473 Precautions when carrying out installation work..................................................................................474 Precautions when completing the operations.......................................................................................475 SPECIAL TOOL LIST....................................................................................................................476 STARTING MOTOR.......................................................................................................................478 Removal..........................................................................................................................478 Installation.....................................................................................................................478 ALTERNATOR...........................................................................................................................479 Removal..........................................................................................................................479 Installation.....................................................................................................................479 ENGINE COMPONENTS....................................................................................................................480 RADIATOR.............................................................................................................................481 Removal..........................................................................................................................481 Installation.....................................................................................................................484 ENGINE...............................................................................................................................485 Removal.......................................................................................................................... 5 Installation.....................................................................................................................490 TORQUE CONVERTER, TRANSMISSION.......................................................................................................493 Removal..........................................................................................................................493 Installation.....................................................................................................................503 TORQUE CONVERTER.....................................................................................................................507 Disassembly......................................................................................................................507 Assembly.........................................................................................................................509 TRANSMISSION.........................................................................................................................513 Disassembly......................................................................................................................513 Torque Converter.............................................................................................................515 Transmission.................................................................................................................517 Assembly.........................................................................................................................520 TRANSMISSION CLUTCH PACK.............................................................................................................527 Disassembly......................................................................................................................527 FORWARD, 1st Clutch Assembly.................................................................................................527 REVERSE, 2ND CLUTCH ASSEMBLY.................................................................................................530 3RD, 4TH CLUTCH ASSEMBLY.....................................................................................................533 Assembly.........................................................................................................................537 FORWARD, 1ST CLUTCH ASSEMBLY.................................................................................................537 REVERSE, 2ND CLUTCH ASSEMBLY.................................................................................................541 3RD, 4TH CLUTCH ASSEMBLY.....................................................................................................545 PARKING BRAKE........................................................................................................................551 disASSEMBLY......................................................................................................................551 Assembly.........................................................................................................................553 TRANSMISSION CONTROL VALVE...........................................................................................................557 removal..........................................................................................................................557 Installation.....................................................................................................................560 Disassembly......................................................................................................................561 Assembly.........................................................................................................................566 TRANSMISSION ACCUMULATOR VALVE.......................................................................................................573 Disassembly......................................................................................................................573 Assembly.........................................................................................................................574 DRIVE SHAFT ASSEMBLY.................................................................................................................575 Disassembly......................................................................................................................575 ASSEMBLY.........................................................................................................................577 FRONT AXLE...........................................................................................................................579 Removal..........................................................................................................................579 Installation.....................................................................................................................581 REAR AXLE............................................................................................................................583 REMOVAL..........................................................................................................................583 Installation.....................................................................................................................587 FRONT DIFFERENTIAL...................................................................................................................591 REMOVAL..........................................................................................................................591 Installation.....................................................................................................................594 REAR DIFFERENTIAL....................................................................................................................597 Removal..........................................................................................................................597 Installation.....................................................................................................................600 DIFFERENTIAL.........................................................................................................................603 Disassembly......................................................................................................................603 Assembly.........................................................................................................................607 FINAL DRIVE..........................................................................................................................617 Disassembly......................................................................................................................617 Assembly.........................................................................................................................620 CENTER HINGE PIN.....................................................................................................................625 Removal..........................................................................................................................625 Installation.....................................................................................................................636 Upper hinge..................................................................................................................637 Connection of frame..........................................................................................................638 Lower hinge..................................................................................................................638 Upper hinge..................................................................................................................640 STEERING VALVE (ORIBITROL)...........................................................................................................643 Removal..........................................................................................................................643 Installation.....................................................................................................................645 Disassembly......................................................................................................................646 Rotor........................................................................................................................646 Control Side.................................................................................................................647 Assembly.........................................................................................................................649 Control Side.................................................................................................................649 Rotor........................................................................................................................651 STEERING DEMAND VALVE................................................................................................................655 Removal..........................................................................................................................655 Installation.....................................................................................................................656 Disassembly......................................................................................................................657 Assembly.........................................................................................................................662 STEERING AND SWITCH PUMP.............................................................................................................667 Removal..........................................................................................................................667 Installation.....................................................................................................................671 STEERING CYLINDER....................................................................................................................673 Removal..........................................................................................................................673 Installation.....................................................................................................................674 BRAKE VALVE..........................................................................................................................675 Removal..........................................................................................................................675 Installation.....................................................................................................................677 RIGHT BRAKE VALVE (TANDEM)...........................................................................................................679 Disassembly......................................................................................................................679 Assembly.........................................................................................................................680 LEFT BRAKE VALVE (SINGLE)............................................................................................................683 Disassembly......................................................................................................................683 Assembly.........................................................................................................................684 SLACK ADJUSTER.......................................................................................................................685 Removal..........................................................................................................................685 Installation.....................................................................................................................686 Disassembly......................................................................................................................687 Assembly.........................................................................................................................688 WHEEL BRAKE..........................................................................................................................689 Disassembly......................................................................................................................689 ASSEMBLY.........................................................................................................................695 PARKING BRAKE DISC...................................................................................................................705 Removal..........................................................................................................................705 Installation.....................................................................................................................707 ACCUMULATOR CHARGE VALVE.............................................................................................................708 Removal..........................................................................................................................708 Installation.....................................................................................................................708 Disassembly......................................................................................................................709 assembly.........................................................................................................................711 HYDRAULIC TANK.......................................................................................................................713 Removal..........................................................................................................................713 Installation.....................................................................................................................715 WORK EQUIPMENT, PPC PUMP ASSEMBLY....................................................................................................717 Removal..........................................................................................................................717 Installation.....................................................................................................................721 PPC VALVE ASSEMBLY...................................................................................................................723 Removal..........................................................................................................................723 INSTALLATION.....................................................................................................................725 Disassembly......................................................................................................................726 Assembly.........................................................................................................................727 MAIN CONTROL VALVE...................................................................................................................729 Removal..........................................................................................................................729 INSTALLATION.....................................................................................................................732 Disassembly (2-spool version)....................................................................................................733 Hydraulic Lines..............................................................................................................734 Valves.......................................................................................................................734 Spools.......................................................................................................................734 Assembly (2-Spool Version).......................................................................................................735 Spools.......................................................................................................................736 Valves.......................................................................................................................736 Assembly (2-Spool Version).......................................................................................................737 Hydraulic Lines..............................................................................................................738 Disassembly (3-spool version; Hydraulic Lines)...................................................................................739 Hydraulic Lines..............................................................................................................740 Valves.......................................................................................................................742 Spools.......................................................................................................................742 Assembly (3-spool version; VALVES, SPOOLS).......................................................................................745 Spools.......................................................................................................................746 Valves.......................................................................................................................746 Assembly (3-spool version; VALVES, SPOOLS).......................................................................................747 assembly (3-spool version; Hydraulic Lines)......................................................................................749 Hydraulic Lines..............................................................................................................750 DUMP CYLINDER........................................................................................................................751 Removal..........................................................................................................................751 INSTALLATION.....................................................................................................................753 LIFT CYLINDER........................................................................................................................755 Removal..........................................................................................................................755 INSTALLATION.....................................................................................................................757 HYDRAULIC CYLINDERS..................................................................................................................759 Disassembly......................................................................................................................759 Assembly.........................................................................................................................762 WORK EQUIPMENT.......................................................................................................................767 Removal..........................................................................................................................767 INSTALLATION.....................................................................................................................771 Bucket and bucket link.......................................................................................................771 Dump cylinder................................................................................................................771 Lift cylinder................................................................................................................771 Lift arm, bellcrank, bucket link.............................................................................................771 Bellcrank, bucket link.......................................................................................................772 COUNTERWEIGHT........................................................................................................................773 Removal..........................................................................................................................773 INSTALLATION.....................................................................................................................774 FUEL TANK............................................................................................................................775 Removal..........................................................................................................................775 INSTALLATION.....................................................................................................................777 CAB ASSEMBLY.........................................................................................................................779 Removal..........................................................................................................................779 INSTALLATION.....................................................................................................................780 MAIN MONITOR.........................................................................................................................781 Removal..........................................................................................................................781 Installation.....................................................................................................................782 MAINTENANCE MONITOR..................................................................................................................783 Removal..........................................................................................................................783 INSTALLATION.....................................................................................................................783 AIR CONDITIONER UNIT.................................................................................................................785 Removal..........................................................................................................................785 INSTALLATION.....................................................................................................................791 AIR CONDITIONER CONDENSER............................................................................................................793 Removal..........................................................................................................................793 INSTALLATION.....................................................................................................................795 RECEIVER-DRIER.......................................................................................................................797 Removal..........................................................................................................................797 INSTALLATION.....................................................................................................................798 AIR CONDITIONER COMPRESSOR...........................................................................................................799 Removal..........................................................................................................................799 INSTALLATION.....................................................................................................................800 40 MAINTENANCE STANDARD.................................................................................................................802 ENGINE AND TRANSMISSION MOUNT........................................................................................................803 TORQUE CONVERTER.....................................................................................................................804 TRANSMISSION.........................................................................................................................805 TRANSMISSION.....................................................................................................................806 FORWARD, 1ST CLUTCH..................................................................................................................807 REVERSE, 2ND CLUTCH..................................................................................................................808 3RD, 4TH CLUTCH......................................................................................................................809 TRANSMISSION VALVES..................................................................................................................810 UPPER VALVE......................................................................................................................810 LOWER VALVE......................................................................................................................811 FLOW VALVE.......................................................................................................................812 ACCUMULATOR VALVE................................................................................................................813 DRIVE SHAFTS.........................................................................................................................814 AXLE MOUNT...........................................................................................................................815 FRONT AXLE...........................................................................................................................816 REAR AXLE............................................................................................................................817 DIFFERENTIAL.........................................................................................................................819 LIMITED SLIP DIFFERENTIAL............................................................................................................821 FINAL DRIVE..........................................................................................................................823 STEERING COLUMN......................................................................................................................824 STEERING VALVE.......................................................................................................................825 STEERING CYLINDER MOUNT..............................................................................................................826 SLACK ADJUSTER.......................................................................................................................827 LEFT BRAKE VALVE.....................................................................................................................828 RIGHT BRAKE VALVE....................................................................................................................829 BRAKE................................................................................................................................830 PARKING BRAKE........................................................................................................................831 TORQUE CONVERTER, TRANSMISSION PUMP..................................................................................................832 STEERING, SWITCH PUMP................................................................................................................833 EQUIPMENT, PPC PUMP..................................................................................................................834 2 SPOOL CONTROL VALVE................................................................................................................835 3 SPOOL CONTROL VALVE................................................................................................................837 PPC VALVE............................................................................................................................839 CUT OFF VALVE........................................................................................................................840 CENTER HINGE PIN.....................................................................................................................841 WORK EQUIPMENT LINKAGE...............................................................................................................843 BOOM CYLINDER........................................................................................................................845 BUCKET CYLINDER......................................................................................................................846 STEERING CYLINDER....................................................................................................................847 BUCKET...............................................................................................................................848 BUCKET POSITIONER AND BOOM KICK OUT..................................................................................................849 90 OTHERS................................................................................................................................850 ELECTRICAL CIRCUIT DIAGRAM (1 OF 4)..................................................................................................851 ELECTRICAL CIRCUIT DIAGRAM (2 OF 4)..................................................................................................852 ELECTRICAL CIRCUIT DIAGRAM (3 OF 4)..................................................................................................853 ELECTRICAL CIRCUIT DIAGRAM (4 OF 4)..................................................................................................854
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