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KOMATSU GALEO WA150-5 WHEEL LOADER SHOP MANUAL VEBM934100 – PDF DOWNLOAD
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Description
KOMATSU GALEO WA150-5 WHEEL LOADER SHOP MANUAL VEBM934100 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU GALEO WA150-5 WHEEL LOADER SHOP MANUAL VEBM934100 – PDF DOWNLOAD
Language : English
Pages : 776
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU GALEO WA150-5 WHEEL LOADER SHOP MANUAL VEBM934100 – PDF DOWNLOAD
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 7 GENERAL ASSEMBLY DRAWINGS................................................................................................................ 8 SPECIFICATIONS........................................................................................................................... 9 WEIGHT TABLE............................................................................................................................. 13 LIST OF LUBRICANT AND COOLANT............................................................................................................ 15 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................................................. 17 Engine mount and transfer mount.......................................................................................................... 18 Damper................................................................................................................................... 19 Cooling system........................................................................................................................... 20 Power train.............................................................................................................................. 21 Power train system diagram............................................................................................................... 22 Drive shaft.............................................................................................................................. 24 HST hydraulic piping diagram............................................................................................................. 25 HST pump................................................................................................................................. 26 High-pressure relief valve............................................................................................................... 28 Low-pressure relief valve................................................................................................................ 30 HST charge pump.......................................................................................................................... 31 Speed-related valve (DA valve)........................................................................................................... 32 High-pressure cut-off valve.............................................................................................................. 33 HST motor................................................................................................................................ 34 EP servo valve........................................................................................................................... 37 HA servo valve........................................................................................................................... 38 Forward-reverse shuttle valve............................................................................................................ 39 Transfer................................................................................................................................. 40 Clutch solenoid valve.................................................................................................................... 51 Axle..................................................................................................................................... 52 Differential............................................................................................................................. 54 Limited-slip differential................................................................................................................ 60 Final drive.............................................................................................................................. 64 Axle mounting and center hinge pin....................................................................................................... 66 Steering piping.......................................................................................................................... 71 Steering column.......................................................................................................................... 72 Priority valve........................................................................................................................... 73 Orbit-roll valve......................................................................................................................... 76 Steering cylinder........................................................................................................................ 84 Emergency steering piping................................................................................................................ 86 Emergency steering valve................................................................................................................. 87 Brake piping............................................................................................................................. 90 Brake valve.............................................................................................................................. 91 Inching valve............................................................................................................................ 95 Charge valve............................................................................................................................. 96 Accumulator (for brake)..................................................................................................................100 Slack adjuster...........................................................................................................................101 Brake....................................................................................................................................104 Parking brake control....................................................................................................................107 Parking brake............................................................................................................................108 Hydraulic piping.........................................................................................................................110 Work equipment lever linkage.............................................................................................................112 Hydraulic tank...........................................................................................................................113 3-gear pump unit.........................................................................................................................116 Accumulator (for ppc circuit)............................................................................................................118 Lock valve...............................................................................................................................119 E.C.S.S. valve...........................................................................................................................122 Accumulator (for E.C.S.S.)...............................................................................................................124 Hydraulic piping of coolingsystem.......................................................................................................125 Cooling fan motor........................................................................................................................126 Work equipment control valve.............................................................................................................128 Work equipment PPC valve.................................................................................................................141 Work equipment linkage...................................................................................................................148 Bucket...................................................................................................................................150 Bucket positioner and boom kick-out......................................................................................................151 Work equipment cylinder..................................................................................................................157 Air conditioner..........................................................................................................................158 Machine monitoring system................................................................................................................159 Machine monitor..........................................................................................................................169 List of items displayed onmonitor.......................................................................................................170 Electrical system (HSTcontroller system)................................................................................................196 HST controller...........................................................................................................................200 Engine start circuit.....................................................................................................................201 Engine stop circuit......................................................................................................................203 Preheating circuit.......................................................................................................................204 Parking brake circuit....................................................................................................................205 Electronically controlled suspension system..............................................................................................208 Sensors..................................................................................................................................209 20 TESTING AND ADJUSTING.....................................................................................................................215 STANDARD VALUE TABLE FOR ENGINE..........................................................................................................216 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................217 TESTING AND ADJUSTING....................................................................................................................223 Tools for testing, adjusting, and troubleshooting....................................................................................224 Measuring engine speed...............................................................................................................226 Special tools required...........................................................................................................226 MEASURING HIGH-IDLING AND LOW-IDLING SPEEDS......................................................................................226 MEASURING HST STALL SPEED........................................................................................................227 MEASURING HYDRAULIC SPEED........................................................................................................227 MEASURING FULL STALL SPEED.......................................................................................................227 Measuring exhaust gas color..........................................................................................................228 Special tools required...........................................................................................................228 Adjusting valve clearance............................................................................................................229 Special tools required...........................................................................................................229 Measuring compression pressure.......................................................................................................231 Special tools required...........................................................................................................231 Measuring blow-by pressure...........................................................................................................232 Special tools required...........................................................................................................232 Testing and adjusting fuel injection timing..........................................................................................233 Special tools required...........................................................................................................233 Measuring engine oil pressure........................................................................................................234 Special tools required...........................................................................................................234 Measuring, testing operating force of accelerator pedal..............................................................................235 Special tools required...........................................................................................................235 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL..........................................................................235 OPERATING ANGLE OF ACCELERATOR PEDAL.............................................................................................236 Adjusting engine stop solenoid.......................................................................................................237 Adjusting engine speed sensor........................................................................................................238 Testing and adjusting air conditioner compressor belt tension........................................................................238 Testing..........................................................................................................................238 Adjusting........................................................................................................................238 Measuring directional lever..........................................................................................................239 Special tools required...........................................................................................................239 Operating effort of directional lever............................................................................................239 Travel of directional lever......................................................................................................239 Testing and adjusting HST oil pressure...............................................................................................240 Special tools required...........................................................................................................240 Adjusting........................................................................................................................243 Measuring clutch control pressure....................................................................................................245 Special tools required...........................................................................................................245 Testing and adjusting steering wheel.................................................................................................246 Special tools required...........................................................................................................246 MEASURING PLAY OF STEERING WHEEL.................................................................................................246 Method of measurement............................................................................................................246 MEASURING OPERATING FORCE OF STEERING WHEEL......................................................................................247 Measurement method...............................................................................................................247 MEASURING OPERATING TIME FOR STEERING WHEEL......................................................................................247 Measurement method...............................................................................................................247 Testing and adjusting steering oil pressure..........................................................................................248 Special tools required...........................................................................................................248 Method of measuring main relief pressure.........................................................................................248 Method of adjusting main relief pressure.........................................................................................249 Bleeding air from steering circuit...................................................................................................250 Testing hydraulic fan................................................................................................................251 Special tools required...........................................................................................................251 Measuring fan speed..............................................................................................................251 Measuring oil pressure...........................................................................................................251 Measuring brake pedal................................................................................................................252 Operating effort of pedal........................................................................................................252 Testing and adjusting brake pedal linkage............................................................................................253 Testing..........................................................................................................................253 Adjusting........................................................................................................................253 Measuring brake performance..........................................................................................................254 Measurement method...............................................................................................................254 Testing and adjusting accumulator charge pressure....................................................................................255 Special tools required...........................................................................................................255 Measuring........................................................................................................................255 Adjusting........................................................................................................................255 Measuring brake oil pressure.........................................................................................................256 Special tools required...........................................................................................................256 Measuring........................................................................................................................256 Brake test tool..................................................................................................................257 Measuring wear of brake disc.........................................................................................................258 Special tool required............................................................................................................258 Bleeding air from brake circuit......................................................................................................259 Special tools required...........................................................................................................259 Measuring parking brake performance..................................................................................................260 Measurement method...............................................................................................................260 Testing and adjusting parking brake control cable....................................................................................261 Special tool required............................................................................................................261 Testing..........................................................................................................................261 Adjusting........................................................................................................................261 Measuring and adjusting work equipment control lever.................................................................................262 Special tools required...........................................................................................................262 Measurement......................................................................................................................262 Testing and adjusting work equipment hydraulic pressure..............................................................................263 Special tools required...........................................................................................................263 Measuring condition..............................................................................................................263 Measuring........................................................................................................................263 Adjusting........................................................................................................................263 Testing and adjusting work equipment PPC oil pressure................................................................................264 Special tools required...........................................................................................................264 Measuring condition..............................................................................................................264 Measuring........................................................................................................................264 Bleeding air.........................................................................................................................266 Special tools required...........................................................................................................266 Releasing remaining pressure in hydraulic circuit....................................................................................267 Testing and adjusting bucket positioner..............................................................................................268 Testing..........................................................................................................................268 Adjusting........................................................................................................................268 Testing and adjusting of boom kick-out...............................................................................................269 Testing..........................................................................................................................269 Adjusting........................................................................................................................269 Checking proximity switch actuation display lamp.....................................................................................270 Proximity switch actuation display lamp (red)....................................................................................270 Procedure for checking diode.........................................................................................................271 Method of connecting T-adapter for HST controller....................................................................................272 Special functions of machine monitor.................................................................................................273 Flow of modes and functions..........................................................................................................274 Operator mode....................................................................................................................277 Service mode 1...................................................................................................................277 Service mode 2...................................................................................................................277 Character display................................................................................................................277 Operating switches...............................................................................................................277 Operator mode operation and displays.............................................................................................277 Error code table.....................................................................................................................282 Procedure for switching to Service Mode 1 and screen display.....................................................................284 Real-time monitoring items.......................................................................................................289 Table of filter and oil replacement interval set items (when sipping)............................................................290 Service mode 2...................................................................................................................291 Pm clinic inspection chart...........................................................................................................292 WA150-5H H50051 and up...........................................................................................................292 TROUBLESHOOTING..........................................................................................................................295 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................296 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................297 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................298 CHECK BEFORE TROUBLESHOOTING.........................................................................................................306 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................307 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No...........................................................................308 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................312 T-ADAPTER TABLE......................................................................................................................333 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................337 CONNECTOR LAYOUT DRAWING.............................................................................................................344 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)......................................................................................349 HST controller system diagram........................................................................................................350 Before troubleshooting code display..................................................................................................352 ERROR CODE AND POSSIBLE CAUSES TABLE.............................................................................................352 Before troubleshooting electrical system.............................................................................................353 FUSE BOX CONNECTION TABLE........................................................................................................353 Information contained in troubuleshooting table......................................................................................354 Related circuit diagram..........................................................................................................355 Phenomena code table.............................................................................................................355 Error Code [989F00] (HST motor protection caution (00))..........................................................................356 Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX))....................................................357 Related circuit diagram..........................................................................................................358 Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC)).............................................359 Related circuit diagram..........................................................................................................359 Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ)).............................................360 Related circuit diagram..........................................................................................................361 Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)).............................................362 Related circuit diagram..........................................................................................................363 Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ))..............................................364 Related circuit diagram..........................................................................................................365 Troubleshooting Code [HST-1] (Defective HST controller power source (HST controller does not func................................366 Related circuit diagram..........................................................................................................367 Troubleshooting Code [HST-2] (Travel speed does not shifted).....................................................................368 Related circuit diagram..........................................................................................................370 Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled..........................................371 Related circuit diagram..........................................................................................................372 HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position..................................373 Related circuit diagram..........................................................................................................375 HST-5 Travel speed is not increased..............................................................................................376 Related circuit diagram..........................................................................................................378 HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position......................................373 Related circuit diagram..............................................................................................................375 HST-5 Travel speed is not increased..................................................................................................376 Related circuit diagram..............................................................................................................378 Related electrical circuit diagram...................................................................................................380 Related circuit diagram..........................................................................................................380 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE)......................................................................................379 RELATED ELECTRICAL CIRCUIT DIAGRAM...................................................................................................380 ECSS-1 Malfunction of travel damper..................................................................................................381 Specification of load meter (STD)................................................................................................381 Malfunction of travel damper.....................................................................................................381 a) Travel damper does not operate................................................................................................381 b) Travel damper is not reset....................................................................................................384 TROUBLSHOOTING OF MONITOR SYSTEM (MON MODE)..............................................................................................387 Monitor system circuit diagram.......................................................................................................388 Before troubleshooting code display..................................................................................................392 ERROR CODE AND POSSIBLE CAUSES TABLE.............................................................................................392 Before troubleshooting electrical system.............................................................................................393 FUSE BOX CONNECTION TABLE........................................................................................................393 Information contained in troubuleshooting table......................................................................................394 Related circuit diagram..........................................................................................................395 Phenomena code table.............................................................................................................395 Error Code [15B0NX] (HST oil filter clogged (NX))....................................................................................396 Related circuit diagram..........................................................................................................396 Error Code [2G42ZG] (Decreased brake oil pressure (ZG))..............................................................................397 Related circuit diagram..........................................................................................................397 Error Code [989F00] (HST motor protection caution (00))..............................................................................398 Error Code [989FN1] (HST overrunning (N1))...........................................................................................399 Error Code [AB00L6] (Defective battery charging circuit (L6))........................................................................400 Related circuit diagram..........................................................................................................400 Error Code [AB00MA] (Defective battery charging circuit (MA))........................................................................401 Related circuit diagram..........................................................................................................401 Error Code [B@BAZG] (Degreased engine oil pressure (ZG)).............................................................................402 Related circuit diagram..........................................................................................................402 Error Code [B@BCNS] (Engine water temperature overheating (NS))......................................................................403 Related circuit diagram..........................................................................................................403 Error Code [B@BCZK] (Alarm indicating low coolant level (ZK))........................................................................404 Related circuit diagram..........................................................................................................404 Error Code [B@C7NS] (Axle oil temperature overheating (NS))..........................................................................405 Related circuit diagram..........................................................................................................405 Error Code [B@CRNS] (HST oil temperature overheating (NS))...........................................................................406 Related circuit diagram..........................................................................................................406 Error Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6))...............................................................408 Related circuit diagram..........................................................................................................409 Error Code [DAF0KT] (Controller inside failure (KT)).................................................................................410 Error Code [DAJ0KR] (HST controller communication failure (KR))......................................................................412 Related circuit diagram..........................................................................................................413 Error Code [DD15LD] (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)).....................................414 Related circuit diagram..........................................................................................................414 Error Code [DD16LD] (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)).....................................415 Related circuit diagram..........................................................................................................415 Error Code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)).....................................416 Related circuit diagram..........................................................................................................416 Error Code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)).....................................417 Related circuit diagram..........................................................................................................417 Error Code [DDK3KB] (Multiple directional lever FR signal input (KB))................................................................418 Related circuit diagram..........................................................................................................419 Error Code [DDS5L6] (Decreased steering oil pressure (L6))...........................................................................420 Related circuit diagram..........................................................................................................420 Error Code [DGE2KX] (Engine coolant temperature (High temperature) sensor system failure (KX)).......................................421 Related circuit diagram..........................................................................................................421 Error Code [DGE3L6] (Engine coolant temperature (Low temperature) sensor system failure (L6))........................................423 Related circuit diagram..........................................................................................................423 Error Code [DGH1KX] (HST oil temperature sensor system failure (KX)).................................................................424 Related circuit diagram..........................................................................................................424 Error Code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA))..........................................................425 Related circuit diagram..........................................................................................................425 Error Code [DGR4KX] (Axle oil temperature sensor system failure (KX))................................................................426 Related circuit diagram..........................................................................................................426 Error Code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6))...........................................................427 Related circuit diagram..........................................................................................................427 Troubleshooting Code [MON-1] (The parking brake indicator lamp does not light ON)....................................................429 Related circuit diagram..........................................................................................................431 Related circuit diagram..........................................................................................................432 Troubleshooting Code [MON-2] (The brake oil pressure caution lamp does not light ON).................................................433 Related circuit diagram..........................................................................................................433 Troubleshooting Code [MON-3] (The engine water temperature caution lamp does not light ON, or after the engine starts, the eng.......434 Related circuit diagram..........................................................................................................434 Troubleshooting Code [MON-4] (The HST oil temperature caution lamp does not light ON, or after the engine starts, the HST oil .......435 Related circuit diagram..........................................................................................................435 Troubleshooting Code [MON-5] (The fuel level gauge does not rise or decrease. )......................................................436 Related circuit diagram..........................................................................................................436 Troubleshooting Code [MON-6] (The radiator coolant level caution lamp does not light ON).............................................437 Related circuit diagram..........................................................................................................437 Troubleshooting Code [MON-7] (The steering oil pressure caution lamp does not light ON)..............................................438 Related circuit diagram..........................................................................................................438 Troubleshooting Code [MON-8] (The emergency steering oil pressure indicator lamp does not light ON)..................................439 Related circuit diagram..........................................................................................................439 Troubleshooting Code [MON-9] (Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1))............................440 Related circuit diagram..........................................................................................................440 Troubleshooting Code [MON-10] (Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2))...........................442 Related circuit diagram..........................................................................................................443 Troubleshooting Code [MON-11] (Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3))...........................444 Related circuit diagram..........................................................................................................445 Troubleshooting Code [MON-12] (Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4))...........................446 Related circuit diagram..........................................................................................................447 Troubleshooting Code [MON-13] (The alarm buzzer does not sound or stop)..............................................................448 Related circuit diagram..........................................................................................................449 Troubleshooting Code [MON-14] The wiper does not function............................................................................450 Troubleshooting Code [MON-15] The lamps do not work properly.........................................................................450 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................................................451 Electrical system diagram............................................................................................................452 Parking brake related diagram........................................................................................................456 Before troubleshooting electrical system.............................................................................................458 Fuse box connection table........................................................................................................458 Information contained in troubuleshooting table......................................................................................460 Related circuit diagram..........................................................................................................461 Troubleshooting Code [E-1] (The engine does not start)...............................................................................462 a) Defective starting motor system...............................................................................................462 Related circuit diagram..........................................................................................................465 Troubleshooting Code [E-2] (The engine does not stop)................................................................................468 Related circuit diagram..........................................................................................................469 Troubleshooting Code [E-3] (Preheating is impossible or constant)....................................................................470 a) Preheating is impossible......................................................................................................470 b) Preheating is constant........................................................................................................475 Related circuit diagram..........................................................................................................476 Cont'd Related circuit diagram...................................................................................................477 Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function)...................................................478 a) Parking brake dragging prevention does not function (mechanical type).........................................................478 b) Parking brake "non-applied" indicator does not light up (mechanical type).....................................................480 Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation).......................................................482 Related circuit diagram..........................................................................................................484 Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation)...................................................485 Related circuit diagram..........................................................................................................487 Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and cancellation)...........................................495 Related circuit diagram..........................................................................................................496 Troubleshooting Code [E-8] (Travel direction is not changed normally)................................................................488 a) When directional lever is set in "F", machine does not travel forward.........................................................488 Troubleshooting Code [E-9] (The wiper does not function).............................................................................497 a) The rear wiper does not function..............................................................................................497 Related circuit diagram..........................................................................................................499 b) The rear wiper does not function..............................................................................................500 Related circuit diagram..........................................................................................................501 Troubleshooting Code [E-10] (The window washer does not function)....................................................................502 Related circuit diagram..........................................................................................................504 Troubleshooting Code [E-11] (Lamps do not work properly).............................................................................505 a) Neither high beam nor low beam of headlamp light up...........................................................................505 Related circuit diagram..........................................................................................................507 b) Head lamp (Lo beam) does not light ON.........................................................................................508 Related circuit diagram..........................................................................................................508 c) Head lamp (Hi beam) does not light ON.........................................................................................509 Related circuit diagram..........................................................................................................509 d) Clearance lamp (Small lamp) does not light ON.................................................................................510 Related circuit diagram..........................................................................................................511 e) Turn signal lamp does not blink...............................................................................................512 Related circuit diagram..........................................................................................................513 f) Working lamp does not light ON................................................................................................514 Related circuit diagram..........................................................................................................515 Troubleshooting Code [E-12] (The horn does not sound)................................................................................516 Related circuit diagram..........................................................................................................517 Troubleshooting Code [E-13] (Defective of the air conditioner).......................................................................521 a) The air conditioner does not work.............................................................................................521 Related circuit diagram..........................................................................................................522 c) Does not cool or temperature cannot be adjusted...............................................................................523 Related circuit diagram..........................................................................................................525 d) Impossible to switch between recirculated air and fresh air...................................................................526 Related circuit diagram..........................................................................................................526 e) Impossible to switch vents....................................................................................................526 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).................................................................................531 Method of using troubleshooting chart................................................................................................532 Error code and cause table...........................................................................................................534 H-1 The machine does not start.......................................................................................................536 H-2 The travel speed is slow.........................................................................................................537 H-3 The thrusting force is weak......................................................................................................538 H-4 Engine stalls when traveling or engine speed drops excessively...................................................................539 H-5 The gear is not shifted..........................................................................................................540 H-6 The steering wheel does not turn.................................................................................................541 H-7 The steering wheel is heavy......................................................................................................542 H-8 Steering wheel shakes or jerks...................................................................................................543 H-9 Machine deviates naturally to one side when traveling............................................................................543 H-10 The brake does not work or does not work well...................................................................................544 H-11 The brake is not released or is dragged.........................................................................................545 H-12 The lift arm does not rise or lower.............................................................................................546 H-13 The lift arm moves slowly or the lift arm rising force is insufficient..........................................................547 H-14 When rising, the lift arm comes to move slowly at specific height...............................................................548 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).................................................548 H-16 Hydraulic drifts of the lift arm occur often....................................................................................548 H-17 The lift arm wobbles during operation...........................................................................................548 H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily.......................................549 H-19 The bucket does not tilt back...................................................................................................550 H-20 The bucket moves slowly or the tilting-back force is insufficient...............................................................551 H-21 The bucket comes to operate slowly in he midst of tilting-back..................................................................552 H-22 The bucket cylinder cannot hold down the bucket.................................................................................552 H-23 Hydraulic drifts of the bucket occur often......................................................................................552 H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD").........................................553 H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily..........................................553 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....................................................553 H-27 The travel damper does not operate and machine pitches and bounces..............................................................554 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................................555 Method of using troubleshooting charts...............................................................................................556 S-1 Starting performance is poor (Starting always takes time)........................................................................560 S-2 Engine does not start............................................................................................................562 (1) Engine does not turn.........................................................................................................562 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected).....................................................563 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)...................................................564 S-3 Engine does not pick up smoothly (Follow-up is poor).............................................................................565 S-4 Engine stops during operations...................................................................................................566 S-5 Engine does not rotate smoothly (Hunting)........................................................................................567 S-6 Engine lacks output (or lacks power).............................................................................................568 S-7 Exhaust smoke is black (Incomplete combustion)...................................................................................569 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................................................................570 S-9 Oil becomes contaminated quickly.................................................................................................571 S-10 Fuel consumption is excessive...................................................................................................572 S-11 Oil is in cooling water, or water spurts back, or water level goes down.........................................................573 S-12 Oil pressure caution lamp lights up (Drop in oil pressure)......................................................................574 S-13 Oil level rises (Water, fuel in oil)............................................................................................575 S-14 Water temperature becomes too high (Overheating)................................................................................576 S-15 Abnormal noise is made..........................................................................................................577 S-16 Vibration is excessive..........................................................................................................578 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................579 HOW TO READ THIS MANUAL..................................................................................................................580 PRECAUTIONS WHEN PERFORMING OPERATION....................................................................................................582 SPECIAL TOOL LIST........................................................................................................................584 SKETCHES OF SPECIAL TOOLS................................................................................................................587 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.................................................................................594 REMOVAL AND INSTALLATION OF NOZZLE HOLDER................................................................................................598 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.......................................................................................600 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY..............................................................................................607 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY............................................................................................615 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER..............................................................................................617 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY................................................................................618 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...........................................................................619 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...........................................................................................621 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY............................................................................................623 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY............................................................................................625 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY.......................................................................................645 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY.......................................................................................646 REMOVAL AND INSTALLATION OF FRONT AXEL ASSEMBLY..........................................................................................652 REMOVAL AND INSTALLATION OF REAR AXEL ASSEMBLY...........................................................................................654 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY........................................................................................657 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY........................................................................................668 REMOVAL AND INSTALLATION OF HST PUMP AND 3-GEAR PUMP ASSEMBLY............................................................................691 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY.........................................................................................694 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY.........................................................................................696 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY........................................................................698 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY.................................................................................701 REMOVAL AND INSTALLATION OF HYDRAULIC TANK...............................................................................................702 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY......................................................................................704 DISASSMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...................................................................................710 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY......................................................................................716 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)...........................................................................720 REMOVAL AND INSTALLATION OF CENTER HINGE PIN.............................................................................................729 REMOVAL AND INSTALLATION OF COUNTERWEIGHT................................................................................................737 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................................................................................738 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................740 REMOVAL AND INSTALLATION OF MONITOR PANEL................................................................................................741 90 OTHERS....................................................................................................................................745 Hydraulic circuit diagram................................................................................................................747 Electrical circuit diagram 1/4 (1/4).....................................................................................................749 Electrical circuit diagram 1/4 (2/4).....................................................................................................751 Electrical circuit diagram 1/4 (3/4).....................................................................................................753 Electrical circuit diagram 1/4 (4/4).....................................................................................................755 Electrical circuit diagram 2/4...........................................................................................................757 Electrical circuit diagram 3/4...........................................................................................................759 Electrical circuit diagram 4/4...........................................................................................................761 Electrical circuit diagram 1/4 (1/4).....................................................................................................763 Electrical circuit diagram 1/4 (2/4).....................................................................................................765 Electrical circuit diagram 1/4 (3/4).....................................................................................................767 Electrical circuit diagram 1/4 (4/4).....................................................................................................769 Electrical circuit diagram 2/4...........................................................................................................771 Electrical circuit diagram 3/4...........................................................................................................773 Electrical circuit diagram 4/4...........................................................................................................775
S.S 21/12/24
