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KOMATSU HS150S-11 SHOP MANUAL SEBMW00801 – PDF DOWNLOAD
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Description
KOMATSU HS150S-11 SHOP MANUAL SEBMW00801 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HS150S-11 SHOP MANUAL SEBMW00801 – PDF DOWNLOAD
Language : English
Pages : 589
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HS150S-11 SHOP MANUAL SEBMW00801 – PDF DOWNLOAD
COVER......................................................................................................................................................................................................................................................................................................... 1 CONTENTS...................................................................................................................................................................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................................................................................................................................................................... 23 DIMENSIONS................................................................................................................................................................................................................................................................................................ 24 SPECIFICATIONS............................................................................................................................................................................................................................................................................................ 25 WEIGHT TABLE.............................................................................................................................................................................................................................................................................................. 28 LIST OF LUBRICANTS AND WATER.............................................................................................................................................................................................................................................................................. 29 10 STRUCTURE AND FUNCTION..................................................................................................................................................................................................................................................................................... 30 POWER TRAIN SKELETON...................................................................................................................................................................................................................................................................................... 31 HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER,TRANSMISSION,AND BRAKE COOLING............................................................................................................................................................................................................................. 33 HYDRAULIC SYSTEM DIAGRAM FOR TORQUE CONVERTER,TRANSMISSION,AND BRAKE COOLING.............................................................................................................................................................................................................................. 35 TORQUE CONVERTER.......................................................................................................................................................................................................................................................................................... 37 MAIN RELIEF VALVE......................................................................................................................................................................................................................................................................................... 39 TORQUE CONVERTER VALVE.................................................................................................................................................................................................................................................................................... 41 TRANSMISSION.............................................................................................................................................................................................................................................................................................. 46 TRANSMISSION VALVE........................................................................................................................................................................................................................................................................................ 49 ECMV (ELECTRONIC CONTROL MODULATION VALVE)................................................................................................................................................................................................................................................................ 50 FRONT AXLE................................................................................................................................................................................................................................................................................................ 55 REAR AXLE................................................................................................................................................................................................................................................................................................. 56 IDLE AXLE................................................................................................................................................................................................................................................................................................. 57 DIFFERENTIAL.............................................................................................................................................................................................................................................................................................. 58 FINAL DRIVE............................................................................................................................................................................................................................................................................................... 59 FRONT BRAKE............................................................................................................................................................................................................................................................................................... 60 REAR BRAKE................................................................................................................................................................................................................................................................................................ 61 PARKING BRAKE............................................................................................................................................................................................................................................................................................. 62 STEERING COLUMN........................................................................................................................................................................................................................................................................................... 63 STEERING LINKAGE.......................................................................................................................................................................................................................................................................................... 64 DEMAND VALVE.............................................................................................................................................................................................................................................................................................. 65 CROSSOVER RELIEF VALVE.................................................................................................................................................................................................................................................................................... 68 STEERING VALVE............................................................................................................................................................................................................................................................................................ 69 FRONT SUSPENSION.......................................................................................................................................................................................................................................................................................... 70 REAR SUSPENSION CYLINDER.................................................................................................................................................................................................................................................................................. 71 AIR CURCUIT DIGRAM........................................................................................................................................................................................................................................................................................ 72 AIR GOVERNOR.............................................................................................................................................................................................................................................................................................. 74 SAFETEY VALVE............................................................................................................................................................................................................................................................................................. 76 CHECK VALVE............................................................................................................................................................................................................................................................................................... 76 DOUBLE CHECK VALVE........................................................................................................................................................................................................................................................................................ 77 HAND BRAKE VALVE.......................................................................................................................................................................................................................................................................................... 78 BRAKE VALVE............................................................................................................................................................................................................................................................................................... 80 PARKING BRAKE CONTROL VALVE............................................................................................................................................................................................................................................................................... 83 BRAKE RELAY VALVE (ACTS AS EMERGENCY RELAY)............................................................................................................................................................................................................................................................... 85 PARKING RELAY VALVE....................................................................................................................................................................................................................................................................................... 88 SPRING CYLINDER........................................................................................................................................................................................................................................................................................... 90 SLACK ADJUSTER............................................................................................................................................................................................................................................................................................ 91 FRONT BRAKE CHAMBER....................................................................................................................................................................................................................................................................................... 92 REAR BRAKE CHAMBER........................................................................................................................................................................................................................................................................................ 93 STEERING,HOIST HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................................. 94 HOIST VALVE............................................................................................................................................................................................................................................................................................... 96 HOIST CYLINDER............................................................................................................................................................................................................................................................................................ 97 ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................................................. 98 AUTOMATIC SHIFT CONTROL SYSTEM............................................................................................................................................................................................................................................................................102 AUTOMATIC RETARDER VALVE..................................................................................................................................................................................................................................................................................108 HORN VALVE................................................................................................................................................................................................................................................................................................109 WIPER SWITCH..............................................................................................................................................................................................................................................................................................109 SENSORS,SWITCHES..........................................................................................................................................................................................................................................................................................110 METER LAMP................................................................................................................................................................................................................................................................................................119 20 TESTING AND ADJUSTING......................................................................................................................................................................................................................................................................................121 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.............................................................................................................................................................................................................................................................122 STANDARD VALUE TABLE FOR CHASSIS..........................................................................................................................................................................................................................................................................123 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM................................................................................................................................................................................................................................................................127 TESTING AND ADJUSTING.....................................................................................................................................................................................................................................................................................130 TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING.......................................................................................................................................................................................................................................................131 SKETCHES OF SPECIAL TOOLS.............................................................................................................................................................................................................................................................................133 ADJUSTING VALVE CLEARANCE.............................................................................................................................................................................................................................................................................134 MEASURING COMPRESSION PRESSURE........................................................................................................................................................................................................................................................................135 MEASURING BLOW-BY.....................................................................................................................................................................................................................................................................................136 ADJUSTING FAN BELT TENSION............................................................................................................................................................................................................................................................................137 MEASURING ENGINE SPEED................................................................................................................................................................................................................................................................................138 MEASURING ENGINE OIL PRESSURE.........................................................................................................................................................................................................................................................................139 MEASURING BOOST PRESSURE..............................................................................................................................................................................................................................................................................140 MEASURING EXHAUST GAS TEMPERATURE.....................................................................................................................................................................................................................................................................141 MEASURING EXHAUST GAS COLOR...........................................................................................................................................................................................................................................................................142 TESTING AND ADJUSTING FUEL INJECTION TIMING...........................................................................................................................................................................................................................................................143 BLEEDING AIR FROM FUEL INJECTION PUMP.................................................................................................................................................................................................................................................................145 ADJUSTING ENGINE STOP MOTOR CABLE.....................................................................................................................................................................................................................................................................146 ADJUSTING ACCELERATOR PEDAL...........................................................................................................................................................................................................................................................................147 ADJUSTING ENGINE SPEED SENSOR.........................................................................................................................................................................................................................................................................148 TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE........................................................................................................................................................................................................................................................149 TESTING TORQUE CONVERTER STALL SPEED..................................................................................................................................................................................................................................................................150 TESTING BRAKE PRESSURE................................................................................................................................................................................................................................................................................151 BLEEDING AIR FROM BRAKE CIRCUIT.......................................................................................................................................................................................................................................................................152 TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE.......................................................................................................................................................................................................................................................153 TESTING WEAR OF FRONT BRAKE PAD.......................................................................................................................................................................................................................................................................154 TESTING WEAR OF REAR BRAKE DISC.......................................................................................................................................................................................................................................................................155 TESTING AND ADJUSTING SUSPENSION CYLINDER.............................................................................................................................................................................................................................................................156 TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE.......................................................................................................................................................................................................................................................161 ADJUSTING HOIST LEVER LINKAGE.........................................................................................................................................................................................................................................................................162 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT....................................................................................................................................................................................................................................163 BLEEDING AIR FROM HYDRAULIC CYLINDER(STEERING CYLINDER)...............................................................................................................................................................................................................................................166 EMERGENCY TRAVEL WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM...........................................................................................................................................................................................................................................167 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS............................................................................................................................................................................................................................................168 PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT................................................................................................................................................................................................................................170 TROUBLESHOOTING...........................................................................................................................................................................................................................................................................................171 POINTS TO REMEMBER WHEN TROUBLESHOOTING...............................................................................................................................................................................................................................................................172 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................................................................................................................................................................173 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................................................................................................................................................................................174 CHECKS BEFORE TROUBLESHOOTING.........................................................................................................................................................................................................................................................................182 TYPE OF CONNECTOR AND POSITION OF INSTALLATION........................................................................................................................................................................................................................................................184 CONNECTOR PIN ARRANGEMENT DIAGRAM.....................................................................................................................................................................................................................................................................189 CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................................................................................................................................................................................195 METHOD OF USING JUDGEMENT TABLE.......................................................................................................................................................................................................................................................................206 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................................................................................................................................207 METHOD OF LED DISPLAY FOR TRANSMISSION CONTROLLER.....................................................................................................................................................................................................................................................209 ACTION TAKEN BY TRANSMISSION CONTROLLER AND PROBLEMS ON MACHINE.......................................................................................................................................................................................................................................213 TROUBLESHOOTING OF ENGINE(D MODE).....................................................................................................................................................................................................................................................................229 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................................................................................................................................230 D-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)......................................................................................................................................................................................................................................234 D-2 ENGINE DOES NOT START.........................................................................................................................................................................................................................................................................235 (1) ENGINE DOES NOT TURN......................................................................................................................................................................................................................................................................235 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)...................................................................................................................................................................................................................236 (3) EXHAUST SMOKE COMES OUT,BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).................................................................................................................................................................................................................237 D-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...........................................................................................................................................................................................................................................238 D-4 ENGINE STOPS DURING OPERATIONS................................................................................................................................................................................................................................................................239 D-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)......................................................................................................................................................................................................................................................240 D-6 ENGINE LACKS OUTPUT(NO POWER).................................................................................................................................................................................................................................................................241 D-7 EXHAUST GAS IS BLACK(INCOMPLETE COMBUSTION)...................................................................................................................................................................................................................................................242 D-8 OIL CONSUMPTION IS EXCESSIVE,OR EXHAUST SMOKE IS BLUE.........................................................................................................................................................................................................................................243 D-9 OIL BECOMES CONTAMINATED QUICKLY..............................................................................................................................................................................................................................................................244 D-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................................................................................................................................................................245 D-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN........................................................................................................................................................................................................................246 D-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)....................................................................................................................................................................................................................................247 D-13 OIL LEVEL RISES(WATER,FUEL IN OIL)...........................................................................................................................................................................................................................................................248 D-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)..............................................................................................................................................................................................................................................249 D-15 ABNORMAL NOISE IS MADE.......................................................................................................................................................................................................................................................................250 D-16 VIBRATION IS EXCESSIVE.......................................................................................................................................................................................................................................................................251 TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR START/STOP SYSTEM(G MODE).............................................................................................................................................................................................................................252 G-1 ENGINE DOES NOT START(FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)..................................................................................................................................................................................................................253 G-2 ENGINE DOES NOT STOP(FUEL INJECTION PUMP STOP LEVER STAYS AT RUN POSITION)....................................................................................................................................................................................................................256 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(A MODE).............................................................................................................................................................................................................................................258 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM............................................................................................................................................................................................................260 JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS.............................................................................................................................................................................................................................261 A-1 ABNORMALITY IN POWER SOUCE....................................................................................................................................................................................................................................................................263 a) [ ][DEFECTIVE CONTROLLER POWER SOURCE]IS DISPLAYED(ALL LEDS OFF).........................................................................................................................................................................................................................263 b) [0.1](DROP IN VOLTAGE OF CONTROLLER)IS DISPLAYED...........................................................................................................................................................................................................................................264 c) [0.2](DROP IN VOLTAGE OF SOLENOID)IS DISPLAYED.............................................................................................................................................................................................................................................265 A-2 [0.3](NEUTRAL SAFETY)IS DISPLAYED.............................................................................................................................................................................................................................................................266 A-3 CONTROLLER SYSTEM.............................................................................................................................................................................................................................................................................267 a) [ . ][ONLY DOT LIGHTS UP] OR [0.4](DATA ERROR)IS DISPLAYED.................................................................................................................................................................................................................................267 b) [0.5](DOUBLE ENGAGEMENT FOR CLUTCH)IS DISPLAYED............................................................................................................................................................................................................................................267 A-4 [0.6](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN TRANSMISSION CUT RELAY)IS DISPLAYED............................................................................................................................................................................................268 A-5 [0.8](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN AUTOMATIC RETARDER SOLENOID)IS DISPLAYED.......................................................................................................................................................................................269 A-6 [0.9](DISCONNECTION,SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SOLENOID)IS DISPLAYED............................................................................................................................................................................................270 A-7 SPEED SENSOR SYSTEM...........................................................................................................................................................................................................................................................................271 a) [1.0](DISCONNECTION IN ENGINE SPEED SENSOR) OR [6.0](DEFECTIVE OUTPUT OF ENGINE SPEED SENSOR)..............................................................................................................................................................................................271 b) [1.1](DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR) OR [6.1](DEFECTIVE OUTPUT OF TRANSMISSION INPUT SHAFT SPEED SENSOR)..........................................................................................................................................................272 c) [1.2](DISCONNECTION IN TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR) OR [6.2](DEFECTIVE OUTPUT OF TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR)............................................................................................................................................273 d) [1.3](DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR) OR [6.3](DEFECTIVE OUTPUT OF TRANSMISSION OUTPUT SHAFT SPEED SENSOR)........................................................................................................................................................274 A-8 SLIPPING CLUTCH OR SPEED SENSOR SYSTEM........................................................................................................................................................................................................................................................275 a) [2.1][DEFECTIVE LOCK-UP CLUTCH SYSTEM] IS DISPLAYED........................................................................................................................................................................................................................................275 b) [2.2][FAILURE IN HI CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] OR [2.3][FAILURE IN LO CLUTCH OR INPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED..............................................................................................................................................275 c) [2.4][FAILURE IN 1ST CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.5][FAILURE IN 2ND CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.6][FAILURE IN 3RD CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] OR [2.8][FAILURE IN R CLUTCH OR OUTPUT SHAFT SPEED SENSOR SYSTEM] IS DISPLAYED....275 A-9 [A.1]ABNORMALITY IN MODEL SELECTION SIGNAL IS DISPLAYED.......................................................................................................................................................................................................................................276 A-10 ABNORMALITY IN SHIFT LEVER SYSTEM............................................................................................................................................................................................................................................................277 a) [0.7][SHORT CIRCUIT WITH 12V OUTPUT CIRCUIT] IS DISPLAYED..................................................................................................................................................................................................................................277 b) [1.5][SHORT CIRCUIT,SHORT CIRCUIT WITH GROUND IN LEVER SIGNAL SYSTEM] IS DISPLAYED.........................................................................................................................................................................................................278 c) [1.6][DISCONNECTION IN LEVER SIGNAL SYSTEM] IS DISPLAYED...................................................................................................................................................................................................................................280 A-11 [A.1][DISCONNECTION IN ACCELERATOR SIGNAL,DEFECTIVE ADJUSTMENT,DISCONNECTED LINK] IS DISPLAYED...............................................................................................................................................................................................282 A-12 [1.9][SHORT CIRCUIT WITH GROUND IN TRANSMISSION VALVE OIL TEMPERATURE SENSOR] IS DISPLAYED...................................................................................................................................................................................................284 A-13 PRESSURE CONTROL VALVE SYSTEM................................................................................................................................................................................................................................................................285 a) [3.1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ]..............................................................................................................................................................285 a) [3.3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ]..................................................................................................................................................................285 a) [3.5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] OR [3.6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ].................................................................................................................................................................285 a) [3.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅰ] IS DISPLAYED.....................................................................................................................................................................................................................285 b) [4.1][DEFECTIVE LOCK-UP CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.2][DEFECTIVE HI CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ]..............................................................................................................................................................286 b) [4.3][DEFECTIVE LO CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.4][DEFECTIVE 1ST CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ]..................................................................................................................................................................286 b) [4.5][DEFECTIVE 2ND CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] OR [4.6][DEFECTIVE 3RD CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ].................................................................................................................................................................286 b) [4.8][DEFECTIVE R CLUTCH PRESSURE CONTROL VALVE SYSTEM Ⅱ] IS DISPLAYED.....................................................................................................................................................................................................................286 b1) CHECKING FILL SIGNAL SYSTEM...............................................................................................................................................................................................................................................................286 b2) CHECKING WHEN [4.2] OR [4.3] IS DISPLAYED.................................................................................................................................................................................................................................................287 b3) CHECKING WHEN [4.4] OR [4.6] OR [4.8] IS DISPLAYED........................................................................................................................................................................................................................................287 A-14 FLOW DETECTION VALVE SYSTEM..................................................................................................................................................................................................................................................................288 [5.1][DISCONNECTION IN LOCK-UP CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.2][DISCONNECTION IN HI CLUTCH FLOW CONTROL VALVE SYSTEM]...............................................................................................................................................................288 [5.3][DISCONNECTION IN LO CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.4][DISCONNECTION IN 1ST CLUTCH FLOW CONTROL VALVE SYSTEM]...................................................................................................................................................................288 [5.5][DISCONNECTION IN 2ND CLUTCH FLOW CONTROL VALVE SYSTEM] OR [5.6][DISCONNECTION IN 3RD CLUTCH FLOW CONTROL VALVE SYSTEM]..................................................................................................................................................................288 [5.8][DISCONNECTION IN R CLUTCH FLOW CONTROL VALVE SYSTEM] IS DISPLAYED.......................................................................................................................................................................................................................288 A-15 PRESSURE CONTEOL SOLENOID SYSTEM.............................................................................................................................................................................................................................................................289 a) [7.1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]..............................................................................................................................................289 a) [7.3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]..................................................................................................................................................289 a) [7.5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [7.6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM].................................................................................................................................................289 a) [7.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED.............................................................................................................................................................................................................289 b) [9.1][SHORT CIRCUIT IN LOCK-UP CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.2][SHORT CIRCUIT IN HI CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]..............................................................................................................................................291 b) [9.3][SHORT CIRCUIT IN LO CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.4][SHORT CIRCUIT IN 1ST CLUTCH PRESSURE CONTROL SOLENOID SYSTEM]..................................................................................................................................................291 b) [9.5][SHORT CIRCUIT IN 2ND CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] OR [9.6][SHORT CIRCUIT IN 3RD CLUTCH PRESSURE CONTROL SOLENOID SYSTEM].................................................................................................................................................291 b) [9.8][SHORT CIRCUIT IN R CLUTCH PRESSURE CONTROL SOLENOID SYSTEM] IS DISPLAYED.............................................................................................................................................................................................................291 A-16 PRESSURE SENSOR SYSTEM.......................................................................................................................................................................................................................................................................293 a) [8.1][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] OR [8.3][DEFECTIVE OUTPUT OF TORQUE CONVERTER INLET PRESSURE SENSOR] IS DISPLAYED........................................................................................................................................293 b) [8.2][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] OR [8.4][DEFECTIVE OUTPUT OF TORQUE CONVERTER OUTLET PRESSURE SENSOR] IS DISPLAYED......................................................................................................................................294 ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM......................................................................................................................................................................................................................................................295 TROUBLESHOOTING FOR METER PANEL SYSTEM(E MODE)........................................................................................................................................................................................................................................................299 E-1 WATER TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY............................................................................................................................................................................................................................300 a) GIVES NO DISPLAY...........................................................................................................................................................................................................................................................................300 b) GIVES ABNORMAL DISPLAY.....................................................................................................................................................................................................................................................................300 E-2 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY.............................................................................................................................................................................................................302 a) GIVES NO DISPLAY...........................................................................................................................................................................................................................................................................302 b) GIVES ABNORMAL DISPLAY.....................................................................................................................................................................................................................................................................302 E-3 RETARDER OIL TEMPERATURE GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY.....................................................................................................................................................................................................................304 a) GIVES NO DISPLAY...........................................................................................................................................................................................................................................................................304 b) GIVES ABNORMAL DISPLAY.....................................................................................................................................................................................................................................................................304 E-4 FUEL GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY.........................................................................................................................................................................................................................................306 a) GIVES NO DISPLAY...........................................................................................................................................................................................................................................................................306 b) GIVES ABNORMAL DISPLAY.....................................................................................................................................................................................................................................................................306 E-5 SERVICE METER DOES NOT MOVE...................................................................................................................................................................................................................................................................308 TROUBLESHOOTING FOR PILOT LAMP SYSTEM(F MODE).........................................................................................................................................................................................................................................................309 F-1 ABNORMALITY IN LIGHTING UP OF RETARDER BRAKE LAMP.............................................................................................................................................................................................................................................310 a) RETARDER IS NOT BEING OPERATED,BUT PILOT LAMP LIGHTS UP....................................................................................................................................................................................................................................310 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN RETARDER IS OPERATED................................................................................................................................................................................................................................310 F-2 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP........................................................................................................................................................................................................................................312 a) PARKING BRAKE IS AT TRAVEL POSITION,BUT PILOT LAMP LIGHTS UP...............................................................................................................................................................................................................................312 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE LEVER IS SET TO PARKING POSITION......................................................................................................................................................................................................312 F-3 ABNORMALITY IN LIGHTING UP OF FRONT BRAKE OIL LEVEL PILOT LAMP................................................................................................................................................................................................................................314 a) FRONT BRAKE OIL LEVEL IS NORMAL,BUT PILOT LAMP LIGHTS UP...................................................................................................................................................................................................................................314 b) THERE IS ABNORMALITY IN FRONT BRAKE OIL LEVEL,BUT PILOT LAMP DOES NOT LIGHT UP.............................................................................................................................................................................................................314 F-4 ABNORMALITY IN LIGHTING UP OF REAR BRAKE CAUTION LAMP.........................................................................................................................................................................................................................................316 a) REAR BRAKE OIL PRESSURE IS NORMAL,BUT CAUTION LAMP LIGHTS UP...............................................................................................................................................................................................................................316 b) THERE IS ABNORMALITY IN REAR BRAKE,BUT CAUTION LAMP DOES NOT LIGHT UP......................................................................................................................................................................................................................316 F-5 ABNORMALITY IN LIGHTING UP OF ENGINE OIL PRESSURE PILOT LAMP..................................................................................................................................................................................................................................318 a) PILOT LAMP LIGHTS UP WHEN ENGINE IS RUNNING(ENGINE OIL PRESSURE IS NORMAL).................................................................................................................................................................................................................318 b) PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT ON(ENGINE STOPPED).................................................................................................................................................................................................................318 F-6 ABNORMALITY IN LIGHTING UP OF BATTERY CHARGE CAUTION LAMP.....................................................................................................................................................................................................................................319 a) CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING..............................................................................................................................................................................................................................................319 b) PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT ON(ENGINE STOPPED).................................................................................................................................................................................................................319 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM......................................................................................................................................................................................................................................................321 TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR(C MODE).......................................................................................................................................................................................................................................322 TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR...........................................................................................................................................................................................................................................323 BASIC AIR CIRCUIT OF AIR COMPRESSOR...............................................................................................................................................................................................................................................................323 C-1 AIR PRESSURE DOES NOT RISE AT ALL.............................................................................................................................................................................................................................................................324 C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED PRESSURE RANGE(GREEN RANGE OF AIR GAUGE)..............................................................................................................................................................................................................325 C-3 AIR PRESSURE RISES BUT CHARGING TAKES A LONG TIME.............................................................................................................................................................................................................................................326 C-4 AIR BLOWS OUT FROM SAFETY VALVE...............................................................................................................................................................................................................................................................327 TROUBLESHOOTING OF HYDRAULIC AND MACHINE SYSTEMS(H MODE)..............................................................................................................................................................................................................................................328 METHOD OF USING MATRIX TROUBLESHOOTING TABLES.....................................................................................................................................................................................................................................................329 H-1 MACHINE DOES NOT START........................................................................................................................................................................................................................................................................331 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING.....................................................................................................................................................................................................................................................332 H-5 TRANSMISSION DOES NOT SHIFT UP................................................................................................................................................................................................................................................................332 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING...................................................................................................................................................................................................................................................333 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING...............................................................................................................................................................................................................................................339 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH......................................................................................................................................................................................................................................................341 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW..........................................................................................................................................................................................................................................................342 H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE.....................................................................................................................................................................................................................................343 H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE......................................................................................................................................................................................................................................344 H-12 STEERING WHEEL IS HEAVY......................................................................................................................................................................................................................................................................345 H-13 STEERING WHEEL DOES NOT WORK.................................................................................................................................................................................................................................................................346 H-14 STEERING WHEEL VIBRATES......................................................................................................................................................................................................................................................................346 H-15 HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)............................................................................................................................................................................................................................................347 H-16 HOIST CYLINDER DOES NOT WORK.................................................................................................................................................................................................................................................................348 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.......................................................................................................................................................................................................................................................349 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................................................................................................................................350 METHOD OF USING MANUAL....................................................................................................................................................................................................................................................................................352 STANDARD TIGHTENING TORQUE................................................................................................................................................................................................................................................................................353 PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................................................................................................................................................................................355 COATING MATERIALS.........................................................................................................................................................................................................................................................................................357 SPECIAL TOOL LIST.........................................................................................................................................................................................................................................................................................359 SKETCHES OF SPECIAL TOOLS.................................................................................................................................................................................................................................................................................361 STARTING MOTOR............................................................................................................................................................................................................................................................................................363 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................363 ALTERNATOR................................................................................................................................................................................................................................................................................................364 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................364 ENGINE OIL COOLER.........................................................................................................................................................................................................................................................................................365 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................365 FUEL INJECTION PUMP.......................................................................................................................................................................................................................................................................................366 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................366 AIR COMPRESSOR............................................................................................................................................................................................................................................................................................367 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................367 AIR CONDITIONER COMPRESSOR................................................................................................................................................................................................................................................................................368 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................368 AIR CONDITIONER CONDENSER.................................................................................................................................................................................................................................................................................369 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................369 WATER PUMP................................................................................................................................................................................................................................................................................................370 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................370 AFTERCOOLER CORE..........................................................................................................................................................................................................................................................................................371 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................371 EXHAUST BRAKE CYLINDER....................................................................................................................................................................................................................................................................................372 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................372 TURBOCHARGER..............................................................................................................................................................................................................................................................................................373 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................373 NOZZLE HOLDER.............................................................................................................................................................................................................................................................................................374 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................374 CYLINDER HEAD.............................................................................................................................................................................................................................................................................................375 REMOVAL...............................................................................................................................................................................................................................................................................................375 INSTALLATION..........................................................................................................................................................................................................................................................................................377 ENGINE FRONT SEAL.........................................................................................................................................................................................................................................................................................379 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................379 ENGINE REAR SEAL..........................................................................................................................................................................................................................................................................................381 REMOVAL...............................................................................................................................................................................................................................................................................................381 INSTALLATION..........................................................................................................................................................................................................................................................................................382 ENGINE....................................................................................................................................................................................................................................................................................................385 REMOVAL...............................................................................................................................................................................................................................................................................................385 INSTALLATION..........................................................................................................................................................................................................................................................................................388 RADIATOR..................................................................................................................................................................................................................................................................................................389 REMOVAL...............................................................................................................................................................................................................................................................................................389 INSTALLATION..........................................................................................................................................................................................................................................................................................391 OIL COOLER................................................................................................................................................................................................................................................................................................392 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................392 OUTPUT SHAFT..............................................................................................................................................................................................................................................................................................393 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................393 DISASSEMBLY...........................................................................................................................................................................................................................................................................................394 ASSEMBLY..............................................................................................................................................................................................................................................................................................396 TORQUE CONVERTER,TRANSMISSION.............................................................................................................................................................................................................................................................................400 REMOVAL...............................................................................................................................................................................................................................................................................................400 INSTALLATION..........................................................................................................................................................................................................................................................................................402 DISCONNECTION.........................................................................................................................................................................................................................................................................................404 CONNECTION............................................................................................................................................................................................................................................................................................405 TORQUE CONVERTER..........................................................................................................................................................................................................................................................................................406 DISASSEMBLY...........................................................................................................................................................................................................................................................................................406 ASSEMBLY..............................................................................................................................................................................................................................................................................................412 PTO.......................................................................................................................................................................................................................................................................................................418 DISASSEMBLY...........................................................................................................................................................................................................................................................................................418 ASSEMBLY..............................................................................................................................................................................................................................................................................................419 TRANSMISSION..............................................................................................................................................................................................................................................................................................421 DISASSEMBLY...........................................................................................................................................................................................................................................................................................421 ASSEMBLY..............................................................................................................................................................................................................................................................................................439 TRANSMISSION CONTROL VALVE(ECMV)..........................................................................................................................................................................................................................................................................457 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................457 TRANSMISSION,MAIN RELIEF VALVE............................................................................................................................................................................................................................................................................458 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................458 DIFFERENTIAL..............................................................................................................................................................................................................................................................................................459 REMOVAL...............................................................................................................................................................................................................................................................................................459 INSTALLATION..........................................................................................................................................................................................................................................................................................460 DISASSEMBLY...........................................................................................................................................................................................................................................................................................461 ASSEMBLY..............................................................................................................................................................................................................................................................................................464 FRONT WHEEL...............................................................................................................................................................................................................................................................................................472 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................472 REAR WHEEL................................................................................................................................................................................................................................................................................................473 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................473 FRONT BRAKE CALIPER PAD...................................................................................................................................................................................................................................................................................474 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................474 FRONT BRAKE CALIPER.......................................................................................................................................................................................................................................................................................475 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................475 DISASSEMBLY...........................................................................................................................................................................................................................................................................................476 ASSEMBLY..............................................................................................................................................................................................................................................................................................477 FRONT WHEEL HUB ..........................................................................................................................................................................................................................................................................................479 DISASSEMBLY...........................................................................................................................................................................................................................................................................................479 ASSEMBLY..............................................................................................................................................................................................................................................................................................480 FINAL DRIVE CARRIER.......................................................................................................................................................................................................................................................................................483 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................483 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................................................................................................................484 REAR WHEEL BRAKE..........................................................................................................................................................................................................................................................................................485 REMOVAL...............................................................................................................................................................................................................................................................................................485 INSTALLATION..........................................................................................................................................................................................................................................................................................487 REAR BRAKE................................................................................................................................................................................................................................................................................................489 DISASSEMBLY...........................................................................................................................................................................................................................................................................................489 ASSEMBLY..............................................................................................................................................................................................................................................................................................491 FRONT SUSPENSION CYLINDER.................................................................................................................................................................................................................................................................................494 REMOVAL...............................................................................................................................................................................................................................................................................................494 INSTALLATION..........................................................................................................................................................................................................................................................................................495 DISASSEMBLY...........................................................................................................................................................................................................................................................................................496 ASSEMBLY..............................................................................................................................................................................................................................................................................................497 AIR GOVERNOR..............................................................................................................................................................................................................................................................................................498 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................498 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................................................................................................................499 BRAKE VALVE...............................................................................................................................................................................................................................................................................................500 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................500 DISASSEMBLY...........................................................................................................................................................................................................................................................................................501 ASSEMBLY..............................................................................................................................................................................................................................................................................................503 PARKING BRAKE SPRING CYLINDER.............................................................................................................................................................................................................................................................................505 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................505 PARKING BRAKE CHAMBER.....................................................................................................................................................................................................................................................................................506 DISASSEMBLY...........................................................................................................................................................................................................................................................................................506 ASSEMBLY..............................................................................................................................................................................................................................................................................................507 FRONT BRAKE CHAMBER.......................................................................................................................................................................................................................................................................................508 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................508 DISASSEMBLY...........................................................................................................................................................................................................................................................................................509 ASSEMBLY..............................................................................................................................................................................................................................................................................................511 REAR BRAKE CHAMBER........................................................................................................................................................................................................................................................................................513 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................513 DISASSEMBLY...........................................................................................................................................................................................................................................................................................514 ASSEMBLY..............................................................................................................................................................................................................................................................................................518 SLACK ADJUSTER............................................................................................................................................................................................................................................................................................521 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................521 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................................................................................................................522 TRANSMISSION CONTROL,RETARDER BRAKE COOLING PUMP AND HOIST,STEERING PUMP..................................................................................................................................................................................................................................523 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................523 EMERGENCY STEERING MOTOR PUMP.............................................................................................................................................................................................................................................................................524 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................524 STEERING VALVE............................................................................................................................................................................................................................................................................................525 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................525 DISASSEMBLY...........................................................................................................................................................................................................................................................................................526 ASSEMBLY..............................................................................................................................................................................................................................................................................................531 DEMAND VALVE..............................................................................................................................................................................................................................................................................................539 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................539 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................................................................................................................540 RELIEF VALVE..............................................................................................................................................................................................................................................................................................541 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................................................................................................................................541 HOIST VALVE...............................................................................................................................................................................................................................................................................................542 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................542 DISASSEMBLY...........................................................................................................................................................................................................................................................................................543 ASSEMBLY..............................................................................................................................................................................................................................................................................................544 STEERING CYLINDER.........................................................................................................................................................................................................................................................................................545 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................545 DISASSEMBLY...........................................................................................................................................................................................................................................................................................546 ASSEMBLY..............................................................................................................................................................................................................................................................................................548 TRANSMISSION CONTROLLER...................................................................................................................................................................................................................................................................................550 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................550 SHIFT INDICATOR CONTROLLER................................................................................................................................................................................................................................................................................550 REMOVAL AND INSTALLATION..............................................................................................................................................................................................................................................................................550 PARKING BRAKE SHOE........................................................................................................................................................................................................................................................................................551 REMOVAL...............................................................................................................................................................................................................................................................................................551 INSTALLATION..........................................................................................................................................................................................................................................................................................552 40 MAINTENANCE STANDARD.......................................................................................................................................................................................................................................................................................553 DAMPER....................................................................................................................................................................................................................................................................................................554 TORQUE CONVERTER..........................................................................................................................................................................................................................................................................................555 TRANSMISSION..............................................................................................................................................................................................................................................................................................557 MAIN RELIEF VALVE.........................................................................................................................................................................................................................................................................................560 TRANSMISSION VALVE,ECMV...................................................................................................................................................................................................................................................................................561 FRONT AXLE................................................................................................................................................................................................................................................................................................562 DIFFERENTIAL..............................................................................................................................................................................................................................................................................................563 FINAL DRIVE...............................................................................................................................................................................................................................................................................................565 FRONT BRAKE...............................................................................................................................................................................................................................................................................................566 REAR BRAKE................................................................................................................................................................................................................................................................................................567 PARKING BRAKE.............................................................................................................................................................................................................................................................................................569 REAR BRAKE CHAMBER........................................................................................................................................................................................................................................................................................570 FRONG BRAKE CHAMBER.......................................................................................................................................................................................................................................................................................571 SLACK ADJUSTER............................................................................................................................................................................................................................................................................................572 HYDRAULIC PUMP............................................................................................................................................................................................................................................................................................573 STEERING,HOIST PUMP.......................................................................................................................................................................................................................................................................................574 STEERING CYLINDER.........................................................................................................................................................................................................................................................................................576 DEMAND VALVE..............................................................................................................................................................................................................................................................................................577 CROSSOVER RELIEF VALVE....................................................................................................................................................................................................................................................................................577 HOIST VALVER..............................................................................................................................................................................................................................................................................................578 HOIST CYLINDER............................................................................................................................................................................................................................................................................................579 FLOW CONTROL VALVE........................................................................................................................................................................................................................................................................................580 STEERING LINKAGE..........................................................................................................................................................................................................................................................................................581 REAR AXLE SUPPORT.........................................................................................................................................................................................................................................................................................582 FRONT SUSPENSION CYLINDER.................................................................................................................................................................................................................................................................................583 90 OTHERS.....................................................................................................................................................................................................................................................................................................584 ELECTRIC CIRCUIT DIAGRAM..................................................................................................................................................................................................................................................................................585 ELECTRIC CIRCUIT DIAGRAM(AIR CONDITIONER).................................................................................................................................................................................................................................................................586 ELECTRIC CIRCUIT DIAGRAM(SIREN,WORK LAMP,SHUTTER,OUTRIGGER)...............................................................................................................................................................................................................................................587 HYDRAURIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................................................588 AIR CIRCUIT DIAGRAM.......................................................................................................................................................................................................................................................................................589
DESCRIPTION:
KOMATSU HS150S-11 SHOP MANUAL SEBMW00801 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” 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.
S.S 17/12/24
