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KOMATSU WA120L-3MC SERVICE REPAIR MANUAL (SN:54104 & UP) KOMATSU WA120L-3MC – PDF DOWNLOAD
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- KOMATSU WA120L-3MC SERVICE REPAIR MANUAL
- SERIAL NUMBER:54104 & UP
- PUBLICATION NUMBER:SEBM021800
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Description
KOMATSU WA120L-3MC SERVICE REPAIR MANUAL (SN:54104 & UP) KOMATSU WA120L-3MC
KOMATSU WA120L-3MC SERVICE REPAIR MANUAL (SN:54104 & UP) KOMATSU WA120L-3MC – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA120L-3MC SERVICE REPAIR MANUAL (SN:54104 & UP) KOMATSU WA120L-3MC
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - 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” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU WA120L-3MC SERVICE REPAIR MANUAL (SN:54104 & UP) KOMATSU WA120L-3MC
COVER..................................................................................................................................................................................................... 1 CONTENTS ................................................................................................................................................................................................. 2 01 GENERAL ............................................................................................................................................................................................... 23 GENERAL ASSEMBLY DRAWING.............................................................................................................................................................................. 24 SPECIFICATIONS........................................................................................................................................................................................ 25 WEIGHT TABLE ......................................................................................................................................................................................... 28 LIST OF LUBRICANT AND WATER........................................................................................................................................................................... 30 10 STRUCTURE AND FUNCTION................................................................................................................................................................................. 32 POWER TRAIN........................................................................................................................................................................................... 33 POWER TRAIN SYSTEM.................................................................................................................................................................................... 34 TORQUE CONVERTER, TRANSMISSION PIPING................................................................................................................................................................. 36 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM................................................................................................................................................................. 37 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................ 38 TORQUE CONVERTER ..................................................................................................................................................................................... 39 TRANSMISSION.......................................................................................................................................................................................... 41 TRANSMISSION CONTROL VALVE............................................................................................................................................................................ 51 TRANSMISSION CONTROL ................................................................................................................................................................................. 72 DRIVE SHAFT .......................................................................................................................................................................................... 73 AXLE.................................................................................................................................................................................................. 74 FINAL DRIVE........................................................................................................................................................................................... 80 AXLE MOUNT............................................................................................................................................................................................ 81 CENTER HINGE PIN...................................................................................................................................................................................... 83 STEERING PIPING....................................................................................................................................................................................... 84 STEERING COLUMN....................................................................................................................................................................................... 85 PRIORITY VALVE........................................................................................................................................................................................ 86 STEERING VALVE (DRBIT-ROLL)........................................................................................................................................................................... 89 BRAKE PIPING.......................................................................................................................................................................................... 97 BRAKE CONTROL......................................................................................................................................................................................... 98 BRAKE BOOSTER......................................................................................................................................................................................... 99 BRAKE ................................................................................................................................................................................................103 PARKING BRAKE CONTROL.................................................................................................................................................................................105 PARKING BRAKE ........................................................................................................................................................................................106 HYDRAULIC PIPING .....................................................................................................................................................................................107 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...............................................................................................................................................................109 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................................................................110 HYDRAULIC TANK........................................................................................................................................................................................112 PPC VALVE.............................................................................................................................................................................................115 ACCUMULATOR...........................................................................................................................................................................................122 MAIN CONTROL VALVE....................................................................................................................................................................................123 WORK EQUIPMENT LINKAGE................................................................................................................................................................................136 BUCKET................................................................................................................................................................................................138 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................................139 PROXIMITY SWITCH......................................................................................................................................................................................141 ROPS CAB..............................................................................................................................................................................................143 AIR CONDITIONER.......................................................................................................................................................................................144 ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)........................................................................................................................................................145 ELECTRICAL WIRING DIAGRAM ............................................................................................................................................................................148 AIR CONDITIONING AND HEATER ELECTRICAL DIAGRAM........................................................................................................................................................153 CENTRAL PANEL.........................................................................................................................................................................................154 SENSOR................................................................................................................................................................................................155 ENGINE STARTING CIRCUIT...............................................................................................................................................................................156 ENGINE STOP CIRCUIT...................................................................................................................................................................................157 FUEL CUT-OFF SOLENOID.................................................................................................................................................................................158 AUTOMATIC PREHEATING CIRCUIT (O.H.S. CONTROLLER)......................................................................................................................................................159 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM................................................................................................................................................................163 20 TESTING AND ADJUSTING..................................................................................................................................................................................182 STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................................................183 STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................................................................184 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....................................................................................................................................................187 ADJUSTING VALVE CLEARANCE.............................................................................................................................................................................189 TESTING AND ADJUSTING FUEL INJECTION TIMING...........................................................................................................................................................190 MEASURING EXHAUST COLOR...............................................................................................................................................................................191 MEASURING BLOW-BY PRESSURE............................................................................................................................................................................192 MEASURING ENGINE OIL PRESSURE.........................................................................................................................................................................193 MEASURING ENGINE SPEED................................................................................................................................................................................194 ADJUSTING ENGINE STOP SOLENOID........................................................................................................................................................................195 MEASURING ACCELERATOR PEDAL...........................................................................................................................................................................196 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER......................................................................................................................................................198 MEASURING STALL SPEED.................................................................................................................................................................................199 MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE.................................................................................................................................................201 METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE...................................................................................................................................................203 TESTING AND ADJUSTING STEERING WHEEL..................................................................................................................................................................205 MEASURING STEERING OIL PRESWSURE .....................................................................................................................................................................208 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL......................................................................................................................................................210 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.............................................................................................................................................................211 MEASURING BRAKE PERFORMANCE...........................................................................................................................................................................213 MEASURING BRAKE OIL PRESSURE..........................................................................................................................................................................214 TESTINMG FOR BRAKE DISC WEAR..........................................................................................................................................................................215 BLEEDING AIR FROM BRAKE SYSTEM .......................................................................................................................................................................216 MEASURING PARKING BRAKE PERFORMANCE...................................................................................................................................................................217 TESTING AND ADJUSTING PARKING BRAKE LINKAGE...........................................................................................................................................................218 TESTING PARKING BRAKE DISC WEAR.......................................................................................................................................................................219 MEASURING PARKING BRAKE DISC WEAR.....................................................................................................................................................................220 ADJUSTING WORK EQUIPMENT PPC VALVE....................................................................................................................................................................221 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...........................................................................................................................................................222 MEASURING WORK EQUIPMENT..............................................................................................................................................................................224 TESTING AND ADJUSTING BUCKET POSITIONER...............................................................................................................................................................226 TESTING AND ADJUSTING BOOM KICK-OUT...................................................................................................................................................................227 TROUBLESHOOTING.......................................................................................................................................................................................229 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................................................................................................230 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................................................................231 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................................................................232 CHECKS BEFORE TROUBLESHOOTING.....................................................................................................................................................................240 CONNECTOR TYPE AND INSTALLATION POSITION..........................................................................................................................................................241 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................................................................................248 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................................270 TROUBLESHOOTING OF ENGINE (S4D102E-1) SYSTEM (S MODE).............................................................................................................................................278 S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)..................................................................................................................................279 S-2 ENGINE DOES NOT START.....................................................................................................................................................................280 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................................................................283 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................................................................284 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................................................................285 S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................................................................................286 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)..............................................................................................................................................287 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).....................................................................................................................................288 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................................................................................................................................289 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................................................................290 S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN......................................................................................................................291 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................................292 S-13 OIL LEVEL RISES..........................................................................................................................................................................293 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).........................................................................................................................................294 S-15 ABNORMAL NOISE IS MADE...................................................................................................................................................................295 S-16 VIBRATION IS EXCESSIVE...................................................................................................................................................................296 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)..................................................................................................................................................297 M MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................299 M-1 ABNORMALITY IN POWER SUPPLY SYSTEM OR GROUND SYSTEM OF MONITOR PANEL......................................................................................................................301 a) WHEN THE STARTING SWITCH IS TURNED ON, THE [ENGINE OIL PRESSURE], [PARKING BRAKE], [BRAKE OIL LEVEL] AND [PREHEATING] LAMPS DO NOT LIGHT UP AT THE SAME TIME. (POWER SUPPLY SYSTEM)....301 b) WHEN THE STARTING SWITCH IS TURNED ON, THE [BATTERY CHARGE LEVEL], [TURN SIGNAL], [HIGH BEAM] AND [SERVICE METER] LAMPS DO NOT LIGHT UP OR FLASH AT THE SAME TIME. (GND SYSTEM)........301 M-2 ABNORMALITY IN AUTOMATIC PREHEATING PILOT LAMP............................................................................................................................................303 a) THE PREHEATING PILOT LAMP DOES NOT LIGHT UP WHILE THE AUTOMATIC PREHEATING SYSTEM (QHS) IS WORKING.....................................................................................303 b) THOUGH THE AUTOMATIC PREHEATING SYSTEM (QHS) DOES NOT WORK, THE PREHEATING PILOT LAMP LIGHTS UP........................................................................................303 M-3 ABNORMALITY IN BRAKE OIL LEVEL CAUTION LAMP...............................................................................................................................................305 a) WHEN THE STARTING SWITCH IS TURNED ON, THE LAMP DOES NOT LIGHT UP .....................................................................................................................305 b) THOUGH THE OIL LEVEL IS NORMAL WHILE ENGINE IS RUNNING, THE LAMP LIGHTS UP ............................................................................................................305 c) THOUGH THE OIL LEVEL IS ABNORMAL WHILE ENGINE IS RUNNING , THE LAMP DOES NOT LIGHT UP .................................................................................................306 M-4 ABNORMALITY IN PARKING BRAKE PILOT LAMP ..................................................................................................................................................307 a) THE LAMP DOES NOT LIGHT UP EVEN WHEN THE PARKING BRAKE PEDAL IS DEPRESSED.............................................................................................................307 B) THE LAMP DOES NOT GO OUT EVEN WHEN THE PARKING PEDAL IS RELEASED......................................................................................................................307 M-5 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP ..........................................................................................................................................309 a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON .....................................................................................................................309 b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING .......................................................................................................................................309 M-6 ABNORMALITY IN BATTERY CHARGE LEVEL CAUTION LAMP .........................................................................................................................................310 a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON .....................................................................................................................310 b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING .......................................................................................................................................310 M-7 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....................................................................................................................................312 a) THE GAUGE DOES NOT MOVE UP FROM C (THE LOWEST POSITION)................................................................................................................................312 b) THE GAUGE DOES NOT MOVE DOWN FROM H (THE HIGHEST POSITION).............................................................................................................................312 c) TORQUE CONVERTER OIL TEMPERATURE INDICATED ON THE GAUGE IS DIFFERENT FROM THE REAL TEMPERATURE.........................................................................................313 M-8 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE...........................................................................................................................................314 a) GAUGE DOES NOT MOVE UP FROM C (LOWEST LEVEL)...........................................................................................................................................314 b) GAUGE DOES NOT MOVE DOWN FROM H (HIGHEST LEVEL)........................................................................................................................................314 c) READING ON GAUGE DIFFERS FROM THE ACTUAL ENGINE COOLANT TEMPERATURE....................................................................................................................315 M-9 ABNORMALITY IN FUEL LEVEL GAUGE...........................................................................................................................................................316 a) GAUGE DOES NOT MOVE UP FROM E (LOWEST LEVEL)...........................................................................................................................................316 b) GAUGE DOES NOT MOVE DOWN FROM F (HIGHEST LEVEL)........................................................................................................................................316 c) READING ON GAUGE DIFFERS FROM THE ACTUAL FUEL LEVEL ...................................................................................................................................317 M-10 ABNORMALITY IN SERVICE METER.............................................................................................................................................................318 a) SERVICE METER WORKS WHEN ENGINE STOPS..................................................................................................................................................318 b) SERVICE METER DOES NOT WORK WHILE ENGINE IS RUNNING ...................................................................................................................................318 c) INDICATOR LAMP DOES NOT FLASH WHEN SERVICE METER IS WORKING ...........................................................................................................................318 M-11 HIGH BEAM PILOT LAMP, TURN SIGNAL PILOT LAMP DO NOT LIGHT UP OR FLASH....................................................................................................................320 a) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP ................................................................................................................................................320 b) TURN SIGNAL PILOT LAMP DOES NOT FLASH..................................................................................................................................................321 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....................................................................................................................................................322 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING, STOPPING AND BATTERY CHARGING.................................................................................................................323 E-1 ENGINE DOES NOT START.....................................................................................................................................................................324 a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START...................................................................................................................324 b) FUEL CUT OFF VALVE DOES NOT WORK.......................................................................................................................................................327 E-2 ABNORMALITY IN PREHEATING SYSTEM (QHS)....................................................................................................................................................328 a) PREHEATING IS NOT CARRIED OUT..........................................................................................................................................................328 b) PREHEATING IS CARRIED OUT, BUT MONITOR DISPLAY IS NOT TURNED ON .......................................................................................................................329 c) PREHEATING IS ALWAYS CARRIED OUT FOR 45 SEC............................................................................................................................................329 d) PREHEATING STAYS ON ...................................................................................................................................................................329 e) THE PREHEATING TIME REDUCES OR BECOMES UNCERTAIN.......................................................................................................................................330 E-3 TRANSMISSION DOES NOT COME TO NEUTRAL WHILE PARKING BRAKE IS APPLIED. (BUT THE TRANSMISSION CUTOFF IS IN ORDER)...........................................................................332 E-4 BOOM KICKOUT CANNOT BE CARRIED OUT........................................................................................................................................................333 E-5 BUCKET POSITIONER FUNCTION IS ABNORMAL....................................................................................................................................................336 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (AUTO-SHIFT TRANSMISSION) (A MODE )................................................................................................................339 OUTLINE.......................................................................................................................................................................................340 1. FUNCTION...............................................................................................................................................................................340 2. WHEN CARRYING OUT TROUBLESHOOTING......................................................................................................................................................340 3. FAILURE CODE TABLE.....................................................................................................................................................................340 4. TABLE OF FAILURE MODES AND CAUSES......................................................................................................................................................341 5. RELATED ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL..............................................................................................................................342 A-1 FAILURE CODE [12] ABNORMALITY IN F SOLENOID SIGNAL SYSTEM.................................................................................................................................344 A-2 FAILURE CODE [13] ABNORMALITY IN R SOLENOID SIGNAL SYSTEM.................................................................................................................................344 A-3 FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...............................................................................................................................345 A-4 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.............................................................................................................................346 A-5 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM..........................................................................................................................347 A-6 FAILURE CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM...........................................................................................................................348 A-7 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...............................................................................................................................349 A-8 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL .....................................................................................................................................350 A-9 ABNORMALITY IN KICK-DOWN SWITCH SYSTEM....................................................................................................................................................351 A-10 ABNORMALITY IN TRANSMISSION CUT-OFF SIGNAL SYSTEM........................................................................................................................................352 A-11 ABNORMALITY IN NEUTRALIZER RELAY SIGNAL SYSTEM...........................................................................................................................................353 A-12 ABNORMALITY IN ALARM BUZZER SIGNAL SYSTEM................................................................................................................................................354 A-13 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM............................................................................................................................................355 A-14 ABNORMALITY IN MODEL SELECTION HARNESS...................................................................................................................................................356 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (H MODE).....................................................................................................................357 H-1 MACHINE DOES NOT TRAVEL...................................................................................................................................................................358 H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES......................................................................................................................360 H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR....................................................................................................................................362 H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................................................................................363 H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH .................................................................................................................................................364 H-6 STEERING WHEEL DOES NOT TURN..............................................................................................................................................................365 H-7 STEERING IS HEAVY.........................................................................................................................................................................366 H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK.........................................................................................................................................367 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.....................................................................................................................................367 H-10 BRAKES DO NOT WORK BRAKING EFFECT IS POOR................................................................................................................................................368 H-11 BRAKE IS NOT RELEASED, BRAKE DRAGS.......................................................................................................................................................369 H-12 BOOM DOES NOT MOVE UP....................................................................................................................................................................370 H-13 BOOM MOVES TOO SLOWLY OR LACKS LIFTING FORCE.............................................................................................................................................371 H-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.................................................................................................................................372 H-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)...............................................................................................................................372 H-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM .......................................................................................................................................................372 H-17 BOOM SHAKES DURING OPERATION ............................................................................................................................................................373 H-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.................................................................................................................373 H-19 BUCKET DOES NOT TILT BACK................................................................................................................................................................374 H-20 BUCKET MOVES TOO SLOWLY OR LACKS TILT-BACK FORCE.........................................................................................................................................375 H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION .................................................................................................................................376 H-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.............................................................................................................................................376 H-23 EXCESSIVE HYDRAULIC DRIFT OR BUCKET......................................................................................................................................................376 H-24 BUCKET SHAKES DURING TRAVEL WITH LOAD (WORK EQUIPMENT VALVE AT HOLD).....................................................................................................................377 H-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT................................................................................................................377 H-26 BOOM AND BUCKET CONTROL LEVERS ARE HEAVY AND DO NOT MOVE SMOOTH..........................................................................................................................378 30 DISASSEMBLY AND ASSEMBLY...............................................................................................................................................................................379 METHOD OF USING MANUAL................................................................................................................................................................................381 PRECAUTIONS WHEN CARRYING OUT OPERATION...............................................................................................................................................................382 SPECIAL TOOL LIST.....................................................................................................................................................................................384 STARTING MOTOR........................................................................................................................................................................................386 REMOVAL AND INSTALLATION..........................................................................................................................................................................386 ALTERNATOR............................................................................................................................................................................................387 REMOVAL AND INSTALLATION..........................................................................................................................................................................387 FUEL INJECTION PUMP...................................................................................................................................................................................388 REMOVAL ..........................................................................................................................................................................................388 INSTALLATION......................................................................................................................................................................................390 ENGINE OIL COOLER.....................................................................................................................................................................................393 REMOVAL AND INSTALLATION..........................................................................................................................................................................393 WATER PUMP............................................................................................................................................................................................394 REMOVAL AND INSTALLATION..........................................................................................................................................................................394 NOZZLE HOLDER.........................................................................................................................................................................................395 REMOVAL...........................................................................................................................................................................................395 INSTALLATION......................................................................................................................................................................................396 THERMOSTAT............................................................................................................................................................................................397 REMOVAL AND INSTALLATION..........................................................................................................................................................................397 TURBOCHARGER..........................................................................................................................................................................................398 REMOVAL AND INSTALLATION..........................................................................................................................................................................398 CYLINDER HEAD.........................................................................................................................................................................................399 REMOVAL...........................................................................................................................................................................................399 INSTALLATION......................................................................................................................................................................................404 RADIATOR..............................................................................................................................................................................................407 REMOVAL ..........................................................................................................................................................................................407 INSTALLATION......................................................................................................................................................................................408 ENGINE................................................................................................................................................................................................409 REMOVAL...........................................................................................................................................................................................409 INSTALLATION......................................................................................................................................................................................410 TORQUE CONVERTER CHARGING PUMP........................................................................................................................................................................413 REMOVAL AND INSTALLATION..........................................................................................................................................................................413 TORQUE CONVERTER, TRANSMISSION........................................................................................................................................................................414 REMOVAL ..........................................................................................................................................................................................414 INSTALLATION......................................................................................................................................................................................422 TORQUE CONVERTER......................................................................................................................................................................................423 DISASSEMBLY.......................................................................................................................................................................................423 ASSEMBLY..........................................................................................................................................................................................425 TRANSMISSION..........................................................................................................................................................................................427 DISASSEMBLY.......................................................................................................................................................................................427 ASSEMBLY..........................................................................................................................................................................................438 CLUTCH PACK...........................................................................................................................................................................................453 DISASSEMBLY ......................................................................................................................................................................................453 ASSEMBLY..........................................................................................................................................................................................459 TRANSMISSION CONTROL VALVE............................................................................................................................................................................473 REMOVAL...........................................................................................................................................................................................473 INSTALLATION......................................................................................................................................................................................474 DISASSEMBLY ......................................................................................................................................................................................475 ASSEMBLY..........................................................................................................................................................................................477 TRANSMISSION SOLENOID VALVE...........................................................................................................................................................................479 DISASSEMBLY AND ASSEMBLY..........................................................................................................................................................................479 TRANSMISSION ACCUMULATOR VALVE........................................................................................................................................................................480 DISASSEMBLY ......................................................................................................................................................................................480 ASSEMBLY..........................................................................................................................................................................................481 DRIVE SHAFT...........................................................................................................................................................................................482 DISASSEMBLY.......................................................................................................................................................................................482 ASSEMBLY..........................................................................................................................................................................................484 FRONT AXLE............................................................................................................................................................................................486 REMOVAL...........................................................................................................................................................................................486 INSTALLATION......................................................................................................................................................................................487 REAR AXLE.............................................................................................................................................................................................488 REMOVAL...........................................................................................................................................................................................488 INSTALLATION......................................................................................................................................................................................492 DIFFERENTIAL..........................................................................................................................................................................................497 DISASSEMBLY.......................................................................................................................................................................................497 ASSEMBLY..........................................................................................................................................................................................501 AXLE HOUSING..........................................................................................................................................................................................511 DISASSEMBLY ......................................................................................................................................................................................511 ASSEMBLY..........................................................................................................................................................................................516 CENTER HINGE PIN......................................................................................................................................................................................524 REMOVAL...........................................................................................................................................................................................524 INSTALLATION......................................................................................................................................................................................533 PRIORITY VALVE........................................................................................................................................................................................542 REMOVAL...........................................................................................................................................................................................542 INSTALLATION......................................................................................................................................................................................543 STEERING VALVE........................................................................................................................................................................................544 REMOVAL...........................................................................................................................................................................................544 INSTALLATION......................................................................................................................................................................................546 DISASSEMBLY ......................................................................................................................................................................................547 ASSEMBLY..........................................................................................................................................................................................550 STEERING CYLINDER.....................................................................................................................................................................................555 REMOVAL...........................................................................................................................................................................................555 INSTALLATION......................................................................................................................................................................................556 BRAKE BOOSTER.........................................................................................................................................................................................557 REMOVAL...........................................................................................................................................................................................557 INSTALLATION......................................................................................................................................................................................559 DISASSEMBLY.......................................................................................................................................................................................560 ASSEMBLY..........................................................................................................................................................................................563 PARKING BRAKE.........................................................................................................................................................................................568 REMOVAL...........................................................................................................................................................................................568 INSTALLATION......................................................................................................................................................................................570 HYDRAULIC TANK........................................................................................................................................................................................571 REMOVAL...........................................................................................................................................................................................571 INSTALLATION......................................................................................................................................................................................572 HYDRAULIC, STEERING PPC PUMP..........................................................................................................................................................................573 REMOVAL ..........................................................................................................................................................................................573 INSTALLATION......................................................................................................................................................................................574 MAIN CONTROL VALVE....................................................................................................................................................................................575 REMOVAL ..........................................................................................................................................................................................575 INSTALLATION......................................................................................................................................................................................577 DISASSEMBLY.......................................................................................................................................................................................578 ASSEMBLY..........................................................................................................................................................................................580 BUCKET CYLINDER.......................................................................................................................................................................................582 REMOVAL ..........................................................................................................................................................................................582 INSTALLATION......................................................................................................................................................................................583 BOOM CYLINDER.........................................................................................................................................................................................584 REMOVAL...........................................................................................................................................................................................584 INSTALLATION......................................................................................................................................................................................585 HYDRAULIC CYLINDER....................................................................................................................................................................................586 DISASSEMBLY.......................................................................................................................................................................................586 ASSEMBLY..........................................................................................................................................................................................588 WORK EQUIPMENT........................................................................................................................................................................................590 REMOVAL ..........................................................................................................................................................................................590 INSTALLATION......................................................................................................................................................................................593 FUEL TANK.............................................................................................................................................................................................596 REMOVAL ..........................................................................................................................................................................................596 INSTALLATION......................................................................................................................................................................................597 COUNTERWEIGHT.........................................................................................................................................................................................598 REMOVAL AND INSTALLATION..........................................................................................................................................................................598 INSTRUMENT PANEL......................................................................................................................................................................................599 REMOVAL AND INSTALLATION..........................................................................................................................................................................599 ENGINE HOOD ..........................................................................................................................................................................................600 REMOVAL AND INSTALLATION..........................................................................................................................................................................600 40 MAINTENANCE STANDARD...................................................................................................................................................................................601 ENGINE MOUNT, TRANSMISSION MOUNT......................................................................................................................................................................602 TORQUE CONVERTER, CHARGING PUMP.......................................................................................................................................................................603 TORQUE CONVERTER......................................................................................................................................................................................604 TRANSMISSION..........................................................................................................................................................................................605 TRANSMISSION CONTROL VALVE............................................................................................................................................................................617 ACCUMULATOR VALVE.....................................................................................................................................................................................621 DRIVE SHAFT...........................................................................................................................................................................................622 DIFFERENTIAL..........................................................................................................................................................................................623 FINAL DRIVE...........................................................................................................................................................................................626 AXLE MOUNT............................................................................................................................................................................................628 CENTER HINGE PIN......................................................................................................................................................................................629 STEERING COLUMN.......................................................................................................................................................................................631 PRIORITY VALVE........................................................................................................................................................................................632 STEERING CYLINDER MOUNT...............................................................................................................................................................................633 BRAKE BOOSTER.........................................................................................................................................................................................634 BRAKE.................................................................................................................................................................................................635 PARKING BRAKE.........................................................................................................................................................................................636 HYDRAULIC PUMP AND PPC PUMP...........................................................................................................................................................................637 MAIN CONTROL VALVE....................................................................................................................................................................................638 PPC VALVE.............................................................................................................................................................................................644 STEERING CYLINDER, HYDRAULIC CYLINDER.................................................................................................................................................................646 WORK EQUIPMENT LINKAGE................................................................................................................................................................................647 BUCKET ...............................................................................................................................................................................................649 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................................................................................................650
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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