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KOMATSU WA150-5 SERVICE REPAIR MANUAL (SN:65001 & UP) – PDF DOWNLOAD
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- KOMATSU WA150-5 SERVICE REPAIR MANUAL
- SERIAL NUMBER:65001 & UP
- PUBLICATION NUMBER:SEBM033808
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Description
KOMATSU WA150-5 SERVICE REPAIR MANUAL (SN:65001 & UP)
KOMATSU WA150-5 SERVICE REPAIR MANUAL (SN:65001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA150-5 SERVICE REPAIR MANUAL (SN:65001 & UP)
- 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 WA150-5 SERVICE REPAIR MANUAL (SN:65001 & UP)
COVER ................................................................................................................................................................................. 0 CONTENTS............................................................................................................................................................................... 0 01 GENERAL............................................................................................................................................................................. 28 GENERAL ASSEMBLY DRAWINGS.......................................................................................................................................................... 29 SPECIFICATIONS..................................................................................................................................................................... 30 WEIGHT TABLE....................................................................................................................................................................... 34 LIST OF LUBRICANT AND COOLANT...................................................................................................................................................... 36 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD........................................................................................................................................ 37 ENGINE MOUNT AND TRANSFER MOUNT.................................................................................................................................................... 38 DAMPER............................................................................................................................................................................. 39 COOLING SYSTEM..................................................................................................................................................................... 40 POWER TRAIN........................................................................................................................................................................ 41 POWER TRAIN SYSTEM DIAGRAM......................................................................................................................................................... 42 DRIVE SHAFT ....................................................................................................................................................................... 44 HST HYDRAULIC PIPING DIAGRAM....................................................................................................................................................... 45 HST PUMP........................................................................................................................................................................... 46 HIGH-PRESSURE RELIEF VALVE......................................................................................................................................................... 48 LOW-PRESSURE RELIEF VALVE.......................................................................................................................................................... 50 HST CHARGE PUMP.................................................................................................................................................................... 51 SPEED-RELATED VALVE (DA VALVE)..................................................................................................................................................... 52 HIGH-PRESSURE CUT-OFF VALVE........................................................................................................................................................ 53 HST MOTOR.......................................................................................................................................................................... 54 EP SERVO VALVE..................................................................................................................................................................... 57 HA SERVO VALVE..................................................................................................................................................................... 58 FORWARD-REVERSE SHUTTLE VALVE...................................................................................................................................................... 59 TRANSFER........................................................................................................................................................................... 60 CLUTCH SOLENOID VALVE.............................................................................................................................................................. 71 AXLE............................................................................................................................................................................... 72 DIFFERENTIAL....................................................................................................................................................................... 74 LIMITED-SLIP DIFFERENTIAL.......................................................................................................................................................... 80 FINAL DRIVE........................................................................................................................................................................ 84 AXLE MOUNTING AND CENTER HINGE PIN................................................................................................................................................. 86 STEERING PIPING.................................................................................................................................................................... 91 STEERING COLUMN.................................................................................................................................................................... 92 PRIORITY VALVE..................................................................................................................................................................... 93 ORBIT-ROLL VALVE................................................................................................................................................................... 96 STEERING CYLINDER..................................................................................................................................................................104 EMERGENCY STEERING PIPING..........................................................................................................................................................106 EMERGENCY STEERING VALVE...........................................................................................................................................................107 BRAKE PIPING.......................................................................................................................................................................110 BRAKE VALVE........................................................................................................................................................................111 INCHING VALVE......................................................................................................................................................................115 CHARGE VALVE.......................................................................................................................................................................116 ACCUMULATOR (FOR BRAKE)............................................................................................................................................................120 SLACK ADJUSTER.....................................................................................................................................................................121 BRAKE..............................................................................................................................................................................123 PARKING BRAKE CONTROL..............................................................................................................................................................126 PARKING BRAKE......................................................................................................................................................................127 HYDRAULIC PIPING...................................................................................................................................................................128 WORK EQUIPMENT LEVER LINKAGE.......................................................................................................................................................130 HYDRAULIC TANK.....................................................................................................................................................................131 3-GEAR PUMP UNIT...................................................................................................................................................................133 ACCUMULATOR (FOR PPC CIRCUIT)......................................................................................................................................................135 LOCK VALVE.........................................................................................................................................................................136 E.C.S.S. VALVE ....................................................................................................................................................................137 ACCUMULATOR (FOR E.C.S.S.).........................................................................................................................................................139 HYDRAULIC PIPING OF COOLING SYSTEM.................................................................................................................................................140 COOLING FAN MOTOR..................................................................................................................................................................141 WORK EQUIPMENT CONTROL VALVE.......................................................................................................................................................143 WORK EQUIPMENT PPC VALVE...........................................................................................................................................................156 WORK EQUIPMENT LINKAGE.............................................................................................................................................................162 BUCKET.............................................................................................................................................................................164 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................165 WORK EQUIPMENT CYLINDER............................................................................................................................................................171 AIR CONDITIONER....................................................................................................................................................................172 MACHINE MONITORING SYSTEM..........................................................................................................................................................173 MACHINE MONITOR....................................................................................................................................................................182 LIST OF ITEMS DISPLAYED ON MONITOR.................................................................................................................................................183 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)..........................................................................................................................................209 HST CONTROLLER.....................................................................................................................................................................213 ENGINE START CIRCUIT...............................................................................................................................................................214 ENGINE STOP CIRCUIT................................................................................................................................................................216 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)...................................................................................................................................217 PARKING BRAKE CIRCUIT..............................................................................................................................................................218 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM........................................................................................................................................221 SENSORS............................................................................................................................................................................222 20 TESTING AND ADJUSTING...............................................................................................................................................................228 STANDARD VALUE TABLE FOR ENGINE....................................................................................................................................................229 STANDARD VALUE TABLE FOR CHASSIS...................................................................................................................................................230 TESTING AND ADJUSTING..............................................................................................................................................................235 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..............................................................................................................................236 MEASURING ENGINE SPEED.........................................................................................................................................................238 MEASURING EXHAUST GAS COLOR....................................................................................................................................................240 ADJUSTING VALVE CLEARANCE......................................................................................................................................................241 MEASURING COMPRESSION PRESSURE.................................................................................................................................................243 MEASURING BLOW-BY PRESSURE.....................................................................................................................................................244 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................................................................................................................245 MEASURING ENGINE OIL PRESSURE..................................................................................................................................................246 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL........................................................................................................................247 ADJUSTING ENGINE STOP SOLENOID.................................................................................................................................................249 ADJUSTING ENGINE SPEED SENSOR..................................................................................................................................................250 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..................................................................................................................250 MEASURING DIRECTIONAL LEVER....................................................................................................................................................251 TESTING AND ADJUSTING HST OIL PRESSURE.........................................................................................................................................252 MEASURING CLUTCH CONTROL PRESSURE..............................................................................................................................................257 TESTING AND ADJUSTING STEERING WHEEL...........................................................................................................................................258 TESTING AND ADJUSTING STEERING OIL PRESSURE....................................................................................................................................260 BLEEDING AIR FROM STEERING CIRCUIT.............................................................................................................................................262 TESTING HYDRAULIC FAN..........................................................................................................................................................263 MEASURING BRAKE PEDAL..........................................................................................................................................................264 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE......................................................................................................................................265 MEASURING BRAKE PERFORMANCE....................................................................................................................................................266 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE..............................................................................................................................267 MEASURING BRAKE OIL PRESSURE...................................................................................................................................................268 MEASURING WEAR OF BRAKE DISC...................................................................................................................................................270 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................................................................................271 MEASURING PARKING BRAKE PERFORMANCE............................................................................................................................................272 TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE..............................................................................................................................273 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...........................................................................................................................274 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE........................................................................................................................275 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE..........................................................................................................................276 BLEEDING AIR...................................................................................................................................................................278 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..............................................................................................................................279 TESTING AND ADJUSTING BUCKET POSITIONER........................................................................................................................................280 TESTING AND ADJUSTING OF BOOM KICK-OUT.........................................................................................................................................281 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...............................................................................................................................282 PROCEDURE FOR CHECKING DIODE...................................................................................................................................................283 METHOD OD CONNECTING T-ADAPTER FOR HST CONTROLLER..............................................................................................................................284 SPECIAL FUNCTIONS OF MACHINE MONITOR...........................................................................................................................................285 FLOW OF MODES AND FUNCTIONS....................................................................................................................................................286 ERROR CODE TABLE...............................................................................................................................................................294 PM CLINIC INSPECTION CHART.....................................................................................................................................................304 TROUBLESHOOTING....................................................................................................................................................................307 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................................................................308 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................................................................................................309 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................................................................................................310 CHECK BEFORE TROUBLESHOOTING...................................................................................................................................................318 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................319 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.....................................................................................................................320 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................................................................................................323 T- BRANCH BOX AND T- BRANCH ADAPTER TABLE......................................................................................................................................359 CONNECTOR TYPES AND MOUNTING LOCATIONS.........................................................................................................................................362 CONNECTOR LAYOUT DRAWING.......................................................................................................................................................369 TROUBLESHOOTING OF HST CONTROLLER SYSTEM(HST MODE).............................................................................................................................374 HST CONTROLLER SYSTEM DIAGRAM..............................................................................................................................................375 BEFORE TROUBLESHOOTING CODE DISPLAY........................................................................................................................................377 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...................................................................................................................................378 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.............................................................................................................................379 ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))....................................................................................................................381 ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))..............................................................................................382 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC)).......................................................................................384 ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).......................................................................................385 ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).......................................................................................387 ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))........................................................................................389 TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))....................................................................391 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)...............................................................................................................393 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED.....................................................................................396 HST-4 TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION............................................................................398 HST-5 TRAVEL SPEED IS NOT INCREASED........................................................................................................................................401 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE)............................................................................................................................404 RELATED ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................................405 ECSS-1 MALFUNCTION OF TRAVEL DAMPER........................................................................................................................................406 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE)....................................................................................................................................411 MONITOR SYSTEM CIRCUIT DIAGRAM.............................................................................................................................................412 BEFORE TROUBLESHOOTING CODE DISPLAY........................................................................................................................................416 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...................................................................................................................................417 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.............................................................................................................................418 ERROR CODE [15BONX](HST OIL FILTER CLOGGED(NX))............................................................................................................................420 ERROR CODE [2G42ZG](DECREASED BRAKE OIL PRESSURE(ZG))......................................................................................................................421 ERROR CODE [989F00](HST MOTOR PROTECTION CAUTION(00))......................................................................................................................422 ERROR CODE [989FN1](HST OVERRUNNING (N1))..................................................................................................................................423 ERROR CODE [AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...............................................................................................................424 ERROR CODE [AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...............................................................................................................425 ERROR CODE [B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG)).....................................................................................................................426 ERROR CODE [B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING (NS)).............................................................................................................427 ERROR CODE [B@BCZK](ALARM INDICATING LOW COOLANT LEVEL (ZK))...............................................................................................................428 ERROR CODE [B@C7NS](AXLE OIL TEMPERATURE OVERHEATING (NS)).................................................................................................................429 ERROR CODE [B@CRNS](HST OIL TEMPERATURE OVERHEATING (NS))..................................................................................................................430 ERROR CODE [D5ZHL6](STARTING SWITCH"C"(IGN"C") INPUT FAILURE (L6)).........................................................................................................431 ERROR CODE [DAFOKT](CONTROLLER INSIDE FAILURE (KT))........................................................................................................................433 ERROR CODE [DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE (KR)).............................................................................................................434 ERROR CODE [DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1) INPUT ERROR(LD))..............................................................................436 ERROR CODE [DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2) INPUT ERROR(LD))..............................................................................437 ERROR CODE [DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3 )INPUT ERROR(LD))..............................................................................438 ERROR CODE [DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR (LD))..............................................................................439 ERROR CODE [DDK3KB](MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB)).......................................................................................................440 ERROR CODE [DDS5L6](DECREASED STEERING OIL PRESSURE(L6))...................................................................................................................442 ERROR CODE [DGE2KX](ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX))................................................................................443 ERROR CODE [DGE3L6](ENGINE COOLANT TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))..................................................................................444 ERROR CODE [DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)).........................................................................................................445 ERROR CODE [DGR4KA](AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))..................................................................................................446 ERROR CODE [DGR4KX](AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))........................................................................................................447 ERROR CODE [DHE4L6](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))...................................................................................................448 TROUBLESHOOTING CODE [MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...........................................................................................449 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).......................................................................................453 TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)....454 TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)..............455 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.).............................................................................................456 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...................................................................................457 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)....................................................................................458 TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)........................................................................459 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1))...................................................................460 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))..................................................................461 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))..................................................................462 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))..................................................................463 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)....................................................................................................465 TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION..................................................................................................................467 TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY...............................................................................................................467 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..................................................................................................................................468 ELECTRICAL SYSTEM DIAGRAM..................................................................................................................................................469 PARKING BRAKE RELATED DIAGRAM..............................................................................................................................................472 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM ..................................................................................................................................474 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.............................................................................................................................475 TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START).....................................................................................................................477 TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)......................................................................................................................483 TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)..........................................................................................................485 TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE (MECHANICAL TYPE)DOES NOT FUNCTION)..........................................................................................490 TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION).............................................................................................495 TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION).........................................................................................498 TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION).................................................................................501 TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)......................................................................................................503 TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION)...................................................................................................................510 TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)..........................................................................................................515 TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY)...................................................................................................................518 TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)......................................................................................................................529 TROUBLESHOOTING CODE [E-13] (DEFECTIVE THE AIR CONDITIONER)................................................................................................................531 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)........................................................................................................................546 METHOD OF USING TROUBLESHOOTING CHART......................................................................................................................................547 ERROR CODE AND CAUSE TABLE.................................................................................................................................................549 H-1 THE MACHINE DOES NOT START.............................................................................................................................................551 H-2 THE TRAVEL SPEED IS SLOW...............................................................................................................................................552 H-3 THE THRUSTING FORCE IS WEAK............................................................................................................................................553 H-4 ENGINE STALLS WHEN TRAVELLING OR ENGINE SPEED DROPS EXCESSIVELY........................................................................................................554 H-5 THE GEAR IS NOT SHIFTED................................................................................................................................................555 H-6 THE STEERING WHEEL DOES NOT TURN.......................................................................................................................................556 H-7 THE STEERING WHEEL IS HEAVY............................................................................................................................................557 H-8 STEERING WHEEL SHAKES OR JERKS ........................................................................................................................................558 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING..................................................................................................................558 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL.........................................................................................................................559 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED...............................................................................................................................560 H-12 THE LIFT ARM DOES NOT RISE OR LOWER...................................................................................................................................561 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT................................................................................................562 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT .....................................................................................................563 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).......................................................................................563 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN..........................................................................................................................563 H-17 THE LIFT ARM WOBBLES DURING OPERATION.................................................................................................................................563 H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM "HOLD" TO "RAISE" ,THE LIFT ARM FALLS TEMPORARILY.............................................................................564 H-19 THE BUCKET DOES NOT TILT BACK.........................................................................................................................................565 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT ....................................................................................................566 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILITNG-BACK........................................................................................................567 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.......................................................................................................................567 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN............................................................................................................................567 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVES IS SET TO "HOLD")..............................................................................568 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT", THE BUCKET FALLS TEMPORARILY................................................................................568 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY..........................................................................................568 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES....................................................................................................569 TROUBLESHOOTING OF ENGINE(S MODE)..............................................................................................................................................570 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................................................................571 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..............................................................................................................575 S-2 ENGINE DOES NOT START..................................................................................................................................................577 (1) ENGINE DOES NOT TURN...............................................................................................................................................577 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)............................................................................................578 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).........................................................................................579 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) ..................................................................................................................580 S-4 ENGINE STOPS DURING OPERATIONS.........................................................................................................................................581 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..............................................................................................................................582 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...................................................................................................................................583 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).........................................................................................................................584 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................................................................................585 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................................................586 S-10 FUEL CONSUMPTION IS EXCESSIVE.........................................................................................................................................587 S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..................................................................................................588 S-12 OIL PRESSURE CAUTION TAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................................................589 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)..................................................................................................................................590 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................................................................................591 S-15 ABNORMAL NOISE IS MADE................................................................................................................................................592 S-16 VIBRATION IS EXCESSIVE................................................................................................................................................593 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................594 HOW TO READ THIS MANUAL............................................................................................................................................................595 PRECAUTIONS WHEN PERFORMING OPERATION..............................................................................................................................................597 SPECIAL TOOL LIST..................................................................................................................................................................599 SKETCHES OF SPECIAL TOOLS..........................................................................................................................................................602 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...........................................................................................................................607 REMOVAL AND INSTALLATION OF NOZZLE HOLDER..........................................................................................................................................611 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.................................................................................................................................613 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY........................................................................................................................................620 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY......................................................................................................................................628 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER........................................................................................................................................630 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY..........................................................................................................................631 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY.....................................................................................................................632 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.....................................................................................................................................634 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY......................................................................................................................................636 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY......................................................................................................................................638 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY.................................................................................................................................658 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY.................................................................................................................................659 REMOVAL AND INSTALLATION OF FRONT AXEL ASSEMBLY....................................................................................................................................663 REMOVAL AND INSTALLATION OF REAR AXEL ASSEMBLY.....................................................................................................................................665 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY..................................................................................................................................668 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY..................................................................................................................................679 REMOVAL AND INSTALLATION OF HST PUMP AND 3-GEAR PUMP ASSEMBLY......................................................................................................................702 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY...................................................................................................................................705 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY...................................................................................................................................707 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY..................................................................................................................709 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY...........................................................................................................................712 REMOVAL AND INSTALLATION OF HYDRAULIC TANK.........................................................................................................................................713 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY................................................................................................................................715 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY............................................................................................................................721 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY................................................................................................................................725 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).....................................................................................................................729 REMOVAL AND INSTALLATION OF CENTER HINGE PIN.......................................................................................................................................738 REMOVAL AND INSTALLATION OF COUNTERWEIGHT..........................................................................................................................................746 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY..........................................................................................................................747 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY....................................................................................................................749 REMOVAL AND INSTALLATION OF MONITOR PANEL..........................................................................................................................................750 REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY................................................................................................................................753 90 OTHERS..............................................................................................................................................................................754 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................................................755 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................756 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................757 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................758 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................759 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................760 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................761 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................762 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................763 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................764 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................765 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................766 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................767 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................768 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................769
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