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KOMATSU WA150-5 SHOP MANUAL VEBM934100 – PDF DOWNLOAD
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Description
KOMATSU WA150-5 SHOP MANUAL VEBM934100 – PDF DOWNLOAD
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KOMATSU WA150-5 SHOP MANUAL VEBM934100 – PDF DOWNLOAD
Language : English
Pages : 776
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA150-5 SHOP MANUAL VEBM934100 – PDF DOWNLOAD
SHOP MANUAL WA150-5H_VEBM934100......................................................................................... 1 01 GENERAL.......................................................................................................... 7 GENERAL ASSEMBLY DRAWINGS....................................................................................... 8 SPECIFICATIONS.................................................................................................. 9 WEIGHT TABLE.................................................................................................... 13 LIST OF LUBRICANT AND COOLANT................................................................................... 15 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD..................................................................... 17 Damper.......................................................................................................... 19 Engine mount and transfer mount................................................................................. 18 Cooling system.................................................................................................. 20 Power train..................................................................................................... 21 Power train system diagram...................................................................................... 22 Drive shaft..................................................................................................... 24 HST hydraulic piping diagram.................................................................................... 25 HST pump........................................................................................................ 26 High-pressure relief valve...................................................................................... 28 Low-pressure relief valve....................................................................................... 30 HST charge pump................................................................................................. 31 Speed-related valve (DA valve).................................................................................. 32 High-pressure cut-off valve..................................................................................... 33 HST motor....................................................................................................... 34 EP servo valve.................................................................................................. 37 HA servo valve.................................................................................................. 38 Forward-reverse shuttle valve................................................................................... 39 Transfer........................................................................................................ 40 Clutch solenoid valve........................................................................................... 51 Axle............................................................................................................ 52 Differential.................................................................................................... 54 Limited-slip differential....................................................................................... 60 Final drive..................................................................................................... 64 Axle mounting and center hinge pin.............................................................................. 66 Steering piping................................................................................................. 71 Steering column................................................................................................. 72 Priority valve.................................................................................................. 73 Orbit-roll valve................................................................................................ 76 Steering cylinder............................................................................................... 84 Emergency steering piping....................................................................................... 86 Emergency steering valve........................................................................................ 87 Brake piping.................................................................................................... 90 Brake valve..................................................................................................... 91 Inching valve................................................................................................... 95 Charge valve.................................................................................................... 96 Accumulator (for brake).........................................................................................100 Slack adjuster..................................................................................................101 Brake...........................................................................................................104 Parking brake control...........................................................................................107 Parking brake...................................................................................................108 Hydraulic piping................................................................................................110 Work equipment lever linkage....................................................................................112 Hydraulic tank..................................................................................................113 3-gear pump unit................................................................................................116 Accumulator (for ppc circuit)...................................................................................118 Lock valve......................................................................................................119 Accumulator (for E.C.S.S.)......................................................................................124 E.C.S.S. valve..................................................................................................122 Hydraulic piping of coolingsystem..............................................................................125 Cooling fan motor...............................................................................................126 Work equipment linkage..........................................................................................148 Bucket..........................................................................................................150 Bucket positioner and boom kick-out.............................................................................151 Work equipment cylinder.........................................................................................157 Air conditioner.................................................................................................158 Machine monitoring system.......................................................................................159 Machine monitor.................................................................................................169 List of items displayed onmonitor..............................................................................170 Electrical system (HSTcontroller system).......................................................................196 HST controller..................................................................................................200 Engine start circuit............................................................................................201 Engine stop circuit.............................................................................................203 Preheating circuit..............................................................................................204 Parking brake circuit...........................................................................................205 Electronically controlled suspension system.....................................................................208 Sensors.........................................................................................................209 Work equipment control valve....................................................................................128 Work equipment PPC valve........................................................................................141 20 TESTING AND ADJUSTING............................................................................................215 STANDARD VALUE TABLE FOR ENGINE.................................................................................216 STANDARD VALUE TABLE FOR CHASSIS................................................................................217 TESTING AND ADJUSTING...........................................................................................223 Tools for testing, adjusting, and troubleshooting...............................................................224 Measuring engine speed..........................................................................................226 Special tools required......................................................................................226 MEASURING HIGH-IDLING AND LOW-IDLING SPEEDS.................................................................226 MEASURING HST STALL SPEED...................................................................................227 MEASURING HYDRAULIC SPEED...................................................................................227 MEASURING FULL STALL SPEED..................................................................................227 Measuring exhaust gas color.....................................................................................228 Special tools required......................................................................................228 Adjusting valve clearance.......................................................................................229 Special tools required......................................................................................229 Measuring compression pressure..................................................................................231 Special tools required......................................................................................231 Measuring blow-by pressure......................................................................................232 Special tools required......................................................................................232 Testing and adjusting fuel injection timing.....................................................................233 Special tools required......................................................................................233 Measuring engine oil pressure...................................................................................234 Special tools required......................................................................................234 Measuring, testing operating force of accelerator pedal.........................................................235 Special tools required......................................................................................235 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL.....................................................235 OPERATING ANGLE OF ACCELERATOR PEDAL........................................................................236 Adjusting engine stop solenoid..................................................................................237 Adjusting engine speed sensor...................................................................................238 Testing and adjusting air conditioner compressor belt tension...................................................238 Testing.....................................................................................................238 Adjusting...................................................................................................238 Measuring directional lever.....................................................................................239 Special tools required......................................................................................239 Operating effort of directional lever.......................................................................239 Travel of directional lever.................................................................................239 Testing and adjusting HST oil pressure..........................................................................240 Special tools required......................................................................................240 Adjusting...................................................................................................243 Measuring clutch control pressure...............................................................................245 Special tools required......................................................................................245 Testing and adjusting steering wheel............................................................................246 Special tools required......................................................................................246 MEASURING PLAY OF STEERING WHEEL............................................................................246 Method of measurement.......................................................................................246 MEASURING OPERATING FORCE OF STEERING WHEEL.................................................................247 Measurement method..........................................................................................247 MEASURING OPERATING TIME FOR STEERING WHEEL.................................................................247 Measurement method..........................................................................................247 Testing and adjusting steering oil pressure.....................................................................248 Special tools required......................................................................................248 Method of measuring main relief pressure....................................................................248 Method of adjusting main relief pressure....................................................................249 Bleeding air from steering circuit..............................................................................250 Testing hydraulic fan...........................................................................................251 Special tools required......................................................................................251 Measuring fan speed.........................................................................................251 Measuring oil pressure......................................................................................251 Measuring brake pedal...........................................................................................252 Operating effort of pedal...................................................................................252 Testing and adjusting brake pedal linkage.......................................................................253 Testing.....................................................................................................253 Adjusting...................................................................................................253 Measuring brake performance.....................................................................................254 Measurement method..........................................................................................254 Testing and adjusting accumulator charge pressure...............................................................255 Special tools required......................................................................................255 Measuring...................................................................................................255 Adjusting...................................................................................................255 Measuring brake oil pressure....................................................................................256 Special tools required......................................................................................256 Measuring...................................................................................................256 Brake test tool.............................................................................................257 Measuring wear of brake disc....................................................................................258 Special tool required.......................................................................................258 Bleeding air from brake circuit.................................................................................259 Special tools required......................................................................................259 Measuring parking brake performance.............................................................................260 Measurement method..........................................................................................260 Testing and adjusting parking brake control cable...............................................................261 Special tool required.......................................................................................261 Testing.....................................................................................................261 Adjusting...................................................................................................261 Measuring and adjusting work equipment control lever............................................................262 Special tools required......................................................................................262 Measurement.................................................................................................262 Testing and adjusting work equipment hydraulic pressure.........................................................263 Special tools required......................................................................................263 Measuring condition.........................................................................................263 Measuring...................................................................................................263 Adjusting...................................................................................................263 Testing and adjusting work equipment PPC oil pressure...........................................................264 Special tools required......................................................................................264 Measuring condition.........................................................................................264 Measuring...................................................................................................264 Bleeding air....................................................................................................266 Special tools required......................................................................................266 Releasing remaining pressure in hydraulic circuit...............................................................267 Testing and adjusting bucket positioner.........................................................................268 Testing.....................................................................................................268 Adjusting...................................................................................................268 Testing and adjusting of boom kick-out..........................................................................269 Testing.....................................................................................................269 Adjusting...................................................................................................269 Checking proximity switch actuation display lamp................................................................270 Proximity switch actuation display lamp (red)...............................................................270 Procedure for checking diode....................................................................................271 Method of connecting T-adapter for HST controller...............................................................272 Special functions of machine monitor............................................................................273 Flow of modes and functions.....................................................................................274 Operator mode...............................................................................................277 Service mode 1..............................................................................................277 Service mode 2..............................................................................................277 Character display...........................................................................................277 Operating switches..........................................................................................277 Operator mode operation and displays........................................................................277 Error code table................................................................................................282 Procedure for switching to Service Mode 1 and screen display................................................284 Real-time monitoring items..................................................................................289 Table of filter and oil replacement interval set items (when sipping).......................................290 Service mode 2..............................................................................................291 Pm clinic inspection chart......................................................................................292 WA150-5H H50051 and up......................................................................................292 TESTING AND ADJUSTING...........................................................................................223 Points to remember when troubleshooting.....................................................................296 Sequence of events in troubleshooting.......................................................................297 Precautions when carrying out maintenance...................................................................298 Check before troubleshooting................................................................................306 Categories, procedure, and method of using troubleshooting charts...........................................307 Phenomena considered to be failures and troubleshooting no..................................................308 Connection table for connector pin numbers..................................................................312 T-adapter table.............................................................................................333 Connector types and mounting locations......................................................................337 Connector layout drawing....................................................................................344 TROUBLESHOOTING.................................................................................................295 HST controller system diagram...............................................................................350 Before troubleshooting code display.........................................................................352 ERROR CODE AND POSSIBLE CAUSES TABLE....................................................................352 Before troubleshooting electrical system....................................................................353 FUSE BOX CONNECTION TABLE...............................................................................353 Information contained in troubuleshooting table.............................................................354 Related circuit diagram.................................................................................355 Phenomena code table....................................................................................355 Error Code [989F00] (HST motor protection caution (00)).................................................356 Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX))...........................357 Related circuit diagram.................................................................................358 Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC))....................359 Related circuit diagram.................................................................................359 Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ))....................360 Related circuit diagram.................................................................................361 Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ))....................362 Related circuit diagram.................................................................................363 Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ)).....................364 Related circuit diagram.................................................................................365 Troubleshooting Code [HST-1] (Defective HST controller power source (HST controller does not func.......366 Related circuit diagram.................................................................................367 Troubleshooting Code [HST-2] (Travel speed does not shifted)............................................368 Related circuit diagram.................................................................................370 Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled.................371 Related circuit diagram.................................................................................372 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).............................................................349 HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position.............373 Related circuit diagram.....................................................................................375 HST-5 Travel speed is not increased.........................................................................376 Related circuit diagram.....................................................................................378 Related electrical circuit diagram..........................................................................380 Related circuit diagram.................................................................................380 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE).............................................................379 ECSS-1 Malfunction of travel damper.........................................................................381 Specification of load meter (STD).......................................................................381 Malfunction of travel damper............................................................................381 a) Travel damper does not operate.......................................................................381 b) Travel damper is not reset...........................................................................384 Monitor system circuit diagram..............................................................................388 Before troubleshooting code display.........................................................................392 ERROR CODE AND POSSIBLE CAUSES TABLE....................................................................392 Before troubleshooting electrical system....................................................................393 FUSE BOX CONNECTION TABLE...............................................................................393 Information contained in troubuleshooting table.............................................................394 Related circuit diagram.................................................................................395 Phenomena code table....................................................................................395 Error Code [15B0NX].........................................................................................396 (HST oil filter clogged (NX))...............................................................................396 Related circuit diagram.................................................................................396 Error Code [2G42ZG].........................................................................................397 (Decreased brake oil pressure (ZG)).........................................................................397 Related circuit diagram.................................................................................397 Error Code [989F00].........................................................................................398 (HST motor protection caution (00)).........................................................................398 Error Code [989FN1].........................................................................................399 (HST overrunning (N1))......................................................................................399 Error Code [AB00L6].........................................................................................400 (Defective battery charging circuit (L6))...................................................................400 Related circuit diagram.................................................................................400 Error Code [AB00MA].........................................................................................401 (Defective battery charging circuit (MA))...................................................................401 Related circuit diagram.................................................................................401 Error Code [B@BAZG].........................................................................................402 (Degreased engine oil pressure (ZG))........................................................................402 Related circuit diagram.................................................................................402 Error Code [B@BCNS].........................................................................................403 (Engine water temperature overheating (NS)).................................................................403 Related circuit diagram.................................................................................403 Error Code [B@BCZK].........................................................................................404 (Alarm indicating low coolant level (ZK))...................................................................404 Related circuit diagram.................................................................................404 Error Code [B@C7NS].........................................................................................405 (Axle oil temperature overheating (NS)).....................................................................405 Related circuit diagram.................................................................................405 Error Code [B@CRNS].........................................................................................406 (HST oil temperature overheating (NS))......................................................................406 Related circuit diagram.................................................................................406 Error Code [D5ZHL6].........................................................................................408 (Starting switch "C" (IGN "C") input failure (L6))..........................................................408 Related circuit diagram.................................................................................409 Error Code [DAF0KT].........................................................................................410 (Controller inside failure (KT))............................................................................410 Error Code [DAJ0KR].........................................................................................412 (HST controller communication failure (KR)).................................................................412 Related circuit diagram.................................................................................413 Error Code [DD15LD].........................................................................................414 (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD))................................414 Related circuit diagram.................................................................................414 Error Code [DD16LD].........................................................................................415 (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD))................................415 Related circuit diagram.................................................................................415 Error Code [DD17LD].........................................................................................416 (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD))................................416 Related circuit diagram.................................................................................416 Error Code [DD18LD].........................................................................................417 (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD))................................417 Related circuit diagram.................................................................................417 Error Code [DDK3KB].........................................................................................418 (Multiple directional lever FR signal input (KB))...........................................................418 Related circuit diagram.................................................................................419 Error Code [DDS5L6].........................................................................................420 (Decreased steering oil pressure (L6))......................................................................420 Related circuit diagram.................................................................................420 Error Code [DGE2KX].........................................................................................421 (Engine coolant temperature (High temperature) sensor system failure (KX))..................................421 Related circuit diagram.................................................................................421 Error Code [DGE3L6].........................................................................................423 (Engine coolant temperature (Low temperature) sensor system failure (L6))...................................423 Related circuit diagram.................................................................................423 Error Code [DGH1KX].........................................................................................424 (HST oil temperature sensor system failure (KX))............................................................424 Related circuit diagram.................................................................................424 Error Code [DGR4KA].........................................................................................425 (Axle oil temperature sensor system discontinuity (KA)).....................................................425 Related circuit diagram.................................................................................425 Error Code [DGR4KX].........................................................................................426 (Axle oil temperature sensor system failure (KX))...........................................................426 Related circuit diagram.................................................................................426 Error Code [DHE4L6].........................................................................................427 (Engine oil pressure sensor system discontinuity (L6))......................................................427 Related circuit diagram.................................................................................427 Troubleshooting Code [MON-1]................................................................................429 (The parking brake indicator lamp does not light ON)........................................................429 Related circuit diagram.................................................................................431 Related circuit diagram.................................................................................432 Troubleshooting Code [MON-2]................................................................................433 (The brake oil pressure caution lamp does not light ON).....................................................433 Related circuit diagram.................................................................................433 Troubleshooting Code [MON-3]................................................................................434 (The engine water temperature caution lamp does not light ON, or after the engine starts, the eng...........434 Related circuit diagram.................................................................................434 Troubleshooting Code [MON-4]................................................................................435 (The HST oil temperature caution lamp does not light ON, or after the engine starts, the HST oil ...........435 Related circuit diagram.................................................................................435 Troubleshooting Code [MON-5]................................................................................436 (The fuel level gauge does not rise or decrease. )..........................................................436 Related circuit diagram.................................................................................436 Troubleshooting Code [MON-6]................................................................................437 (The radiator coolant level caution lamp does not light ON).................................................437 Related circuit diagram.................................................................................437 Troubleshooting Code [MON-7]................................................................................438 (The steering oil pressure caution lamp does not light ON)..................................................438 Related circuit diagram.................................................................................438 Troubleshooting Code [MON-8]................................................................................439 (The emergency steering oil pressure indicator lamp does not light ON)......................................439 Related circuit diagram.................................................................................439 Troubleshooting Code [MON-9]................................................................................440 (Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1))................................440 Related circuit diagram.................................................................................440 Troubleshooting Code [MON-10]...............................................................................442 (Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2))................................442 Related circuit diagram.................................................................................443 Troubleshooting Code [MON-11]...............................................................................444 (Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3))................................444 Related circuit diagram.................................................................................445 Troubleshooting Code [MON-12]...............................................................................446 (Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4))................................446 Related circuit diagram.................................................................................447 Troubleshooting Code [MON-13]...............................................................................448 (The alarm buzzer does not sound or stop)...................................................................448 Related circuit diagram.................................................................................449 Troubleshooting Code [MON-14]...............................................................................450 The wiper does not function.................................................................................450 Troubleshooting Code [MON-15]...............................................................................450 The lamps do not work properly..............................................................................450 TROUBLESHOOTING OF monitor SYSTEM (mon MODE)....................................................................387 Electrical system diagram...................................................................................452 Parking brake related diagram...............................................................................456 Before troubleshooting electrical system....................................................................458 Fuse box connection table...............................................................................458 Information contained in troubuleshooting table.............................................................460 Related circuit diagram.................................................................................461 Troubleshooting Code [E-1]..................................................................................462 (The engine does not start).................................................................................462 a) Defective starting motor system......................................................................462 Related circuit diagram.................................................................................465 Troubleshooting Code [E-2]..................................................................................468 (The engine does not stop)..................................................................................468 Related circuit diagram.................................................................................469 Troubleshooting Code [E-3]..................................................................................470 (Preheating is impossible or constant)......................................................................470 a) Preheating is impossible.............................................................................470 b) Preheating is constant...............................................................................475 Troubleshooting Code [E-4]..................................................................................478 (The parking brake (Mechanical type) does not function).....................................................478 a) Parking brake dragging prevention does not function (mechanical type)................................478 b) Parking brake "non-applied" indicator does not light up (mechanical type)............................480 Troubleshooting Code [E-5]..................................................................................482 (Defective boom kick-out function and cancellation).........................................................482 Related circuit diagram.................................................................................484 Troubleshooting Code [E-6]..................................................................................485 (Defective bucket positioner function and cancellation).....................................................485 Related circuit diagram.................................................................................487 Troubleshooting Code [E-7]..................................................................................495 (Defective lift arm FLOATING holding function and cancellation).............................................495 Related circuit diagram.................................................................................496 Troubleshooting Code [E-9]..................................................................................497 (The wiper does not function)...............................................................................497 a) The rear wiper does not function.....................................................................497 Related circuit diagram.................................................................................499 b) The rear wiper does not function.....................................................................500 Related circuit diagram.................................................................................501 Troubleshooting Code [E-10].................................................................................502 (The window washer does not function).......................................................................502 Related circuit diagram.................................................................................504 Troubleshooting Code [E-11].................................................................................505 (Lamps do not work properly)................................................................................505 a) Neither high beam nor low beam of headlamp light up..................................................505 Related circuit diagram.................................................................................507 b) Head lamp (Lo beam) does not light ON................................................................508 Related circuit diagram.................................................................................508 c) Head lamp (Hi beam) does not light ON................................................................509 Related circuit diagram.................................................................................509 d) Clearance lamp (Small lamp) does not light ON........................................................510 Related circuit diagram.................................................................................511 e) Turn signal lamp does not blink......................................................................512 Related circuit diagram.................................................................................513 f) Working lamp does not light ON.......................................................................514 Related circuit diagram.................................................................................515 Troubleshooting Code [E-12].................................................................................516 (The horn does not sound)...................................................................................516 Related circuit diagram.................................................................................517 Troubleshooting Code [E-13].................................................................................521 (Defective of the air conditioner)..........................................................................521 a) The air conditioner does not work....................................................................521 Related circuit diagram.................................................................................522 c) Does not cool or temperature cannot be adjusted......................................................523 Related circuit diagram.................................................................................525 d) Impossible to switch between recirculated air and fresh air..........................................526 Related circuit diagram.................................................................................526 e) Impossible to switch vents...........................................................................526 Related circuit diagram................................................................................. 0 TROUBLESHOOTING OF ELECTRICAL SYSTEM............................................................................451 (E MODE)........................................................................................................451 b) Defective fuel cut solenoid system.......................................................................466 Related circuit diagram.....................................................................................472 Related circuit diagram.....................................................................................476 Troubleshooting Code [E-8]..................................................................................488 (Travel direction is not changed normally)..................................................................488 a) When directional lever is set in "F", machine does not travel forward................................488 Related circuit diagram.................................................................................491 b) When directional lever is set in "R", machine does not travel in reverse.............................492 b) Air does not flow out or amount of air cannot be adjusted............................................518 Related circuit diagram.................................................................................520 f) Defective cooling (Mechanical system)................................................................527 Related circuit diagram.................................................................................527 g) Defective heating (Defective hot-water circuit)......................................................528 h) Abnormal sound comes out.............................................................................529 i) Water leaks..........................................................................................530 Method of using troubleshooting chart.......................................................................532 Error code and cause table..................................................................................534 H-1.........................................................................................................536 The machine does not start..............................................................................536 H-2.........................................................................................................537 The travel speed is slow................................................................................537 H-3.........................................................................................................538 The thrusting force is weak.............................................................................538 H-4.........................................................................................................539 Engine stalls when traveling or engine speed drops excessively..........................................539 H-5.........................................................................................................540 The gear is not shifted.................................................................................540 H-6.........................................................................................................541 The steering wheel does not turn........................................................................541 H-7.........................................................................................................542 The steering wheel is heavy.............................................................................542 H-8.........................................................................................................543 Steering wheel shakes or jerks..........................................................................543 H-9.........................................................................................................543 Machine deviates naturally to one side when traveling...................................................543 H-10........................................................................................................544 The brake does not work or does not work well...........................................................544 H-11........................................................................................................545 The brake is not released or is dragged.................................................................545 H-12........................................................................................................546 The lift arm does not rise or lower.....................................................................546 H-13........................................................................................................547 The lift arm moves slowly or the lift arm rising force is insufficient..................................547 H-14........................................................................................................548 When rising, the lift arm comes to move slowly at specific height.......................................548 H-15........................................................................................................548 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).........................548 H-16........................................................................................................548 Hydraulic drifts of the lift arm occur often............................................................548 H-17........................................................................................................548 The lift arm wobbles during operation...................................................................548 H-18........................................................................................................549 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily...............549 H-19........................................................................................................550 The bucket does not tilt back...........................................................................550 H-20........................................................................................................551 The bucket moves slowly or the tilting-back force is insufficient.......................................551 H-21........................................................................................................552 The bucket comes to operate slowly in he midst of tilting-back..........................................552 H-22........................................................................................................552 The bucket cylinder cannot hold down the bucket.........................................................552 H-23........................................................................................................552 Hydraulic drifts of the bucket occur often..............................................................552 H-24........................................................................................................553 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD").................553 H-25........................................................................................................553 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily..................553 H-26........................................................................................................553 The control levers of the lift arm and bucket do not move smoothly and heavy............................553 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................531 H-27........................................................................................................554 The travel damper does not operate and machine pitches and bounces......................................554 Method of using troubleshooting charts......................................................................556 S-7 Exhaust gas is black (incomplete combustion)........................................................558 S-1.........................................................................................................560 Starting performance is poor (Starting always takes time)...............................................560 S-2.........................................................................................................562 Engine does not start...................................................................................562 (1) Engine does not turn................................................................................562 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)............................563 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)..........................564 S-3.........................................................................................................565 Engine does not pick up smoothly (Follow-up is poor)....................................................565 S-4.........................................................................................................566 Engine stops during operations..........................................................................566 S-5.........................................................................................................567 Engine does not rotate smoothly (Hunting)...............................................................567 S-6.........................................................................................................568 Engine lacks output (or lacks power)....................................................................568 S-7.........................................................................................................569 Exhaust smoke is black (Incomplete combustion)..........................................................569 S-8.........................................................................................................570 Oil consumption is excessive (or exhaust smoke is blue).................................................570 S-9.........................................................................................................571 Oil becomes contaminated quickly........................................................................571 S-10........................................................................................................572 Fuel consumption is excessive...........................................................................572 S-11........................................................................................................573 Oil is in cooling water, or water spurts back, or water level goes down.................................573 S-12........................................................................................................574 Oil pressure caution lamp lights up (Drop in oil pressure)..............................................574 S-13........................................................................................................575 Oil level rises (Water, fuel in oil)....................................................................575 S-14........................................................................................................576 Water temperature becomes too high (Overheating)........................................................576 S-15........................................................................................................577 Abnormal noise is made..................................................................................577 S-16........................................................................................................578 Vibration is excessive..................................................................................578 TROUBLESHOOTING OF ENGINE (S MODE)..............................................................................555 30 DISASSEMBLY AND ASSEMBLY.........................................................................................579 HOW TO READ THIS MANUAL.........................................................................................580 PRECAUTIONS WHEN PERFORMING OPERATION...........................................................................582 SPECIAL TOOL LIST...............................................................................................584 SKETCHES OF SPECIAL TOOLS.......................................................................................587 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY........................................................594 REMOVAL AND INSTALLATION OF NOZZLE HOLDER.......................................................................598 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..............................................................600 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY.....................................................................607 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...................................................................615 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER.....................................................................617 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.......................................................618 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..................................................619 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..................................................................621 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY...................................................................623 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY...................................................................625 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY..............................................................645 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY..............................................................646 REMOVAL AND INSTALLATION OF FRONT AXEL ASSEMBLY.................................................................652 REMOVAL AND INSTALLATION OF REAR AXEL ASSEMBLY..................................................................654 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY...............................................................657 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY...............................................................668 REMOVAL AND INSTALLATION OF HST PUMP AND 3-GEAR PUMP ASSEMBLY...................................................691 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY................................................................694 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY................................................................696 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...............................................698 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY........................................................701 REMOVAL AND INSTALLATION OF HYDRAULIC TANK......................................................................702 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.............................................................704 DISASSMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..........................................................710 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY.............................................................716 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)..................................................720 REMOVAL AND INSTALLATION OF CENTER HINGE PIN....................................................................729 REMOVAL AND INSTALLATION OF COUNTERWEIGHT.......................................................................737 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.......................................................738 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.................................................740 REMOVAL AND INSTALLATION OF MONITOR PANEL.......................................................................741 90 OTHERS...........................................................................................................745 Hydraulic circuit diagram.......................................................................................747 Electrical circuit diagram 1/4 (1/4)............................................................................749 Electrical circuit diagram 1/4 (2/4)............................................................................751 Electrical circuit diagram 1/4 (3/4)............................................................................753 Electrical circuit diagram 1/4 (4/4)............................................................................755 Electrical circuit diagram 2/4..................................................................................757 Electrical circuit diagram 3/4..................................................................................759 Electrical circuit diagram 4/4..................................................................................761 Electrical circuit diagram 1/4 (1/4)............................................................................763 Electrical circuit diagram 1/4 (2/4)............................................................................765 Electrical circuit diagram 1/4 (3/4)............................................................................767 Electrical circuit diagram 1/4 (4/4)............................................................................769 Electrical circuit diagram 2/4..................................................................................771 Electrical circuit diagram 3/4..................................................................................773 Electrical circuit diagram 4/4..................................................................................775
S.S 21/12/24
