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KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL
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A25001 and up - PUBLICATION NUMBER:CEBMW21020
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Description
KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL
Screenshot of the Manual:
KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL
- 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 chapters for each main group of components; these chapters are further divided into the following sections. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. . Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
Table of Contents:
KOMATSU WA450-2 WHEEL LOADER SERVICE REPAIR MANUAL
MAIN MENU.................................................................................................................................................................................... 0 CONTENTS..................................................................................................................................................................................... 5 10 ENGINE.................................................................................................................................................................................... 21 12 TESTING AND ADJUSTING................................................................................................................................................................. 21 STANDARD VALUE TABLE................................................................................................................................................................. 22 TOOL LIST FOR TESTING AND ADJUSTING.................................................................................................................................................. 25 ADJUSTING VALVE CLEARANCE............................................................................................................................................................ 26 FUEL INJECTION TIMING................................................................................................................................................................ 27 MEASURING BLOW-BY PRESSURE........................................................................................................................................................... 28 FAN BELT TENSION..................................................................................................................................................................... 29 MEASURING EXHAUST GAS COLOR.......................................................................................................................................................... 31 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE...................................................................................................................... 33 13 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................. 35 STARTING MOTOR ASSEMBLY.............................................................................................................................................................. 37 REMOVAL.......................................................................................................................................................................... 37 INSTALLATION..................................................................................................................................................................... 37 ALTERNATOR ASSEMBLY.................................................................................................................................................................. 38 REMOVAL.......................................................................................................................................................................... 38 INSTALLATION..................................................................................................................................................................... 38 WATER PUMP ASSEMBLY.................................................................................................................................................................. 39 REMOVAL.......................................................................................................................................................................... 39 INSTALLATION..................................................................................................................................................................... 39 TURBOCHARGER ASSEMBLY................................................................................................................................................................ 40 REMOVAL.......................................................................................................................................................................... 40 INSTALLATION..................................................................................................................................................................... 40 CYLINDER HEAD ASSEMBLY............................................................................................................................................................... 41 REMOVAL.......................................................................................................................................................................... 41 INSTALLATION..................................................................................................................................................................... 42 RADIATOR ASSEMBLY.................................................................................................................................................................... 43 REMOVAL.......................................................................................................................................................................... 43 INSTALLATION..................................................................................................................................................................... 46 ENGINE............................................................................................................................................................................... 48 REMOVAL.......................................................................................................................................................................... 48 INSTALLATlON..................................................................................................................................................................... 54 FUEL TANK............................................................................................................................................................................ 60 REMOVAL.......................................................................................................................................................................... 60 INSTALLATION..................................................................................................................................................................... 60 14 MAINTENANCE STANDARD.................................................................................................................................................................. 61 ENGINE MOUNT......................................................................................................................................................................... 62 20 POWER TRAIN............................................................................................................................................................................... 63 21 STRUCTURE AND FUNCTION................................................................................................................................................................ 63 GENERAL.............................................................................................................................................................................. 65 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................................................................ 67 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................................................................................................ 68 DAMPER............................................................................................................................................................................... 69 TORQUE CONVERTER AND TRANSMISSION PIPING............................................................................................................................................. 70 TORQUE CONVERTER CHARGING PUMP....................................................................................................................................................... 71 TORQUE CONVERTER..................................................................................................................................................................... 72 TORQUE CONVERTER OIL FILTER.......................................................................................................................................................... 75 TORQUE CONVERTER OIL COOLER.......................................................................................................................................................... 76 TORQUE CONVERTER RELIEF VALVE........................................................................................................................................................ 77 TRANSMISSION......................................................................................................................................................................... 78 TRANSMISSION foldout # 1......................................................................................................................................................... 79 TRANSMISSION CONTROL VALVE........................................................................................................................................................... 86 UPPER VALVE...................................................................................................................................................................... 88 LOWER VALVE...................................................................................................................................................................... 89 TRANSMISSION SOLENOID VALVE...................................................................................................................................................... 90 EMERGENCY MANUAL SPOOL........................................................................................................................................................... 91 PRIORITY VALVE................................................................................................................................................................... 94 MODULATING VALVE AND QUICK RETURN VALVE.......................................................................................................................................... 95 ACCUMULATOR VALVE................................................................................................................................................................ 98 PILOT REDUCING VALVE.............................................................................................................................................................100 TRANSMISSION PILOT FILTER............................................................................................................................................................101 TRANSFER.............................................................................................................................................................................102 DRIVE SHAFT..........................................................................................................................................................................103 AXLE MOUNT...........................................................................................................................................................................104 AXLE AND DIFFERENTIAL................................................................................................................................................................106 TORQUE PROPORTIONING DIFFERENTIAL................................................................................................................................................111 FINAL DRIVE..........................................................................................................................................................................112 TIRE AND WHEEL.......................................................................................................................................................................113 22 TESTING AND ADJUSTING.................................................................................................................................................................115 STANDARD VALUE TABLE.................................................................................................................................................................116 TOOL LIST FOR TESTING AND ADJUSTING..................................................................................................................................................117 MEASURING ENGINE STALL SPEED.........................................................................................................................................................118 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION..........................................................................................................................120 MEASURING SHIFT LEVER................................................................................................................................................................122 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.......................................................................................................................................123 TIRE AND WHEEL.......................................................................................................................................................................125 TROUBLESHOOTING......................................................................................................................................................................126 PRECAUTIONS WHEN TROUBLESHOOTING.................................................................................................................................................127 METHOD OF READING TROUBLESHOOTING TABLES.........................................................................................................................................129 PREVENTING RECURRENCE OF TROUBLE.................................................................................................................................................131 JUDGMENT ON POWER TRAIN..........................................................................................................................................................132 TROUBLESHOOTING TABLE................................................................................................................................................................134 Machine does not move............................................................................................................................................................134 Machine lacks power or speed (all speed range)...................................................................................................................................136 Excessive time lag when starting machine or shifting gear........................................................................................................................137 Torque converter oil temperature too high........................................................................................................................................138 23 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................139 DAMPER...............................................................................................................................................................................141 REMOVAL..........................................................................................................................................................................141 INSTALLATlON.....................................................................................................................................................................141 DISASSEMBLY......................................................................................................................................................................142 ASSEMBLY.........................................................................................................................................................................144 TORQUE CONVERTER CHARGING PUMP.......................................................................................................................................................148 REMOVAL..........................................................................................................................................................................148 INSTALLATION.....................................................................................................................................................................149 TORQUE CONVERTER AND TRANSMISSION....................................................................................................................................................150 REMOVAL..........................................................................................................................................................................150 INSTALLATION.....................................................................................................................................................................159 TORQUE CONVERTER ASSEMBLY............................................................................................................................................................169 DISASSEMBLY......................................................................................................................................................................169 ASSEMBLY.........................................................................................................................................................................173 TRANSMISSION ASSEMBLY................................................................................................................................................................179 DISASSEMBLY......................................................................................................................................................................179 DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER....................................................................................................................................187 DISASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY......................................................................................................................................189 DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING..................................................................................................................................190 DISASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY......................................................................................................................................191 ASSEMBLY.........................................................................................................................................................................192 ASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY.........................................................................................................................................192 ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING.....................................................................................................................................193 ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY.........................................................................................................................................194 ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER.......................................................................................................................................195 ASSEMBLY OF TRANSMISSION.....................................................................................................................................................197 TRANSFER ASSEMBLY....................................................................................................................................................................205 DISASSEMBLY......................................................................................................................................................................205 DISASSEMBLY OF OUTPUT SHAFT GEAR CASE........................................................................................................................................207 ASSEMBLY.........................................................................................................................................................................208 ASSEMBLY OF OUTPUT SHAFT, GEAR CASE..........................................................................................................................................208 TRANSMISSION CONTROL VALVE...........................................................................................................................................................213 REMOVAL..........................................................................................................................................................................213 INSTALLATION.....................................................................................................................................................................215 DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................217 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE.......................................................................................................................217 DISASSEMBLY AND ASSEMBLY OF SPEED VALVE......................................................................................................................................218 DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE.................................................................................................................................219 FRONT DIFFERENTIAL...................................................................................................................................................................221 REMOVAL..........................................................................................................................................................................221 INSTALLATION.....................................................................................................................................................................225 REAR DIFFERENTIAL....................................................................................................................................................................229 REMOVAL..........................................................................................................................................................................229 INSTALLATION.....................................................................................................................................................................233 DIFFERENTIAL.........................................................................................................................................................................237 DISASSEMBLY......................................................................................................................................................................237 ASSEMBLY.........................................................................................................................................................................240 FRONT AXLE...........................................................................................................................................................................249 REMOVAL..........................................................................................................................................................................249 INSTALLATION.....................................................................................................................................................................252 REAR AXLE............................................................................................................................................................................255 REMOVAL..........................................................................................................................................................................255 INSTALLATION.....................................................................................................................................................................260 DRIVE SHAFT..........................................................................................................................................................................265 DISASSEMBLY......................................................................................................................................................................265 ASSEMBLY.........................................................................................................................................................................267 FINAL DRIVE..........................................................................................................................................................................269 DISASSEMBLY......................................................................................................................................................................269 ASSEMBLY.........................................................................................................................................................................272 24 MAINTENANCE STANDARD..................................................................................................................................................................277 TRANSMISSION MOUNT...................................................................................................................................................................278 TORQUE CONVERTER CHARGING PUMP.......................................................................................................................................................279 DAMPER...............................................................................................................................................................................280 TORQUE CONVERTER.....................................................................................................................................................................281 TORQFLOW TRANSMISSION................................................................................................................................................................283 TRANSMISSION.....................................................................................................................................................................283 TRANSMISSION CONTROL VALVE.......................................................................................................................................................286 UPPER VALVE..................................................................................................................................................................286 LOWER VALVE..................................................................................................................................................................288 SOLENOID VALVE...................................................................................................................................................................290 TRANSFER.............................................................................................................................................................................291 DIFFERENTIAL.........................................................................................................................................................................293 FINAL DRIVE..........................................................................................................................................................................295 DRIVE SHAFT..........................................................................................................................................................................296 AXLE MOUNT...........................................................................................................................................................................297 40 STEERING SYSTEM...........................................................................................................................................................................299 41 STRUCTURE AND FUNCTION................................................................................................................................................................299 STEERING PIPING......................................................................................................................................................................300 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...............................................................................................................................................301 STEERING VALVE.......................................................................................................................................................................302 ORBIT-ROLL VALVE.................................................................................................................................................................303 STOP VALVE.......................................................................................................................................................................304 STEERING PUMP........................................................................................................................................................................305 STEERING CYLINDER....................................................................................................................................................................306 STEERING COLUMN AND ORBIT-ROLL.......................................................................................................................................................307 CENTER HINGE PIN.....................................................................................................................................................................308 42 TESTING AND ADJUSTING.................................................................................................................................................................309 STANDARD VALUE TABLE.................................................................................................................................................................310 TOOL LIST ...........................................................................................................................................................................310 MEASURING STEERING WHEEL PLAY........................................................................................................................................................311 MEASURING OPERATING FORCE OF STEERING WHEEL..........................................................................................................................................312 OPERATING TIME OF STEERING WHEEL.....................................................................................................................................................313 STEERING OIL PRESSURE................................................................................................................................................................314 TROUBLESHOOTING TABLES...............................................................................................................................................................316 1. Steering wheel does not turn..................................................................................................................................................317 2. Steering wheel is sluggish....................................................................................................................................................318 3. Steering wheel moves unsteadily or is subject to large shock..................................................................................................................319 4. Machine tends to turn naturally in one particular direction when traveling....................................................................................................319 5. Left and right turning radii are different....................................................................................................................................319 43 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................321 STEERING VALVE.......................................................................................................................................................................322 REMOVAL..........................................................................................................................................................................322 INSTALLATION.....................................................................................................................................................................324 DISASSEMBLY......................................................................................................................................................................327 ASSEMBLY.........................................................................................................................................................................330 STEERING DEMAND VALVE................................................................................................................................................................335 REMOVAL..........................................................................................................................................................................335 INSTALLATION.....................................................................................................................................................................337 DISASSEMBLY......................................................................................................................................................................340 ASSEMBLY.........................................................................................................................................................................344 STEERING PUMP........................................................................................................................................................................348 REMOVAL..........................................................................................................................................................................348 INSTALLATION.....................................................................................................................................................................349 STEERING CYLINDER....................................................................................................................................................................350 REMOVAL..........................................................................................................................................................................350 INSTALLATION.....................................................................................................................................................................351 DISASSEMBLY......................................................................................................................................................................352 ASSEMBLY.........................................................................................................................................................................354 CENTER HINGE PIN.....................................................................................................................................................................357 REMOVAL..........................................................................................................................................................................357 INSTALLATION.....................................................................................................................................................................366 44 MAINTENANCE STANDARD..................................................................................................................................................................377 STEERING COLUMN AND ORBIT-ROLL.......................................................................................................................................................378 STEERING PUMP........................................................................................................................................................................379 STEERING VALVE.......................................................................................................................................................................380 STEERING CYLINDER MOUNT..............................................................................................................................................................381 STEERING CYLINDER....................................................................................................................................................................382 CENTER HINGE PIN.....................................................................................................................................................................384 50 BRAKE AND AIR SYSTEM......................................................................................................................................................................387 51 STRUCTURE AND FUNCTION................................................................................................................................................................387 GENERAL..............................................................................................................................................................................388 BRAKE AND AIR PIPING.................................................................................................................................................................389 BRAKE AND AIR CIRCUIT SYSTEM.........................................................................................................................................................390 AIR TANK.............................................................................................................................................................................391 SAFETY VALVE.........................................................................................................................................................................393 BRAKE VALVE..........................................................................................................................................................................394 BRAKE ACTUATED...................................................................................................................................................................395 OPERATING IN BALANCE.............................................................................................................................................................396 BRAKE RELEASED...................................................................................................................................................................397 AIR GOVERNOR.........................................................................................................................................................................398 TWO-WAY VALVE........................................................................................................................................................................400 BRAKE CHAMBER........................................................................................................................................................................401 SLACK ADJUSTER.......................................................................................................................................................................403 BRAKE................................................................................................................................................................................406 PARKING BRAKE........................................................................................................................................................................408 PARKING BRAKE SOLENOID VALVE.........................................................................................................................................................410 SPRING CYLINDER......................................................................................................................................................................411 BRAKE CALIPER........................................................................................................................................................................412 52 TESTING AND ADJUSTING.................................................................................................................................................................415 STANDARD VALUE TABLE.................................................................................................................................................................417 TOOL LIST ...........................................................................................................................................................................418 MEASURING BRAKE PEDAL................................................................................................................................................................419 MEASURING AIR........................................................................................................................................................................420 BRAKE PERFORMANCE....................................................................................................................................................................423 CHECKING BRAKE OIL PRESSURE..........................................................................................................................................................424 MEASURING WEAR OF BRAKE DISC.........................................................................................................................................................425 AIR BLEEDING FROM BRAKE LINE.........................................................................................................................................................426 PARKING BRAKE PERFORMANCE............................................................................................................................................................427 CHECKING AND ADJUSTING PARKING BRAKE.................................................................................................................................................428 TROUBLESHOOTING......................................................................................................................................................................431 TROUBLESHOOTING TABLE............................................................................................................................................................432 1. Air pressure does not rise at all.............................................................................................................................................432 2. Air pressure does not rise to the specified range.............................................................................................................................433 3. Brake is ineffective or not very effective....................................................................................................................................434 4. Brake does not release, or drags..............................................................................................................................................435 5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)...............................................................................436 53 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................437 AIR GOVERNOR ........................................................................................................................................................................439 DISASSEMBLY......................................................................................................................................................................439 ASSEMBLY.........................................................................................................................................................................440 BRAKE VALVE .........................................................................................................................................................................441 REMOVAL..........................................................................................................................................................................441 INSTALLATION.....................................................................................................................................................................442 DISASSEMBLY......................................................................................................................................................................443 ASSEMBLY.........................................................................................................................................................................445 BRAKE CHAMBER........................................................................................................................................................................447 REMOVAL..........................................................................................................................................................................447 INSTALLATION.....................................................................................................................................................................449 DISASSEMBLY......................................................................................................................................................................451 ASSEMBLY.........................................................................................................................................................................454 SLACK ADJUSTER.......................................................................................................................................................................457 REMOVAL..........................................................................................................................................................................457 INSTALLATION.....................................................................................................................................................................459 DISASSEMBLY......................................................................................................................................................................461 ASSEMBLY.........................................................................................................................................................................462 BRAKE ASSEMBLY ......................................................................................................................................................................463 DISASSEMBLY .....................................................................................................................................................................463 ASSEMBLY.........................................................................................................................................................................469 SPRING CYLINDER......................................................................................................................................................................477 REMOVAL..........................................................................................................................................................................477 INSTALLATION.....................................................................................................................................................................478 DISASSEMBLY......................................................................................................................................................................479 ASSEMBLY.........................................................................................................................................................................481 PARKING BRAKE........................................................................................................................................................................483 REMOVAL..........................................................................................................................................................................483 INSTALLATION.....................................................................................................................................................................485 PARKING BRAKE PAD....................................................................................................................................................................488 REMOVAL..........................................................................................................................................................................488 INSTALLATION.....................................................................................................................................................................488 54 MAINTENANCE STANDARD..................................................................................................................................................................489 BRAKE VALVE..........................................................................................................................................................................490 BRAKE CHAMBER........................................................................................................................................................................492 SLACK ADJUSTER.......................................................................................................................................................................493 BRAKE................................................................................................................................................................................494 PARKING BRAKE........................................................................................................................................................................496 SPRING CYLINDER......................................................................................................................................................................498 60 WORK EQUIPMENT SYSTEM.....................................................................................................................................................................501 61 STRUCTURE AND FUNCTION................................................................................................................................................................501 GENERAL..............................................................................................................................................................................502 HYDRAULIC PIPING.....................................................................................................................................................................503 HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................................................504 HYDRAULIC TANK.......................................................................................................................................................................506 OIL FILTER BYPASS VALVE..........................................................................................................................................................508 BREATHER.........................................................................................................................................................................509 HYDRAULIC PUMPS......................................................................................................................................................................510 HYDRAULIC PUMP...................................................................................................................................................................510 SWITCH AND PPC PUMP..............................................................................................................................................................511 PPC VALVE............................................................................................................................................................................512 PPC RELIEF VALVE.................................................................................................................................................................514 FUNCTION OF PPC VALVE............................................................................................................................................................515 MAIN CONTROL VALVE...................................................................................................................................................................517 RELIEF VALVE.....................................................................................................................................................................523 SAFETY VALVE.....................................................................................................................................................................524 SUCTION VALVE....................................................................................................................................................................525 FLOAT SELECTOR VALVE AND UNLOADER VALVE..........................................................................................................................................526 ACCUMULATOR..........................................................................................................................................................................528 HYDRAULIC CYLINDER...................................................................................................................................................................529 BUCKET LINKAGE.......................................................................................................................................................................531 BUCKET POSITIONER AND BOOM KICK-OUT..................................................................................................................................................533 WORK EQUIPMENT LEVER LINKAGE.........................................................................................................................................................535 62 TESTING AND ADJUSTING.................................................................................................................................................................537 STANDARD VALUE TABLE.................................................................................................................................................................539 TOOL LIST FOR TESTING AND ADJUSTING..................................................................................................................................................541 MEASURING DUMP AND LEFT CONTROL LEVERS...............................................................................................................................................542 ADJUSTING DUMP AND LIFT CONTROL LEVERS...............................................................................................................................................543 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT.......................................................................................................................................545 MEASURING WORK EQUIPMENT.............................................................................................................................................................548 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT..........................................................................................................................................549 ADJUSTING BUCKET POSITIONER..........................................................................................................................................................550 ADJUSTING BOOM KICK-OUT..............................................................................................................................................................551 TROUBLESHOOTING......................................................................................................................................................................552 TROUBLESHOOTING TABLE............................................................................................................................................................552 1. Lift arm does not rise........................................................................................................................................................552 2. Lift arm moves slowly or does not have sufficient lifting power...............................................................................................................553 3. Lift arm movement becomes slow after it reaches a certain height..............................................................................................................554 4. Bucket cannot be held down with lift arm cylinder.............................................................................................................................554 5. Lift arm has large hydraulic drift............................................................................................................................................554 6. Lift arm movement is unsteady during work.....................................................................................................................................554 7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"............................................................................................554 8. Bucket does not tilt beck.....................................................................................................................................................555 9. Bucket moves slowly or has insufficient tilt back power.......................................................................................................................556 10. Bucket movement becomes slow during tilt back................................................................................................................................557 11. Bucket cannot be held down by the bucket cylinder............................................................................................................................557 12. Bucket has large hydraulic drift.............................................................................................................................................557 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....................................................................................557 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"............................................................................................557 15. Control levers of lift arm and dump move stiffly and sluggishly..............................................................................................................558 63 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................559 HYDRAULIC TANK ......................................................................................................................................................................561 REMOVAL .........................................................................................................................................................................561 INSTALLATION.....................................................................................................................................................................565 HYDRAULIC PUMP ......................................................................................................................................................................568 REMOVAL .........................................................................................................................................................................568 INSTALLATION ....................................................................................................................................................................569 HYDRAULIC FILTER.....................................................................................................................................................................570 REMOVAL .........................................................................................................................................................................570 INSTALLATION.....................................................................................................................................................................570 SWITCH, PPC PUMP.....................................................................................................................................................................571 REMOVAL..........................................................................................................................................................................571 INSTALLATION ....................................................................................................................................................................572 PPC VALVE ...........................................................................................................................................................................573 REMOVAL .........................................................................................................................................................................573 INSTALLATION.....................................................................................................................................................................575 DISASSEMBLY .....................................................................................................................................................................577 ASSEMBLY ........................................................................................................................................................................577 MAIN CONTROL VALVE ..................................................................................................................................................................578 REMOVAL .........................................................................................................................................................................578 INSTALLATION ....................................................................................................................................................................581 DISASSEMBLY......................................................................................................................................................................584 ASSEMBLY.........................................................................................................................................................................586 DUMP CYLINDER........................................................................................................................................................................588 REMOVAL..........................................................................................................................................................................588 INSTALLATION.....................................................................................................................................................................590 LIFT CYLINDER .......................................................................................................................................................................591 REMOVAL .........................................................................................................................................................................591 INSTALLATION ....................................................................................................................................................................592 LIFT AND DUMP CYLINDERS..............................................................................................................................................................593 DISASSEMBLY......................................................................................................................................................................593 ASSEMBLY.........................................................................................................................................................................595 WORK EQUIPMENT ......................................................................................................................................................................598 REMOVAL .........................................................................................................................................................................598 INSTALLATION.....................................................................................................................................................................601 COUNTERWEIGHT........................................................................................................................................................................604 REMOVAL..........................................................................................................................................................................604 INSTALLATION.....................................................................................................................................................................604 64 MAINTENANCE STANDARD..................................................................................................................................................................605 MAIN CONTROL VALVE...................................................................................................................................................................606 SWITCH AND PPC PUMP..................................................................................................................................................................610 HYDRAULIC PUMP.......................................................................................................................................................................612 PPC VALVE............................................................................................................................................................................614 DUMP CYLINDER........................................................................................................................................................................616 LIFT CYLINDER........................................................................................................................................................................618 BUCKET LINKAGE.......................................................................................................................................................................620 BUCKET POSITIONER AND BOOM KICK-OUT..................................................................................................................................................623 BUCKET...............................................................................................................................................................................624 80 ELECTRIC AND ELECTRONIC SYSTEM............................................................................................................................................................625 81 STRUCTURE AND FUNCTION................................................................................................................................................................625 ELECTRICAL WIRING DIAGRAM............................................................................................................................................................626 ENGINE STARTING CIRCUIT..............................................................................................................................................................627 ENGINE STOP CIRCUIT..................................................................................................................................................................629 COMBINATION SWITCH...................................................................................................................................................................630 ELECTRICALTRANSMISSION CONTROL.......................................................................................................................................................631 TRANSMISSION CUT-OFF SWITCH......................................................................................................................................................631 TRANSMISSION CUT-OFF SELECTOR SWITCH.............................................................................................................................................632 NEUTRALIZER RELAY................................................................................................................................................................633 KICK-DOWN SWITCH.................................................................................................................................................................634 KICK-DOWN ELECTRIC CIRCUIT.......................................................................................................................................................635 ELECTRICAL PARKING BRAKE CONTROL.....................................................................................................................................................641 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)..........................................................................................................................................650 INDICATION ON MONITOR PANEL......................................................................................................................................................652 SENSORS..........................................................................................................................................................................655 WIRING HARNESS...................................................................................................................................................................663 OPERATION OF PROXIMITY SWITCH....................................................................................................................................................664 82 TESTING AND ADJUSTING.................................................................................................................................................................669 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...........................................................................................................................................672 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE).......................................................................................................................................675 TROUBLESHOOTING......................................................................................................................................................................677 CHECKS BEFORE TROUBLESHOOTING....................................................................................................................................................678 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART................................................................................................................................679 CONNECTOR TERMINAL NUMBERS.......................................................................................................................................................681 PRECAUTION WHEN HANDLING CONNECTOR...............................................................................................................................................687 ELECTRICAL WIRING DIAGRAM........................................................................................................................................................689 ELECTRICAL CIRCUIT SYSTEM........................................................................................................................................................691 TRANSMISSION CONTROL, PARKING CIRCUIT SYSTEM.................................................................................................................................692 ETHER INJECTION CIRCUIT SYSTEM...............................................................................................................................................693 KICK-DOWN CIRCUIT SYSTEM.....................................................................................................................................................694 VEHICLE MONITOR SYSTEM.......................................................................................................................................................695 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM............................................................................................................................................697 POSITION OF CONNECTORS FOR TROUBLESHOOTING.......................................................................................................................................698 E-1 ENGINE DOES NOT START........................................................................................................................................................704 E-2 ENGINE DOES NOT STOP.........................................................................................................................................................706 E-3 ENGINE STOPS WHEN TRAVELING..................................................................................................................................................706 E-4 PARKING BRAKE DOES NOT WORK..................................................................................................................................................707 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING .....................................................................................................................................708 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON .................................................................................................................710 E-7 WHEN PARKING BRAKE IS APPLIED. SHIFT LEVER DOES .............................................................................................................................710 E-8 TRANSMISSION DOES NOT WORK NORMALLY..........................................................................................................................................711 E-9 KICK-DOWN SWITCH DOES NOT WORK...............................................................................................................................................732 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON............................................................................................................................735 E-11 KICK-DOWN OPERATION IS NOT CANCELED.........................................................................................................................................736 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.............................................................................................................................738 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED....................................................................................................................738 TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM) .......................................................................................................................740 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM.......................................................................................................................741 POSITION OF CONNECTORS FOR TROUBLESHOOTING .....................................................................................................................................742 M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS ...............................................................................749 a) None of monitor panel lights up...........................................................................................................................................749 b) Except for speedometer module, none of monitor panel lights up............................................................................................................749 c) None of CAUTION items light up. ..........................................................................................................................................750 d) Some other parts do not light up. ........................................................................................................................................750 M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT...............................................................................751 M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT) ....................................................752 a) (Engine oil level) flashes. ..............................................................................................................................................752 b) (Radiator water level) flashes............................................................................................................................................753 M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. (SWITCH POSITIONS ARE NORMAL) ...................................................................755 a) (Transmission cut-off) lights up. ........................................................................................................................................755 b) (Parking brake) lights up.................................................................................................................................................756 c) (Working lamp) lights up..................................................................................................................................................756 M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES .........................................................................................758 a) Engine oil pressure system................................................................................................................................................758 b) Alternator system.........................................................................................................................................................758 M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK........................................................................................................759 a) Engine oil pressure system................................................................................................................................................759 b) Alternator system.........................................................................................................................................................759 M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE)..................................................761 a) (Charge level) flashes....................................................................................................................................................761 b) (Fuel level) flashes......................................................................................................................................................761 c) (Brake line failure) flashes..............................................................................................................................................761 d) (Engine oil pressure) flashes.............................................................................................................................................761 e) (Radiator water level) flashes............................................................................................................................................761 f) (Air pressure) flashes....................................................................................................................................................762 g) (Engine water temperature) flashes........................................................................................................................................762 h) (Torque converter oil temperature) flashes................................................................................................................................762 M-8 SPEED SENSOR DISPLAY STAYS AT “0”............................................................................................................................................765 M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.........................................................................................................................766 a) If high beam does not light up............................................................................................................................................766 b) If high beam lights up when head lamp switch is OFF.......................................................................................................................766 c) If Hi beam display lights up when head lamp dimmer switch is at Lo beam position..........................................................................................767 M-10 TURN SIGNAL LAMP DOES NOT FLASH TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING.........................................................................................768 a) If turn signal lamp does not flash........................................................................................................................................768 b) If turn signal lamp stays ON or does not stop flashing....................................................................................................................768 M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND + Cause Remedy ....769 M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.........................................................................................................770 M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH .......771 M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP. ...................................................................................................771 M-15 WHEN STARTING SWITCH IS TURNED TO ON IS ON, ...............................................................................................................................772 a) None of panel lights up...................................................................................................................................................772 b) Some of panel lamps do not light up.......................................................................................................................................772 M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON ..................................................................................773 M-17 SERVICE METER DOES NOT WORK.................................................................................................................................................774 M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED .................................................................................................................................774 M-19 ABNORMALITY IN AIR PRESSURE GAUGE ..........................................................................................................................................775 a) If nothing is displayed in display area...................................................................................................................................775 b) If indicator remains at maximum level.....................................................................................................................................775 M-20 ENGINE WATER TEMPERATURE GAUGE .............................................................................................................................................776 a) If nothing is displayed in display area...................................................................................................................................776 b) If indicator remains at minimum level.....................................................................................................................................776 M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.......................................................................................................................777 a) If nothing is displayed in display area...................................................................................................................................777 b) If indicator remains at minimum level.....................................................................................................................................777 M-22 ABNORMALITY IN FUEL GAUGE...................................................................................................................................................778 a) If nothing is displayed in display area...................................................................................................................................778 b) If indicator remains at FULL..............................................................................................................................................778 83 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................779 REMOVAL OF MACHINE MONITOR...........................................................................................................................................................780 INSTALLATION OF MACHINE MONITOR......................................................................................................................................................780 90 OTHERS....................................................................................................................................................................................781 91 LOGGING SPECIFICATIONS................................................................................................................................................................781 STRUCTURE AND FUNCTION ..............................................................................................................................................................782 HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................................................................782 MAIN CONTROL VALVE ..............................................................................................................................................................784 ARM CYLINDER ....................................................................................................................................................................786 WORK EQUIPMENT ..................................................................................................................................................................787 DISASSEMBLY AND ASSEMBLY ............................................................................................................................................................788 MAIN CONTROL VALVE ..............................................................................................................................................................788 DISASSEMBLY..................................................................................................................................................................788 ASSEMBLY.....................................................................................................................................................................790 MAINTENANCE STANDARD ................................................................................................................................................................792 MAIN CONTROL VALVE...............................................................................................................................................................792 WORK EQUIPMENT ..................................................................................................................................................................794 ARM CYLINDER ....................................................................................................................................................................797 93 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................799 REMOVAL OF CAB ......................................................................................................................................................................800 INSTALLATION OF CAB ................................................................................................................................................................800 97 GEAR PUMP.............................................................................................................................................................................801 GENERAL..............................................................................................................................................................................802 PRINCIPLE OF OPERATION...........................................................................................................................................................803 PRESSURE LOADED TYPE GEAR PUMP...................................................................................................................................................806 FIXED SIDE PLATE TYPE GEAR PUMP..................................................................................................................................................808 SA SERIES............................................................................................................................................................................809 STRUCTURE........................................................................................................................................................................809 TESTING AND ADJUSTING............................................................................................................................................................813 DISASSEMBLY......................................................................................................................................................................816 ASSEMBLY.........................................................................................................................................................................820 MAINTENANCE STANDARD.............................................................................................................................................................825 99 METRIC CONVERSIONS....................................................................................................................................................................827
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