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KOMATSU WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) – PDF DOWNLOAD
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- KOMATSU WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
- Publication Number:CEBM000401
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Description
KOMATSU WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
KOMATSU WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) – PDF DOWNLOAD:
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KOMATSU WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
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 WA450-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP)
MAIN MENU...................................................................................................................................................... 0 CONTENTS....................................................................................................................................................... 2 01 GENERAL..................................................................................................................................................... 24 SPECIFICATION DRAWINGS..................................................................................................................................... 25 SPECIFICATIONS............................................................................................................................................. 26 WEIGHT TABLE............................................................................................................................................... 29 FUEL, COOLANT AND LUBRICANTS............................................................................................................................... 30 ENGINE OIL SPECIFICATIONS.................................................................................................................................. 31 DIESEL FUEL SPECIFICATIONS................................................................................................................................. 32 COOLANT SPECIFICATIONS..................................................................................................................................... 33 10 STRUCTURE AND FUNCTION...................................................................................................................................... 38 POWER TRAIN ............................................................................................................................................... 39 POWER TRAIN SYSTEM......................................................................................................................................... 40 TORQUE CONVERTER, TRANSMISSION PIPING ..................................................................................................................... 42 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM ..................................................................................................................... 43 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .................................................................................................................... 44 TORQUE CONVERTER .......................................................................................................................................... 45 TORQUE CONVERTER OIL FILTER ............................................................................................................................... 48 TRANSMISSION .............................................................................................................................................. 49 TRANSMISSION CONTROL VALVE................................................................................................................................. 59 MODULATION VALVE........................................................................................................................................... 74 TRANSMISSION SOLENOID VALVE................................................................................................................................ 74 ELECTRONIC CONTROL MODULATION VALVE (ECMV)................................................................................................................. 75 PILOT OIL FILTER .......................................................................................................................................... 78 DRIVE SHAFT ............................................................................................................................................... 79 AXLE ...................................................................................................................................................... 80 DIFFERENTIAL .............................................................................................................................................. 82 FINAL DRIVE ............................................................................................................................................... 86 AXLE MOUNT, CENTER HINGE PIN ............................................................................................................................. 87 STEERING PIPING............................................................................................................................................ 88 STEERING COLUMN ........................................................................................................................................... 89 STEERING VALVE ............................................................................................................................................ 90 ORBIT-ROLL VALVE ..........................................................................................................................................104 STOP VALVE ................................................................................................................................................108 EMERGENCY STEERING PUMP ...................................................................................................................................109 DIVERTER VALVE ............................................................................................................................................110 BRAKE PIPING...............................................................................................................................................113 BRAKE CIRCUIT DIAGRAM .....................................................................................................................................114 BRAKE VALVE................................................................................................................................................115 CHARGE VALVE ..............................................................................................................................................120 ACCUMULATOR (FOR BRAKE) ...................................................................................................................................124 SLACK ADJUSTER ............................................................................................................................................125 BRAKE......................................................................................................................................................128 PARKING BRAKE CONTROL .....................................................................................................................................130 PARKING BRAKE..............................................................................................................................................131 PARKING BRAKE SOLENOID VALVE ..............................................................................................................................132 PARKING BRAKE VALVE .......................................................................................................................................133 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE ............................................................................................................134 HYDRAULIC PIPING...........................................................................................................................................135 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................................................................136 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................137 WORK EQUIPMENT LEVER LINKAGE...............................................................................................................................138 HYDRAULIC TANK ............................................................................................................................................139 PPC VALVE .................................................................................................................................................141 PPC RELIEF VALVE ..........................................................................................................................................146 ACCUMULATOR (FOR PPC VALVE) ...............................................................................................................................147 CUT-OFF VALVE .............................................................................................................................................148 MAIN CONTROL VALVE ........................................................................................................................................151 WORK EQUIPMENT LINKAGE ....................................................................................................................................165 BUCKET ....................................................................................................................................................167 BUCKET POSITIONER AND BOOM KICK-OUT .......................................................................................................................168 CAB .......................................................................................................................................................174 AIR CONDITIONER ...........................................................................................................................................175 AIR CONDITIONER CONTROL PANEL (EAGLE) .....................................................................................................................176 ELECTRIC CIRCUIT DIAGRAM...................................................................................................................................178 ELECTRICAL CIRCUIT DIAGRAM (EAGLE A/C).....................................................................................................................181 ELECTRIC CIRCUIT DIAGRAM (WORK EQUIPMENT CONTROLLER).......................................................................................................182 ELECTRIC CIRCUIT DIAGRAM (E.C.S.S.)........................................................................................................................183 ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING)...................................................................................................................184 MACHINE MONITOR SYSTEM ....................................................................................................................................185 MAIN MONITOR ..............................................................................................................................................186 MAINTENANCE MONITOR .......................................................................................................................................191 WORK EQUIPMENT CONTROL SYSTEM.............................................................................................................................. 0 E.C.S.S. (ELECTRIC CONTROLLED SUSPENSION SYSTEM) ..........................................................................................................194 SENSORS ...................................................................................................................................................198 ENGINE STARTING CIRCUIT ...................................................................................................................................203 ENGINE STOP CIRCUIT .......................................................................................................................................204 ETHER START CIRCUIT .......................................................................................................................................205 ELECTRIC TRANSMISSION CONTROL..............................................................................................................................206 KICK-DOWN SWITCH ..........................................................................................................................................209 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM ........................................................................................................................210 TRANSMISSION CUT-OFF SWITCH ...............................................................................................................................215 TRANSMISSION CUT-OFF FUNCTION..............................................................................................................................216 ELECTRIC PARKING BRAKE CONTROL ............................................................................................................................218 20 TESTING AND ADJUSTING.......................................................................................................................................230 STANDARD VALUE TABLE FOR ENGINE............................................................................................................................231 STANDARD VALUE TABLE FOR CHASSIS ..........................................................................................................................232 STANDARD VALUE TABLE FOR ELECTRICAL PARTS .................................................................................................................235 TOOLS FOR TESTING, ADJUSTING, & TROUBLESHOOTING............................................................................................................239 MEASURING ENGINE SPEEDS ...................................................................................................................................240 MEASURING INTAKE MANIFOLD PRESSURE.........................................................................................................................241 MEASURING INTAKE AIR RESTRICTION .........................................................................................................................242 MEASURING ENGINE LUBRICATION OIL PRESSURE .................................................................................................................243 MEASURING FUEL FILTER INLET RESTRICTION ..................................................................................................................244 MEASURING BLOW-BY PRESSURE ................................................................................................................................245 MEASURING ENGINE BACK PRESSURE ............................................................................................................................246 MEASURING COOLANT TEMPERATURE .............................................................................................................................247 MEASURING AND ADJUSTING VALVE CLEARANCE ...................................................................................................................248 MEASURING ACCELERATOR PEDAL ...............................................................................................................................251 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER .........................................................................................................253 MEASURING STALL SPEED .....................................................................................................................................249 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE ......................................................................................254 METHOD OF OPERATING EMERGENCY MANUAL SPOOL ................................................................................................................256 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ................................................................................................................258 TESTING AND ADJUSTING STEERING WHEEL .....................................................................................................................259 TESTING AND ADJUSTING STEERING CONTROL.....................................................................................................................262 MEASURING STEERING OIL PRESSURE ...........................................................................................................................263 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL ..........................................................................................................265 TESTING BRAKE OIL PRESSURE ................................................................................................................................266 MEASURING BRAKE PERFORMANCE ...............................................................................................................................267 MEASURING BRAKE DISC WEAR .................................................................................................................................268 BLEEDING AIR FROM BRAKE SYSTEM ............................................................................................................................269 MEASURING PARKING BRAKE PERFORMANCE .......................................................................................................................270 MANUAL RELEASE METHOD FOR PARKING BRAKE ...................................................................................................................271 TESTING WEAR OF PARKING BRAKE DISC ........................................................................................................................272 MEASURING WORK EQUIPMENT CONTROL LEVER ....................................................................................................................273 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE ...............................................................................................................275 MEASURING WORK EQUIPMENT ..................................................................................................................................279 TESTING AND ADJUSTING BUCKET POSITIONER ...................................................................................................................281 TESTING AND ADJUSTING BOOM KICK-OUT........................................................................................................................282 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)................................................................................................................284 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR .............................................................................................................285 TROUBLESHOOTING............................................................................................................................................286 POINTS TO REMEMBER WHEN TROUBLESHOOTING ...............................................................................................................287 SEQUENCE OF EVENTS IN TROUBLESHOOTING .................................................................................................................288 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..............................................................................................................289 HANDLING CONNECTORS ...................................................................................................................................296 CHECKS BEFORE TROUBLESHOOTING .........................................................................................................................297 METHOD OF USING TROUBLESHOOTING CHARTS ...............................................................................................................298 CONNECTOR TYPES AND MOUNTING LOCATIONS, CONNECTOR PIN ARRANGEMENT DIAGRAM .............................................................................306 CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS..............................................................................................................310 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..............................................................................................................317 S-1 Starting performance is poor (Starting always takes time) .....................................................................................318 S-2 Engine does not start..........................................................................................................................319 (1) Engine does not turn.......................................................................................................................319 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....................................................................320 (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...................................................................321 S-3 Engine does not pick up smoothly (Follow-up is poor) ..........................................................................................322 S-4 Engine stops during operations ................................................................................................................323 S-5 Engine does not rotate smoothly (hunting) .....................................................................................................324 S-6 Engine lacks output (no power) ................................................................................................................325 S-7 Exhaust gas is black (incomplete combustion) ..................................................................................................326 S-8 Oil consumption is excessive (or exhaust gas is blue) .........................................................................................327 S-9 Oil becomes contaminated quickly ..............................................................................................................328 S-10 Fuel consumption is excessive ................................................................................................................329 S-11 Oil is in cooling water, or water spurts back, or water level goes down .....................................................................330 S-12 Oil pressure lamp lights up (drop in oil pressure) ...........................................................................................331 S-13 Oil level rises ..............................................................................................................................332 S-14 Water temperature becomes too high (overheating) ............................................................................................333 S-15 Abnormal noise is made .......................................................................................................................334 S-16 Vibration is excessive .......................................................................................................................335 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)........................................................................................................336 TROUBLE DATA DISPLAY ..............................................................................................................................338 M-1 Main monitor does not work ....................................................................................................................341 M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up ...............................................342 M-3 Speedometer display does not work properly ....................................................................................................343 M-4 Abnormality in shift indicator ................................................................................................................344 (a) Stays at N even when directional lever is at F.............................................................................................344 (b) Stays at N even when directional lever is at R.............................................................................................344 (c) Does not display N even when directional lever is at N and displays R when directional lever is at F.......................................344 (d) Does not display N even when directional lever is at N and displays F when directional lever is at R.......................................345 (e) Does not display 1st, 4th..................................................................................................................345 (f) Does not display 3rd, 4th..................................................................................................................346 (g) Does not display 2nd, 3rd..................................................................................................................346 (h) Does not display 1st, 2nd..................................................................................................................347 M-5 High beam does not light up ...................................................................................................................348 M-6 Turn signal display does not light up .........................................................................................................349 (a) L.H. turn signal does not light up.........................................................................................................349 (b) R.H. turn signal does not light up.........................................................................................................349 M-7 Abnormality in parking display ................................................................................................................350 (a) Parking lamp does not light up.............................................................................................................350 (b) Parking lamp stays lighted up..............................................................................................................350 M-8 Abnormality in preheating system (QGS)......................................................................................................... 0 (a) Does not carry out preheating.............................................................................................................. 0 (b) Always carries out preheating for 1 minute................................................................................................. 0 (c) Preheating stays on........................................................................................................................ 0 (d) Preheating time becomes shorter, or unstable............................................................................................... 0 M-9 Night lighting does not light up ..............................................................................................................351 M-10 Abnormality in front working lamp ............................................................................................................352 (a) Neither monitor display nor front working lamp light up....................................................................................352 (b) Working lamp lights up but monitor display does not light up...............................................................................352 (c) Monitor lights up but working lamp does not light up.......................................................................................352 M-11 Abnormality in rear working lamp .............................................................................................................353 (a) Neither monitor display nor rear working lamp light up.....................................................................................353 (b) Working lamp lights up but monitor display does not light up...............................................................................353 (c) Monitor lights up but working lamp does not light up.......................................................................................353 M-12 Abnormality in transmission cut-off ..........................................................................................................355 (a) When monitor switch is pressed, cut-off function is not switched and display is not given..................................................355 (b) Monitor display goes out but cut-off function stays on.....................................................................................355 (c) Monitor display lights up but cut-off function is not actuated.............................................................................356 M-13 Abnormality in parking brake dragging warning ................................................................................................357 (a) When parking brake is applied, buzzer sounds (Intermittently) even when directional lever is at N, and caution lamp flashes................357 (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po...............357 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated ...................358 (a) Actuated continuously......................................................................................................................358 (b) Not actuated...............................................................................................................................358 M-15 Abnormality in buzzer ........................................................................................................................359 (a) Buzzer does not sound when starting switch is turned ON (during self-check)................................................................359 (b) Buzzer always sounds.......................................................................................................................359 M-16 Condition of monitor switches is not stored in memory ........................................................................................360 M-17 Abnormality in failure display mode ..........................................................................................................361 (a) Does not enter failure display mode........................................................................................................361 (b) Time for time elapsed since failure on failure display mode does not advance...............................................................361 M-18 Abnormality in emergency steering normal display .............................................................................................362 (a) Emergency steering normal display does not light up........................................................................................362 (b) Emergency steering normal display stays lighted up.........................................................................................362 M-19 Abnormality in emergency steering actuation display ..........................................................................................363 (a) Emergency steering actuation display does not light up.....................................................................................363 (b) Emergency steering actuation display stays lighted up......................................................................................363 M-20 Abnormality in auto-greasing system ..........................................................................................................364 (a) Forced greasing cannot be carried out......................................................................................................364 (b) Monitor display flashes rapidly (2 times/set)..............................................................................................364 (c) When no more grease remains, monitor display flashes rapidly (2 times/sec.)................................................................364 (d) Monitor display flashes slowly (1 time/sec)................................................................................................365 (e) Monitor display goes out...................................................................................................................365 M-21 Abnormality in ECSS system ...................................................................................................................366 (a) Display does not change when switch is pressed.............................................................................................366 (b) Monitor display lights up but ECSS function does not work..................................................................................366 M-22 Buzzer does not sound when auto-leveling switch is actuated .................................................................................366 M-23 Failure code is not sent to main monitor (abnormality in network) ............................................................................367 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).................................................................................................368 K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, monitor does not work ..........................369 (a) All lamps on maintenance monitor do not light up for 3 seconds.............................................................................369 (b) Some lamps do not light up.................................................................................................................370 K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out ...............................................370 K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), all lamps on maintenance monitor do not go out ....371 K-4 When starting switch is turned ON (engine stopped), CHECK items flash ........................................................................372 (a) Engine oil level display flashes ..........................................................................................................372 (b) Engine water level display flashes.........................................................................................................373 K-5 When starting switch is turned ON (engine started), CAUTION items flash ......................................................................374 (a) Engine oil pressure display flashes........................................................................................................374 (b) Battery charge level display flashes.......................................................................................................375 (c) Brake oil pressure display flashes.........................................................................................................376 (d) Air cleaner display flashes................................................................................................................377 K-6 CAUTION items are flashing but alarm buzzer does not sound ....................................................................................378 K-7 There is no abnormality in monitor display but alarm buzzer sounds ...........................................................................379 K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up .....................................................380 (a) CHECK lamp.................................................................................................................................380 (b) CAUTION lamp...............................................................................................................................380 K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up .................................381 (a) CHECK lamp.................................................................................................................................381 (b) CAUTION lamp...............................................................................................................................381 Before carrying out troubleshooting, check that there is no abnormality display on the main ...................................................381 K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) .....................382 K-11 Night lighting lights up even when lamp switch is OFF, night lighting ,stays lighted up .....................................................383 K-12 Service meter does not work ..................................................................................................................384 K-13 Service meter is running even when engine is stopped..........................................................................................384 K-14 Abnormality in gauge items ...................................................................................................................385 (a) Abnormality in fuel gauge..................................................................................................................385 (b) Abnormality in engine water temperature gauge..............................................................................................386 (c) Abnormality in torque converter oil temperature gauge......................................................................................387 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................................388 E-1 Engine does not start .........................................................................................................................389 (a) Starting motor does not turn ..............................................................................................................389 (b) Starting motor turns.......................................................................................................................393 E-2 Engine does not stop ..........................................................................................................................395 E-3 Engine stops when machine is traveling ........................................................................................................395 E-4 Parking brake does not work ...................................................................................................................396 (a) Parking brake has no effect when parking brake switch is turned ON (parking)...............................................................396 (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)...................................................396 E-5 Parking brake is applied when machine is traveling ............................................................................................397 E-6 Parking brake is released when starting switch is turned ON ...................................................................................399 E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) ....................................399 E-8 Transmission does not work normally ...........................................................................................................400 (a) Problem in common circuit for transmission (always stays in 2nd)...........................................................................402 (b) Problem in H-L circuit.....................................................................................................................402 (c) Problem in speed circuit...................................................................................................................403 (d) Problem in 4th circuit (does not enter 4th)................................................................................................403 (e) Contact in H-L circuit.....................................................................................................................404 (f) Contact in speed circuit...................................................................................................................406 (g) Contact in 4th circuit (always stays in 4th)...............................................................................................408 (h) Problem in FORWARD circuit (REVERSE is normal).............................................................................................409 (i) Problem in REVERSE circuit (FORWARD is normal).............................................................................................411 (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal).......................................413 (k) Contact in FORWARD circuit.................................................................................................................415 (I) Contact in REVERSE circuit.................................................................................................................417 (m) Problem in common circuit for FORWARD and REVERSE..........................................................................................419 E-9 Kick-down switch does not work (the regular Fl to F4 shifts normally) ........................................................................420 E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function) ..................422 E-11 Kick-down operation cannot be canceled .......................................................................................................422 (a) Not canceled even when directional lever is moved from F to N or R.........................................................................422 (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th).......................................................423 E-12 Kick-down switch is actuated by mistake when traveling in 2nd ................................................................................425 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)..........................................................................426 POWER TRAIN .......................................................................................................................................427 T-1 Machine does not start ....................................................................................................................427 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes .....................................................................429 T-3 Excessive shock when starting machine or shifting gear ....................................................................................431 T-4 Excessive time lag when starting machine or shifting gear .................................................................................432 T-5 Torque converter oil temperature is high ..................................................................................................433 STEERING SYSTEM ...................................................................................................................................434 T-6 Steering does not turn ....................................................................................................................434 T-7 Steering wheel is heavy ...................................................................................................................435 T-8 Steering wheel wobbles or there is excessive shock .......................................................................................436 T-9 Machine steers to one side when traveling ................................................................................................436 T-10 Turning radius to left and right is different ...........................................................................................436 BRAKE SYSTEM ......................................................................................................................................437 T-11 Brakes do not work or braking effect is poor..............................................................................................437 T-12 Brakes are not released or brakes drag ..................................................................................................438 T-13 Parking brake is not released or brake drags .............................................................................................439 WORK EQUIPMENT ....................................................................................................................................440 T-14 Boom does not rise .......................................................................................................................440 T-15 Boom movement is slow or boom lacks lifting power ........................................................................................441 T-16 When boom is raised, it moves slowly at a certain height .................................................................................442 T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ...............................................................................442 T-18 Excessive hydraulic drift of boom ........................................................................................................442 T-19 Boom shakes during operation .............................................................................................................442 T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ................................................................443 T-21 Bucket does not tilt back ................................................................................................................444 T-22 Bucket movement is slow or tilt-back lacks power ........................................................................................445 T-23 Bucket movement becomes slow during tilt-back operation ..................................................................................446 T-24 Bucket cannot be pushed with bucket cylinder..............................................................................................446 T-25 Excessive hydraulic drift of bucket ......................................................................................................446 T-26 Bucket shakes during loading operation (Main control valve at HOLD) .....................................................................447 T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...............................................................447 T-28 Boom, bucket control levers are heavy or do not move smoothly ............................................................................448 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).............................................................................................449 OUTLINE ...........................................................................................................................................450 1. Function........................................................................................................................................450 2. When carrying out troubleshooting...............................................................................................................450 3. Failure code table..............................................................................................................................450 4. Table of troubleshooting modes and causes.......................................................................................................451 A-1 Troubleshooting code [10] Modulation valve solenoid system (disconnection, short circuit) ....................................................452 A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system .................................................453 A-3 Troubleshooting code [12] F solenoid signal system.............................................................................................454 A-4 Troubleshooting code [13] R solenoid signal system.............................................................................................454 A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal system ..........................................................................455 A-6 Troubleshooting code [16] Abnormality in speed -solenoid signal system .......................................................................456 A-7 Troubleshooting code [17] Brake output signal .................................................................................................457 A-8 Troubleshooting code [20] Abnormality in directional lever signal system .....................................................................458 A-9 Troubleshooting code [21] Abnormality in speed lever signal system ..........................................................................459 A-10 Troubleshooting code [22] Abnormality in travel speed signal system .........................................................................460 A-11 Troubleshooting code [23] Abnormality in engine speed signal .................................................................................461 A-12 Hold switch system ...........................................................................................................................462 A-13 Kick-down switch system ......................................................................................................................462 A-14 Kick-down output signal system ...............................................................................................................463 A-15 Transmission cut-off signal system ...........................................................................................................464 A-16 Neutralizer signal system ....................................................................................................................465 A-17 Buzzer signal system .........................................................................................................................466 A-18 Network signal system ........................................................................................................................467 A-19 Controller power source system ...............................................................................................................468 A-20 Abnormality in model selection wiring harness ................................................................................................469 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (IF EQUIPED) (D MODE)............................................................470 JUDGEMENT TABLE FOR CONTROLLER ELECTRlCAL SYSTEM ..................................................................................................471 D-1 ECSS does not work ............................................................................................................................472 (a) Error code [d0] is displayed...............................................................................................................473 (b) Error code [d1] is displayed...............................................................................................................473 (c) Error code [d2] is displayed...............................................................................................................474 (d) Error code [d3] is displayed...............................................................................................................474 (e) Error code [d4] is displayed...............................................................................................................475 (f) No abnormality display is given............................................................................................................475 D-2 ECSS cannot be canceled........................................................................................................................479 D-3 Output is turned ON (travel does not become 5 km/h) (deviates around 5 km/h) .................................................................480 D-4 Output is turned ON when transmission is in 1st ..............................................................................................480 D-5 Output is turned ON when transmission is in 4th................................................................................................481 D-6 Controller LED code is not displayed ..........................................................................................................482 D-7 ECSS is abnormal but main monitor does not give abnormality display ..........................................................................482 TROUBLESHOOTING - EAGLE AIR CONDITIONER................................................................................................................483 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................487 METHOD OF USING MANUAL ....................................................................................................................................489 PRECAUTIONS WHEN CARRYING OUT OPERATION ...................................................................................................................490 SPECIAL TOOL LIST .........................................................................................................................................492 STARTING MOTOR (SEE ENGINE SHOP MANUAL)...................................................................................................................494 ALTERNATOR (SEE ENGINE SHOP MANUAL)........................................................................................................................494 ENGINE OIL COOLER (SEE SHOP MANUAL)........................................................................................................................494 FUEL INJECTION PUMP (SEE ENGINE SHOP MANUAL)...............................................................................................................494 WATER PUMP (SEE ENGINE SHOP MANUAL)........................................................................................................................494 TURBOCHARGER (SEE ENGINE SHOP MANUAL)......................................................................................................................494 NOZZLE HOLDER (SEE ENGINE SHOP MANUAL).....................................................................................................................494 THERMOSTAT (SEE ENGINE SHOP MANUAL)........................................................................................................................494 CYLINDER HEAD (SEE ENGINE SHOP MANUAL).....................................................................................................................494 RADIATOR...................................................................................................................................................495 REMOVAL................................................................................................................................................495 INSTALLATION ..........................................................................................................................................497 ENGINE.....................................................................................................................................................498 REMOVAL ...............................................................................................................................................498 INSTALLATION...........................................................................................................................................503 TORQUE CONVERTER, TRANSMISSION.............................................................................................................................505 REMOVAL................................................................................................................................................505 INSTALLATION ..........................................................................................................................................512 TORQUE CONVERTER...........................................................................................................................................514 DISASSEMBLY ...........................................................................................................................................514 ASSEMBLY ..............................................................................................................................................516 TRANSMISSION...............................................................................................................................................519 DISASSEMBLY ...........................................................................................................................................519 ASSEMBLY ..............................................................................................................................................524 TRANSMISSION CLUTCH PACK...................................................................................................................................530 DISASSEMBLY............................................................................................................................................530 ASSEMBLY ..............................................................................................................................................539 PARKING BRAKE.............................................................................................................................................551 DISASSEMBLY ...........................................................................................................................................551 ASSEMBLY ..............................................................................................................................................553 TRANSMISSION CONTROL VALVE.................................................................................................................................556 REMOVAL................................................................................................................................................556 INSTALLATION...........................................................................................................................................558 DISASSEMBLY............................................................................................................................................559 ASSEMBLY...............................................................................................................................................566 TRANSMISSION ACCUMULATOR VALVE.............................................................................................................................572 DISASSEMBLY............................................................................................................................................572 ASSEMBLY ..............................................................................................................................................573 DRIVE SHAFT................................................................................................................................................574 DISASSEMBLY ...........................................................................................................................................574 ASSEMBLY ..............................................................................................................................................576 FRONT AXLE.................................................................................................................................................578 REMOVAL ...............................................................................................................................................578 INSTALLATION ..........................................................................................................................................580 REAR AXLE..................................................................................................................................................581 REMOVAL................................................................................................................................................581 INSTALLATION ..........................................................................................................................................584 FRONT DIFFERENTIAL.........................................................................................................................................586 REMOVAL................................................................................................................................................586 INSTALLATION...........................................................................................................................................589 REAR DIFFERENTIAL..........................................................................................................................................591 REMOVAL ...............................................................................................................................................591 INSTALLATION ..........................................................................................................................................594 DIFFERENTIAL...............................................................................................................................................596 DISASSEMBLY ...........................................................................................................................................596 ASSEMBLY ..............................................................................................................................................599 FINAL DRIVE................................................................................................................................................607 DISASSEMBLY ...........................................................................................................................................607 ASSEMBLY ..............................................................................................................................................610 CENTER HINGE PIN...........................................................................................................................................614 REMOVAL................................................................................................................................................614 INSTALLATION ..........................................................................................................................................623 STEERING VALVE (ORBIT-ROLL)................................................................................................................................629 REMOVAL................................................................................................................................................629 INSTALLATION ..........................................................................................................................................630 STEERING VALVE.............................................................................................................................................634 DISASSEMBLY ...........................................................................................................................................631 ASSEMBLY ..............................................................................................................................................634 REMOVAL ...............................................................................................................................................639 INSTALLATION ..........................................................................................................................................640 STEERING DEMAND VALVE......................................................................................................................................641 DISASSEMBLY ...........................................................................................................................................641 ASSEMBLY ..............................................................................................................................................645 STEERING, SWITCH PUMP......................................................................................................................................649 REMOVAL ...............................................................................................................................................649 INSTALLATION ..........................................................................................................................................652 STEERING CYLINDER..........................................................................................................................................653 REMOVAL................................................................................................................................................653 INSTALLATION ..........................................................................................................................................654 BRAKE VALVE................................................................................................................................................655 REMOVAL ...............................................................................................................................................655 INSTALLATION ..........................................................................................................................................656 RIGHT BRAKE VALVE (TANDEM)................................................................................................................................657 DISASSEMBLY............................................................................................................................................657 ASSEMBLY ..............................................................................................................................................658 LEFT BRAKE VALVE...........................................................................................................................................659 DISASSEMBLY............................................................................................................................................659 ASSEMBLY ..............................................................................................................................................660 SLACK ADJUSTER.............................................................................................................................................661 REMOVAL ...............................................................................................................................................661 INSTALLATION ..........................................................................................................................................662 DISASSEMBLY ...........................................................................................................................................663 ASSEMBLY...............................................................................................................................................664 BRAKE......................................................................................................................................................665 DISASSEMBLY............................................................................................................................................665 ASSEMBLY...............................................................................................................................................671 PARKING BRAKE DISC.........................................................................................................................................679 REMOVAL ...............................................................................................................................................679 INSTALLATION ..........................................................................................................................................681 HYDRAULIC TANK.............................................................................................................................................682 REMOVAL................................................................................................................................................682 INSTALLATION ..........................................................................................................................................684 WORK EQUIPMENT, PPC PUMP...................................................................................................................................685 REMOVAL ..............................................................................................................................................685 INSTALLATION ..........................................................................................................................................688 PPC VALVE..................................................................................................................................................689 REMOVAL ...............................................................................................................................................689 INSTALLATION ..........................................................................................................................................690 DISASSEMBLY ...........................................................................................................................................691 ASSEMBLY ..............................................................................................................................................692 MAIN CONTROL VALVE.........................................................................................................................................693 REMOVAL................................................................................................................................................693 INSTALLATION ..........................................................................................................................................695 DISASSEMBLY ...........................................................................................................................................696 ASSEMBLY ..............................................................................................................................................698 BUCKET CYLINDER............................................................................................................................................700 REMOVAL ...............................................................................................................................................700 INSTALLATION ..........................................................................................................................................701 BOOM CYLINDER..............................................................................................................................................702 REMOVAL................................................................................................................................................702 INSTALLATION ..........................................................................................................................................703 HYDRAULIC CYLINDER.........................................................................................................................................704 DISASSEMBLY ..........................................................................................................................................704 ASSEMBLY ..............................................................................................................................................707 WORK EQUIPMENT.............................................................................................................................................710 REMOVAL................................................................................................................................................710 INSTALLATION ..........................................................................................................................................713 COUNTERWEIGHT..............................................................................................................................................715 REMOVAL ...............................................................................................................................................715 INSTALLATION ..........................................................................................................................................715 FUEL TANK..................................................................................................................................................716 REMOVAL ...............................................................................................................................................716 INSTALLATION ..........................................................................................................................................717 CAB........................................................................................................................................................718 REMOVAL ...............................................................................................................................................718 INSTALLATION ..........................................................................................................................................719 MAIN MONITOR...............................................................................................................................................720 REMOVAL ...............................................................................................................................................720 INSTALLATION...........................................................................................................................................721 MAINTENANCE MONITOR........................................................................................................................................722 REMOVAL ...............................................................................................................................................722 INSTALLATION ..........................................................................................................................................722 AIR CONDITIONER UNIT.......................................................................................................................................723 REMOVAL ...............................................................................................................................................723 INSTALLATION ..........................................................................................................................................728 AIR CONDITIONER CONDENSER..................................................................................................................................729 REMOVAL ...............................................................................................................................................729 INSTALLATION ..........................................................................................................................................730 DRY RECEIVER...............................................................................................................................................731 REMOVAL................................................................................................................................................731 INSTALLATION ..........................................................................................................................................731 AIR CONDITIONER COMPRESSOR.................................................................................................................................732 REMOVAL ...............................................................................................................................................732 INSTALLATION...........................................................................................................................................733 40 MAINTENANCE STANDARD........................................................................................................................................734 ENGINE MOUNT, TRANSMISSION MOUNT .........................................................................................................................735 TORQUE CONVERTER...........................................................................................................................................736 TRANSMISSION ..............................................................................................................................................737 TRANSMISSION CONTROL VALVE ...............................................................................................................................744 DRIVE SHAFT ...............................................................................................................................................748 DIFFERENTIAL ..............................................................................................................................................749 FINAL DRIVE ...............................................................................................................................................751 AXLE MOUNT ................................................................................................................................................752 STEERING COLUMN ...........................................................................................................................................753 STEERING VALVE ............................................................................................................................................754 STEERING CYLINDER MOUNT ...................................................................................................................................755 SLACK ADJUSTER ............................................................................................................................................756 BRAKE VALVE ...............................................................................................................................................757 BRAKE......................................................................................................................................................760 PARKING BRAKE..............................................................................................................................................762 TORQUE CONVERTER, TRANSMISSION PUMP ......................................................................................................................763 STEERING, SWITCH PUMP .....................................................................................................................................764 HYDRAULIC, PPC PUMP .......................................................................................................................................765 PPC VALVE .................................................................................................................................................766 CUT-OFF VALVE .............................................................................................................................................767 MAIN CONTROL VALVE ........................................................................................................................................768 BOOM CYLINDER .............................................................................................................................................772 BUCKET CYLINDER ...........................................................................................................................................773 CENTER HINGE PIN...........................................................................................................................................774 WORK EQUIPMENT LINKAGE ....................................................................................................................................776 BUCKET ....................................................................................................................................................778 BUCKET POSITIONER AND BOOM KICK-OUT .......................................................................................................................779
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