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Komatsu WA500-1L Wheel Loader Shop Manual CEBMW25010 – PDF DOWNLOAD
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Komatsu WA500-1L Wheel Loader Shop Manual
MACHINE MODEL SERIAL NUMBERS
WA504 1-L A20854 and up
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Description
Komatsu WA500-1L Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA500-1L Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA500-1L
Serial Number: A20854 and up
Book Code: CEBMW25010
Language: English
Pages: 1004
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA500-1L Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
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 WA500-1L Wheel Loader Shop Manual
MAIN MENU........................................................................................................................................................................................................................... 0 CONTENTS............................................................................................................................................................................................................................ 5 10 ENGINE........................................................................................................................................................................................................................... 19 12 TESTING AND ADJUSTING........................................................................................................................................................................................................ 19 STANDARD VALUE TABLE........................................................................................................................................................................................................ 20 TOOL LIST................................................................................................................................................................................................................... 22 VALVE CLEARANCE ............................................................................................................................................................................................................ 23 COMPRESSION PRESSURE ....................................................................................................................................................................................................... 25 FUEL INJECTION ............................................................................................................................................................................................................. 26 TESTING TIMING.......................................................................................................................................................................................................... 26 ADJUSTING TIMING BY DELIVERY CHECK...................................................................................................................................................................................... 27 BLOW-BY PRESSURE ........................................................................................................................................................................................................... 28 ALTERNATOR FAN BELT ........................................................................................................................................................................................................ 29 ENGINE FAN BELT ............................................................................................................................................................................................................ 29 EXHAUST GAS COLOR .......................................................................................................................................................................................................... 30 OIL PRESSURE ............................................................................................................................................................................................................... 32 OIL TEMPERATURE ............................................................................................................................................................................................................ 32 ACCELERATOR PEDAL .......................................................................................................................................................................................................... 33 OPERATING FORCE......................................................................................................................................................................................................... 33 ENGINE ................................................................................................................................................................................................................. 34 13 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................... 35 STARTING MOTOR ............................................................................................................................................................................................................. 37 REMOVAL................................................................................................................................................................................................................. 37 INSTALLATION............................................................................................................................................................................................................ 37 ALTERNATOR ................................................................................................................................................................................................................. 38 REMOVAL................................................................................................................................................................................................................. 38 INSTALLATION............................................................................................................................................................................................................ 38 OIL COOLER ................................................................................................................................................................................................................. 39 REMOVAL................................................................................................................................................................................................................. 39 INSTALLATION............................................................................................................................................................................................................ 39 FUEL INJECTION PUMP ........................................................................................................................................................................................................ 40 REMOVAL................................................................................................................................................................................................................. 40 INSTALLATION............................................................................................................................................................................................................ 40 WATER PUMP ................................................................................................................................................................................................................. 41 REMOVAL................................................................................................................................................................................................................. 41 INSTALLATION............................................................................................................................................................................................................ 41 NOZZLE HOLDER .............................................................................................................................................................................................................. 42 REMOVAL................................................................................................................................................................................................................. 42 INSTALLATION............................................................................................................................................................................................................ 42 TURBOCHARGER................................................................................................................................................................................................................ 43 REMOVAL................................................................................................................................................................................................................. 43 INSTALLATION............................................................................................................................................................................................................ 43 AIR COMPRESSOR ............................................................................................................................................................................................................. 44 REMOVAL................................................................................................................................................................................................................. 44 INSTALLATION............................................................................................................................................................................................................ 44 CYLINDER HEAD .............................................................................................................................................................................................................. 45 REMOVAL................................................................................................................................................................................................................. 45 INSTALLATION............................................................................................................................................................................................................ 50 RADIATOR ................................................................................................................................................................................................................... 56 REMOVAL................................................................................................................................................................................................................. 56 INSTALLATION............................................................................................................................................................................................................ 59 ENGINE...................................................................................................................................................................................................................... 62 REMOVAL ................................................................................................................................................................................................................ 62 INSTALLATION............................................................................................................................................................................................................ 68 FUEL TANK .................................................................................................................................................................................................................. 75 REMOVAL................................................................................................................................................................................................................. 75 INSTALLATION............................................................................................................................................................................................................ 77 14 MAINTENANCE STANDARD ........................................................................................................................................................................................................ 79 ENGINE MOUNT ............................................................................................................................................................................................................... 80 20 POWER TRAIN ..................................................................................................................................................................................................................... 81 21 STRUCTURE AND FUNCTION ...................................................................................................................................................................................................... 81 GENERAL .................................................................................................................................................................................................................... 83 HYDRAULIC CIRCUIT FOR POWER TRAIN ...................................................................................................................................................................................... 86 HYDRAULIC DIAGRAM FOR POWER TRAIN ...................................................................................................................................................................................... 87 DAMPER ..................................................................................................................................................................................................................... 89 TORQUE CONVERTER AND TRANSMISSION PIPING ................................................................................................................................................................................... 91 RADIATOR AND OIL COOLER .................................................................................................................................................................................................... 92 TORQUE CONVERTER AND PTO ................................................................................................................................................................................................... 93 TORQUE CONVERTER OIL FILTER ................................................................................................................................................................................................ 95 TRANSMISSION................................................................................................................................................................................................................ 96 TRANSMISSION foldout # 1................................................................................................................................................................................................ 97 TRANSMISSION CONTROL VALVE..................................................................................................................................................................................................101 UPPER VALVE.............................................................................................................................................................................................................102 LOWER VALVE.............................................................................................................................................................................................................103 TRANSMISSION SOLENOID VALVE ................................................................................................................................................................................................104 TRANSMISSION SOLENOID VALVE ............................................................................................................................................................................................105 EMERGENCY MANUAL SPOOL .................................................................................................................................................................................................107 FORWARD 1st ............................................................................................................................................................................................................108 PRIORITY VALVE .........................................................................................................................................................................................................110 MODULATING VALVE AND QUICK RETURN VALVE ................................................................................................................................................................................111 ACCUMULATOR VALVE ......................................................................................................................................................................................................114 PILOT REDUCING VALVE ...................................................................................................................................................................................................117 MAIN RELIEF VALVE ......................................................................................................................................................................................................119 REDUCING VALVE .........................................................................................................................................................................................................120 TORQUE CONVERTER RELIEF VALVE ..........................................................................................................................................................................................122 LUBRICATION BY-PASS VALVE ..............................................................................................................................................................................................124 TRANSMISSION PILOT OIL FILTER ..............................................................................................................................................................................................126 TRANSFER ...................................................................................................................................................................................................................127 DRIVE SHAFT ................................................................................................................................................................................................................128 CENTER SUPPORT .............................................................................................................................................................................................................129 AXLES ......................................................................................................................................................................................................................130 FRONT ..................................................................................................................................................................................................................130 REAR ...................................................................................................................................................................................................................131 DIFFERENTIAL ...............................................................................................................................................................................................................132 FRONT ..................................................................................................................................................................................................................132 REAR ...................................................................................................................................................................................................................133 TORQUE PROPORTIONING DIFFERENTIAL.......................................................................................................................................................................................135 FINAL DRIVE ................................................................................................................................................................................................................136 AXLE MOUNT .................................................................................................................................................................................................................138 TIRE AND WHEEL .............................................................................................................................................................................................................140 22 TESTING AND ADJUSTING .......................................................................................................................................................................................................141 STANDARD VALUE TABLE .......................................................................................................................................................................................................143 TOOL LIST ..................................................................................................................................................................................................................144 ENGINE STALL SPEED .........................................................................................................................................................................................................145 TORQUE CONVERTER STALL..................................................................................................................................................................................................145 HYDRAULIC STALL.........................................................................................................................................................................................................146 FULL STALL..............................................................................................................................................................................................................146 TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE .............................................................................................................................................................................147 SHIFT LEVER ................................................................................................................................................................................................................149 EMERGENCY MANUAL SPOOL .....................................................................................................................................................................................................151 OPERATION...............................................................................................................................................................................................................151 TIRE AND WHEEL .............................................................................................................................................................................................................153 TROUBLESHOOTING.............................................................................................................................................................................................................154 PRECAUTIONS WHEN TROUBLESHOOTING .......................................................................................................................................................................................155 METHOD OF READING TROUBLESHOOTING TABLES................................................................................................................................................................................157 PREVENTING RECURRENCE OF TROUBLE........................................................................................................................................................................................159 JUDGEMENT ON POWER TRAIN................................................................................................................................................................................................160 TROUBLESHOOTING TABLE...................................................................................................................................................................................................162 Machine does not move...............................................................................................................................................................................................162 Machine lacks power or speed........................................................................................................................................................................................164 Excessive time lag when starting machine or shifting gear...........................................................................................................................................................166 Torque converter oil temperature too high...........................................................................................................................................................................167 23 DISASSEMBLY AND ASSEMBLY ....................................................................................................................................................................................................169 DAMPER .....................................................................................................................................................................................................................172 REMOVAL ................................................................................................................................................................................................................172 INSTALLATION ...........................................................................................................................................................................................................176 DISASSEMBLY ............................................................................................................................................................................................................180 ASSEMBLY ...............................................................................................................................................................................................................183 TORQUE CONVERTER CHARGING PUMP .............................................................................................................................................................................................187 REMOVAL ................................................................................................................................................................................................................187 INSTALLATION ...........................................................................................................................................................................................................187 TORQUE CONVERTER AND TRANSMISSION ..........................................................................................................................................................................................188 REMOVAL ................................................................................................................................................................................................................188 INSTALLATION ...........................................................................................................................................................................................................196 TORQUE CONVERTER ASSEMBLY...................................................................................................................................................................................................206 DISASSEMBLY.............................................................................................................................................................................................................206 PTO ASSEMBLY........................................................................................................................................................................................................208 Disassembly.....................................................................................................................................................................................................208 ASSEMBLY................................................................................................................................................................................................................210 PTO ASSEMBLY........................................................................................................................................................................................................210 Assembly........................................................................................................................................................................................................210 TORQUE CONVERTER ASSEMBLY...........................................................................................................................................................................................212 ASSEMBLY........................................................................................................................................................................................................212 TRANSMISSION ASSEMBLY.......................................................................................................................................................................................................215 DISASSEMBLY.............................................................................................................................................................................................................215 ASSEMBLY................................................................................................................................................................................................................225 TRANSFER CASE ASSEMBLY......................................................................................................................................................................................................237 DISASSEMBLY.............................................................................................................................................................................................................237 ASSEMBLY................................................................................................................................................................................................................242 TRANSMISSION CONTROL VALVE..................................................................................................................................................................................................248 REMOVAL.................................................................................................................................................................................................................248 INSTALLATION............................................................................................................................................................................................................249 LOWER VALVE ASSEMBLY....................................................................................................................................................................................................250 DISASSEMBLY.........................................................................................................................................................................................................251 ASSEMBLY............................................................................................................................................................................................................251 UPPER VALVE ASSEMBLY....................................................................................................................................................................................................252 DISASSEMBLY.........................................................................................................................................................................................................253 ASSEMBLY............................................................................................................................................................................................................253 MAIN RELIEF VALVE ASSEMBLY..............................................................................................................................................................................................254 DISASSEMBLY.........................................................................................................................................................................................................254 ASSEMBLY............................................................................................................................................................................................................254 CENTER SUPPORT..............................................................................................................................................................................................................255 REMOVAL.................................................................................................................................................................................................................255 INSTALLATION............................................................................................................................................................................................................256 DISASSEMBLY.............................................................................................................................................................................................................257 ASSEMBLY................................................................................................................................................................................................................259 DRIVE SHAFT.................................................................................................................................................................................................................261 DISASSEMBLY.............................................................................................................................................................................................................261 ASSEMBLY................................................................................................................................................................................................................263 FRONT AXLE..................................................................................................................................................................................................................265 REMOVAL.................................................................................................................................................................................................................265 INSTALLATION............................................................................................................................................................................................................267 FRONT DIFFERENTIAL..........................................................................................................................................................................................................269 REMOVAL.................................................................................................................................................................................................................269 INSTALLATION............................................................................................................................................................................................................272 REAR AXLE...................................................................................................................................................................................................................275 REMOVAL.................................................................................................................................................................................................................275 INSTALLATION............................................................................................................................................................................................................279 REAR DIFFERENTIAL...........................................................................................................................................................................................................283 REMOVAL.................................................................................................................................................................................................................283 INSTALLATION............................................................................................................................................................................................................284 DIFFERENTIAL GEAR ASSEMBLY..................................................................................................................................................................................................286 DISASSEMBLY.............................................................................................................................................................................................................286 FINE DISASSEMBLY OF PINION ASSEMBLY.................................................................................................................................................................................288 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY.................................................................................................................................................................289 ASSEMBLY................................................................................................................................................................................................................290 FINE ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY.........................................................................................................................................................................290 FINE ASSEMBLY OF PINION ASSEMBLY....................................................................................................................................................................................291 ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................................................................292 FINAL DRIVE.................................................................................................................................................................................................................297 DISASSEMBLY.............................................................................................................................................................................................................297 ASSEMBLY................................................................................................................................................................................................................300 24 MAINTENANCE STANDARD.........................................................................................................................................................................................................305 TRANSMISSION MOUNT .........................................................................................................................................................................................................306 DAMPER .....................................................................................................................................................................................................................307 TORQUE CONVERTER CHARGING PUMP .............................................................................................................................................................................................308 TORQUE CONVERTER AND PTO ...................................................................................................................................................................................................309 TRANSMISSION ...............................................................................................................................................................................................................310 TRANSMISSION CONTROL VALVE .................................................................................................................................................................................................314 UPPER VALVE ............................................................................................................................................................................................................314 LOWER VALVE ............................................................................................................................................................................................................316 SOLENOID VALVE .........................................................................................................................................................................................................318 TRANSFER ...................................................................................................................................................................................................................320 DIFFERENTIAL ...............................................................................................................................................................................................................322 FINAL DRIVE ................................................................................................................................................................................................................326 DRIVE SHAFT ................................................................................................................................................................................................................327 CENTER SUPPORT .............................................................................................................................................................................................................328 AXLE MOUNT..................................................................................................................................................................................................................330 40 STEERING SYSTEM..................................................................................................................................................................................................................333 41 STRUCTURE AND FUNCTION.......................................................................................................................................................................................................333 CENTER HINGE PIN ...........................................................................................................................................................................................................334 STEERING PIPING ............................................................................................................................................................................................................335 STEERING CIRCUIT DIAGRAM ...................................................................................................................................................................................................336 STEERING COLUMN AND GEAR BOX ...............................................................................................................................................................................................337 STEERING LINKAGE ...........................................................................................................................................................................................................338 STEERING CONTROL SYSTEM ....................................................................................................................................................................................................339 STEERING VALVE .........................................................................................................................................................................................................339 ROTOR SEAL .............................................................................................................................................................................................................341 STEERING RELIEF VALVE ..................................................................................................................................................................................................342 SAFETY VALVE (WITH SUCTION VALVE) ......................................................................................................................................................................................343 OPERATION OF DEMAND SPOOL...............................................................................................................................................................................................345 OPERATION OF THE STEERING VALVE ........................................................................................................................................................................................348 TWO-WAY RESTRICTOR VALVE ...................................................................................................................................................................................................351 42 TESTING AND ADJUSTING........................................................................................................................................................................................................353 STANDARD VALUE TABLE .......................................................................................................................................................................................................354 TOOL LIST ..................................................................................................................................................................................................................354 STEERING WHEEL PLAY ........................................................................................................................................................................................................355 OPERATING FORCE OF STEERING WHEEL ..........................................................................................................................................................................................356 OPERATING TIME OF STEERING WHEEL ...........................................................................................................................................................................................357 STEERING OIL PRESSURE ......................................................................................................................................................................................................358 STEERING LINKAGE ...........................................................................................................................................................................................................360 TROUBLESHOOTING TABLES......................................................................................................................................................................................................363 1. Steering wheel does not turn. .......................................................................................................................................................................................364 2. Steering wheel is sluggish. .........................................................................................................................................................................................365 3. Steering wheel moves unsteadily or is subject to large shock. ......................................................................................................................................................366 4. Machine tends to turn naturally in one particular direction when traveling. ........................................................................................................................................366 5. Left and right turning radii are different. .........................................................................................................................................................................366 43 DISASSEMBLY AND ASSEMBLY.....................................................................................................................................................................................................367 STEERING GEAR ..............................................................................................................................................................................................................369 REMOVAL ................................................................................................................................................................................................................369 INSTALLATION............................................................................................................................................................................................................371 STEERING GEAR BOX ..........................................................................................................................................................................................................372 DISASSEMBLY ............................................................................................................................................................................................................372 ASSEMBLY ...............................................................................................................................................................................................................373 STEERING AND PPC PUMP ......................................................................................................................................................................................................376 REMOVAL ................................................................................................................................................................................................................376 INSTALLATION ...........................................................................................................................................................................................................377 STEERING VALVE .............................................................................................................................................................................................................378 REMOVAL ................................................................................................................................................................................................................378 INSTALLATION ...........................................................................................................................................................................................................380 DISASSEMBLY ............................................................................................................................................................................................................382 ASSEMBLY................................................................................................................................................................................................................383 STEERING CYLINDER...........................................................................................................................................................................................................384 REMOVAL.................................................................................................................................................................................................................384 INSTALLATION............................................................................................................................................................................................................386 DISASSEMBLY.............................................................................................................................................................................................................388 ASSEMBLY................................................................................................................................................................................................................390 CENTER HINGE PIN ...........................................................................................................................................................................................................393 REMOVAL ................................................................................................................................................................................................................393 INSTALLATION ...........................................................................................................................................................................................................400 44 MAINTENANCE STANDARD.........................................................................................................................................................................................................409 CENTER HINGE PIN............................................................................................................................................................................................................410 STEERING LINKAGE AND STEERING COLUMN .......................................................................................................................................................................................412 STEERING GEAR BOX ..........................................................................................................................................................................................................414 STEERING PUMP ..............................................................................................................................................................................................................415 STEERING CYLINDER MOUNT ....................................................................................................................................................................................................416 STEERING VALVE .............................................................................................................................................................................................................418 50 BRAKE AND AIR SYSTEM.............................................................................................................................................................................................................421 51 STRUCTURE AND FUNCTION.......................................................................................................................................................................................................421 GENERAL ....................................................................................................................................................................................................................422 AIR SYSTEM .............................................................................................................................................................................................................422 BRAKE CIRCUIT ..........................................................................................................................................................................................................422 BRAKE AND AIR SCHEMATICS ...................................................................................................................................................................................................423 BRAKE AND AIR PIPING ...................................................................................................................................................................................................423 BRAKE AND AIR CIRCUIT DIAGRAM ..........................................................................................................................................................................................423 BRAKE AND AIR CIRCUIT SYSTEM ...........................................................................................................................................................................................423 AIR TANK ...................................................................................................................................................................................................................424 WET TANK ...............................................................................................................................................................................................................424 DRY TANK (UPPER) .......................................................................................................................................................................................................425 DRY TANK (LOWER) .......................................................................................................................................................................................................426 SAFETY VALVE ...............................................................................................................................................................................................................427 BRAKE VALVE ................................................................................................................................................................................................................428 BRAKE ACTUATED .........................................................................................................................................................................................................429 OPERATING IN BALANCE ...................................................................................................................................................................................................430 BRAKE RELEASED .........................................................................................................................................................................................................431 AIR GOVERNOR ...............................................................................................................................................................................................................432 TWO-WAY VALVE ..............................................................................................................................................................................................................434 BRAKE CHAMBER...............................................................................................................................................................................................................435 SLACK ADJUSTER .............................................................................................................................................................................................................437 CHECK VALVE ................................................................................................................................................................................................................440 BRAKE ......................................................................................................................................................................................................................441 PARKING BRAKE ..............................................................................................................................................................................................................443 PARKING BRAKE SOLENOID VALVE ...............................................................................................................................................................................................445 SPRING CYLINDER ............................................................................................................................................................................................................446 BRAKE CALIPER ..............................................................................................................................................................................................................447 52 TESTING AND ADJUSTING........................................................................................................................................................................................................449 STANDARD VALUE TABLE .......................................................................................................................................................................................................451 TOOL LIST ..................................................................................................................................................................................................................452 BRAKE PEDAL ................................................................................................................................................................................................................453 AIR PRESSURE ...............................................................................................................................................................................................................454 BRAKE PERFORMANCE ..........................................................................................................................................................................................................457 BRAKE OIL PRESSURE .........................................................................................................................................................................................................458 BRAKE DISC .................................................................................................................................................................................................................459 AIR BLEEDING FROM BRAKE LINE ...............................................................................................................................................................................................460 PARKING BRAKE ..............................................................................................................................................................................................................461 PERFORMANCE.............................................................................................................................................................................................................461 CHECKING AND ADJUSTING..................................................................................................................................................................................................462 TROUBLESHOOTING.............................................................................................................................................................................................................465 TROUBLESHOOTING TABLE ..................................................................................................................................................................................................466 1. Air pressure does not rise at all. ..............................................................................................................................................................................466 2. Air pressure does not rise to the specified range. .............................................................................................................................................................467 3. Brake is ineffective or not very effective. ....................................................................................................................................................................468 4. Brake does not release, or drags. ...............................................................................................................................................................................469 5. Parking brake does not release, or drags. (Applies to machine equipped with air park- ing brake.) ..............................................................................................................470 53 DISASSEMBLY AND ASSEMBLY.....................................................................................................................................................................................................471 BRAKE VALVE ................................................................................................................................................................................................................473 REMOVAL ................................................................................................................................................................................................................473 INSTALLATION............................................................................................................................................................................................................475 DISASSEMBLY.............................................................................................................................................................................................................477 ASSEMBLY................................................................................................................................................................................................................479 BRAKE CHAMBER...............................................................................................................................................................................................................481 REMOVAL ................................................................................................................................................................................................................481 INSTALLATION ...........................................................................................................................................................................................................483 DISASSEMBLY ............................................................................................................................................................................................................482 ASSEMBLY................................................................................................................................................................................................................487 SLACK ADJUSTER .............................................................................................................................................................................................................490 REMOVAL ................................................................................................................................................................................................................490 INSTALLATION ...........................................................................................................................................................................................................490 DISASSEMBLY ............................................................................................................................................................................................................491 ASSEMBLY ...............................................................................................................................................................................................................492 BRAKE ASSEMBLY..............................................................................................................................................................................................................493 REMOVAL ................................................................................................................................................................................................................493 INSTALLATION............................................................................................................................................................................................................495 DISASSEMBLY (FRONT OR REAR) ............................................................................................................................................................................................499 ASSEMBLY (FRONT OR REAR) ...............................................................................................................................................................................................502 SPRING CYLINDER ............................................................................................................................................................................................................506 REMOVAL ................................................................................................................................................................................................................506 INSTALLATION............................................................................................................................................................................................................507 PARKING BRAKE ..............................................................................................................................................................................................................508 REMOVAL ................................................................................................................................................................................................................508 INSTALLATION............................................................................................................................................................................................................511 PARKING BRAKE PAD ..........................................................................................................................................................................................................514 REMOVAL ................................................................................................................................................................................................................514 INSTALLATION ...........................................................................................................................................................................................................514 AIR GOVERNOR ...............................................................................................................................................................................................................515 DISASSEMBLY ............................................................................................................................................................................................................515 ASSEMBLY ...............................................................................................................................................................................................................516 54 MAINTENANCE STANDARD.........................................................................................................................................................................................................517 BRAKE VALVE ................................................................................................................................................................................................................518 BRAKE CHAMBER ..............................................................................................................................................................................................................520 SLACK ADJUSTER .............................................................................................................................................................................................................521 BRAKE ......................................................................................................................................................................................................................522 PARKING BRAKE ..............................................................................................................................................................................................................524 SPRING CYLINDER ............................................................................................................................................................................................................526 60 WORK EQUIPMENT SYSTEM............................................................................................................................................................................................................527 61 STRUCTURE AND FUNCTION.......................................................................................................................................................................................................527 GENERAL ....................................................................................................................................................................................................................529 HYDRAULIC PIPING ...........................................................................................................................................................................................................530 HYDRAULIC CIRCUIT...........................................................................................................................................................................................................530 SCHEMATICS..............................................................................................................................................................................................................530 DIAGRAM ................................................................................................................................................................................................................530 HYDRAULIC TANK .............................................................................................................................................................................................................531 OIL FILTER By-pass VALVE ...............................................................................................................................................................................................532 BREATHER ...............................................................................................................................................................................................................533 PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE) ............................................................................................................................................................................534 OPERATION OF PPC VALVE .................................................................................................................................................................................................536 PPC RELIEF VALVE .......................................................................................................................................................................................................540 MAIN CONTROL VALVE .........................................................................................................................................................................................................541 RELIEF VALVE............................................................................................................................................................................................................544 SAFETY VALVE (with suction valve).......................................................................................................................................................................................545 SUCTION VALVE ..........................................................................................................................................................................................................546 FLOAT SELECTOR VALVE AND UNLOADER VALVE.................................................................................................................................................................................547 ACCUMULATOR ................................................................................................................................................................................................................549 OPERATION OF MAIN CONTROL VALVE ...........................................................................................................................................................................................550 LIFT AND DUMP SPOOLS AT “HOLD” .........................................................................................................................................................................................550 LIFT SPOOL AT “RAISE”...................................................................................................................................................................................................551 LIFT SPOOL AT “LOWER” ..................................................................................................................................................................................................552 LIFT SPOOL AT “FLOAT ...................................................................................................................................................................................................553 DUMP SPOOL AT “DUMP”....................................................................................................................................................................................................554 DUMP SPOOL AT ‘TILT BACK’...............................................................................................................................................................................................555 BUCKET LINKAGE .............................................................................................................................................................................................................556 BUCKET .....................................................................................................................................................................................................................558 BUCKET POSITIONER AND BOOM KICK-OUT ........................................................................................................................................................................................559 Bucket positioner.......................................................................................................................................................................................................560 Boom kick-out...........................................................................................................................................................................................................560 WORK EQUIPMENT LEVER LINKAGE ...............................................................................................................................................................................................561 62 TESTING AND ADJUSTING........................................................................................................................................................................................................563 STANDARD VALUE TABLE .......................................................................................................................................................................................................565 TOOL LIST ..................................................................................................................................................................................................................566 EMERGENCY MANUAL SPOOL......................................................................................................................................................................................................567 METHOD FOR OPERATION....................................................................................................................................................................................................567 OUTLINE.............................................................................................................................................................................................................567 OPERATION...........................................................................................................................................................................................................567 DUMP AND LIFT CONTROL LEVER ................................................................................................................................................................................................569 MEASURING ..............................................................................................................................................................................................................569 ADJUSTING ..............................................................................................................................................................................................................570 HYDRAULIC CIRCUIT FLUSHING..................................................................................................................................................................................................572 PPC RELIEF VALVE ...........................................................................................................................................................................................................575 MEASURING PRESSURE......................................................................................................................................................................................................575 ADJUSTING...............................................................................................................................................................................................................577 WORK EQUIPMENT .............................................................................................................................................................................................................578 RELIEF VALVE............................................................................................................................................................................................................578 MEASURING TIME..........................................................................................................................................................................................................580 HYDRAULIC DRIFT ........................................................................................................................................................................................................581 BUCKET POSITIONER ..........................................................................................................................................................................................................582 BOOM KICK-OUT ..............................................................................................................................................................................................................583 TROUBLESHOOTING ............................................................................................................................................................................................................584 TROUBLESHOOTING TABLE ..................................................................................................................................................................................................584 1. Lift arm does not rise. .........................................................................................................................................................................................584 2. Lift arm moves slowly or does not have sufficient lifting power. ...............................................................................................................................................585 3. Lift arm movement becomes slow after it reaches a certain height. ...............................................................................................................................................586 4. Bucket cannot be held down with lift arm cylinder................................................................................................................................................................586 5. Lift arm has large hydraulic drift...............................................................................................................................................................................586 6. Lift arm movement is unsteady during work........................................................................................................................................................................586 7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”..............................................................................................................................586 8. Bucket does not tilt back. ......................................................................................................................................................................................587 9. Bucket moves slowly or has insufficient tilt back power. .......................................................................................................................................................588 10. Bucket movement becomes slow during tilt back...................................................................................................................................................................589 11. Bucket cannot be held down by the bucket cylinder. ............................................................................................................................................................589 12. Bucket has large hydraulic drift. ..............................................................................................................................................................................589 13. Bucket moves unsteadily when machine travels 10. Bucket movement becomes slow during tilt back. under load. (Main control valve in “Hold”). Checks before troubleshooting Checks before troubleshooting ....589 14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”. Check before troubleshooting ..............................................................................................589 15. Control levers of lift arm and dump move stiffly and sluggishly. ..............................................................................................................................................590 63 DISASSEMBLY AND ASSEMBLY.....................................................................................................................................................................................................591 HYDRAULIC TANK .............................................................................................................................................................................................................593 REMOVAL ................................................................................................................................................................................................................593 INSTALLATION ...........................................................................................................................................................................................................595 HYDRAULIC FILTER ...........................................................................................................................................................................................................597 REMOVAL ................................................................................................................................................................................................................597 INSTALLATION ...........................................................................................................................................................................................................597 WORK EQUIPMENT PUMP ........................................................................................................................................................................................................598 REMOVAL ................................................................................................................................................................................................................598 INSTALLATION ...........................................................................................................................................................................................................600 SWITCH PUMP.................................................................................................................................................................................................................601 REMOVAL.................................................................................................................................................................................................................601 INSTALLATION............................................................................................................................................................................................................603 PPC VALVE ASSEMBLY .........................................................................................................................................................................................................604 REMOVAL ................................................................................................................................................................................................................604 INSTALLATION............................................................................................................................................................................................................606 DISASSEMBLY.............................................................................................................................................................................................................608 ASSEMBLY................................................................................................................................................................................................................608 PPC RELIEF VALVE ASSEMBLY...............................................................................................................................................................................................609 DISASSEMBLY.........................................................................................................................................................................................................609 ASSEMBLY............................................................................................................................................................................................................609 MAIN CONTROL VALVE .........................................................................................................................................................................................................610 REMOVAL ................................................................................................................................................................................................................610 INSTALLATION ...........................................................................................................................................................................................................613 DISASSEMBLY ............................................................................................................................................................................................................613 ASSEMBLY ...............................................................................................................................................................................................................622 DUMP CYLINDER ..............................................................................................................................................................................................................625 REMOVAL ................................................................................................................................................................................................................625 INSTALLATION............................................................................................................................................................................................................627 LIFT CYLINDER...............................................................................................................................................................................................................629 REMOVAL ................................................................................................................................................................................................................629 INSTALLATION ...........................................................................................................................................................................................................631 LIFT AND DUMP CYLINDERS ....................................................................................................................................................................................................633 DISASSEMBLY ............................................................................................................................................................................................................633 ASSEMBLY ...............................................................................................................................................................................................................635 WORK EQUIPMENT .............................................................................................................................................................................................................638 REMOVAL ................................................................................................................................................................................................................638 INSTALLATION ...........................................................................................................................................................................................................642 COUNTERWEIGHT ..............................................................................................................................................................................................................646 REMOVAL ................................................................................................................................................................................................................646 INSTALLATION ...........................................................................................................................................................................................................646 64 MAINTENANCE STANDARD ........................................................................................................................................................................................................647 HYDRAULIC AND SWITCH PUMP ..................................................................................................................................................................................................648 HYDRAULIC PUMP SAR(3)-100 .............................................................................................................................................................................................648 SWITCH PUMP SAR(3)-100 .................................................................................................................................................................................................648 PPC PUMP ...................................................................................................................................................................................................................649 SAR(1)-014 .............................................................................................................................................................................................................649 PPC VALVE ..................................................................................................................................................................................................................650 MAIN CONTROL VALVE .........................................................................................................................................................................................................652 HYDRAULIC CYLINDERS ........................................................................................................................................................................................................654 STEERING CYLINDER ......................................................................................................................................................................................................654 LIFT CYLINDER ..........................................................................................................................................................................................................654 DUMP CYLINDER ..........................................................................................................................................................................................................655 BUCKET LINKAGE .............................................................................................................................................................................................................656 BUCKET .....................................................................................................................................................................................................................660 BUCKET POSITIONER AND BOOM KICK-OUT ........................................................................................................................................................................................662 80 ELECTRIC AND ELECTRONIC SYSTEM...................................................................................................................................................................................................665 81 STRUCTURE AND FUNCTION ......................................................................................................................................................................................................665 ELECTRICAL WIRING DIAGRAM ..................................................................................................................................................................................................667 ENGINE STARTING CIRCUIT ....................................................................................................................................................................................................668 ENGINE STOP CIRCUIT ........................................................................................................................................................................................................670 PREHEATING CIRCUIT .........................................................................................................................................................................................................671 PREHEATING AND AFTER-HEATING WITH HEATER SWITCH ........................................................................................................................................................................671 PREHEATING WITH STARTING SWITCH.........................................................................................................................................................................................672 AUTOMATIC PREHEATING....................................................................................................................................................................................................674 COMBINATION SWITCH .........................................................................................................................................................................................................677 TRANSMISSION CUT-OFF SWITCH ................................................................................................................................................................................................678 TRANSMISSION CUT-OFF SELECTOR SWITCH........................................................................................................................................................................................679 NEUTRALIZER RELAY ..........................................................................................................................................................................................................680 KICK-DOWN SWITCH ...........................................................................................................................................................................................................681 KICK-DOWN ELECTRIC CIRCUIT .............................................................................................................................................................................................682 ELECTRICAL PARKING BRAKE CONTROL ...........................................................................................................................................................................................688 PARKING BRAKE VALVE.....................................................................................................................................................................................................690 PARKING SAFETY RELAY....................................................................................................................................................................................................690 NEUTRALIZER RELAY.......................................................................................................................................................................................................690 EMERGENCY BRAKE SWITCH..................................................................................................................................................................................................690 CONDITIONS .............................................................................................................................................................................................................691 1. STARTING SWITCH OFF..............................................................................................................................................................................................691 2. STARTING SWITCH ON ..............................................................................................................................................................................................692 2-1. When parking brake switch is turned ON before starting switch is turned ON. ..............................................................................................................................692 2-2. Parking brake switch turned OFF (released) before starting switch is turned ON. Electric ................................................................................................................693 3. PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON....................................................................................................................................694 4. PARKING BRAKE SWITCH ON (operated)...............................................................................................................................................................................695 5. WHEN AIR PRESSURE DROPS. (Emergency brake actuated) ............................................................................................................................................................696 BUCKET POSITIONER AND BOOM KICK-OUT ........................................................................................................................................................................................697 Bucket positioner.......................................................................................................................................................................................................698 Boom kick-out...........................................................................................................................................................................................................698 PROXIMITY SWITCH ...........................................................................................................................................................................................................699 OPERATION ..............................................................................................................................................................................................................699 Lift arm RAISE .....................................................................................................................................................................................................699 Kick-out ...........................................................................................................................................................................................................701 BUCKET "TILT" ..........................................................................................................................................................................................................702 Hold ...............................................................................................................................................................................................................702 Tilt................................................................................................................................................................................................................703 Positioned .........................................................................................................................................................................................................704 ELECTRICAL CIRCUIT DIAGRAM FOR AIR GAUGE ...................................................................................................................................................................................705 ELECTRICAL CIRCUIT DIAGRAM FOR INTERMITTENT WIPER ..........................................................................................................................................................................706 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ................................................................................................................................................................................707 INDICATION ON MONITOR PANEL ............................................................................................................................................................................................709 MONITOR WIRING HARNESS .................................................................................................................................................................................................712 SENSORS ....................................................................................................................................................................................................................713 ENGINE OIL LEVEL SENSOR ................................................................................................................................................................................................713 BRAKE OIL LEVEL.........................................................................................................................................................................................................714 COOLANT LEVEL...........................................................................................................................................................................................................714 FUEL GAUGE..............................................................................................................................................................................................................715 ENGINE OIL PRESSURE.....................................................................................................................................................................................................716 PARKING BRAKE...........................................................................................................................................................................................................717 AIR PRESSURE............................................................................................................................................................................................................718 TORQUE CONVERTER OILTEMPERATURE.........................................................................................................................................................................................719 COOLANT TEMPERATURE.....................................................................................................................................................................................................719 ROTATIONAL SPEED........................................................................................................................................................................................................720 BRAKE LINE FAILURE......................................................................................................................................................................................................720 TRANSMISSION OIL FILTER CLOGGING SENSOR ................................................................................................................................................................................721 82 TESTING AND ADJUSTING .......................................................................................................................................................................................................723 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM .................................................................................................................................................................................726 MACHINE MONITOR (SPEEDOMETER MODULE) .......................................................................................................................................................................................729 TROUBLESHOOTING.............................................................................................................................................................................................................731 CHECKS BEFORE TROUBLESHOOTING ..........................................................................................................................................................................................732 JUDGEMENT ON POWER TRAIN................................................................................................................................................................................................733 METHOD OF READING TROUBLESHOOTING TABLE ................................................................................................................................................................................734 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ......................................................................................................................................................................734 PRECAUTION WHEN HANDLING CONNECTOR ....................................................................................................................................................................................736 CONNECTOR TERMINAL NUMBERS .............................................................................................................................................................................................738 ELECTRICAL WIRING DIAGRAM ..............................................................................................................................................................................................744 ELECTRICAL CONNECTOR (CN) DIAGRAM ......................................................................................................................................................................................744 VEHICLE MONITOR SYSTEM DIAGRAM .........................................................................................................................................................................................744 ELECTRICAL CIRCUIT SYSTEM ..............................................................................................................................................................................................745 ENGINE STARTING AND STOP CIRCUIT SYSTEM.............................................................................................................................................................................745 PARKING BRAKE SYSTEM................................................................................................................................................................................................746 KICK-DOWN CIRCUIT SYSTEM............................................................................................................................................................................................747 PREHEATING CIRCUIT SYSTEM...........................................................................................................................................................................................748 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...................................................................................................................................................................................749 POSITION OF CONNECTORS TROUBLESHOOTING ................................................................................................................................................................................751 TROUBLESHOOTING ............................................................................................................................................................................................................750 E-1 ENGINE DOES NOT START .............................................................................................................................................................................................760 E-2 ENGINE DOES NOT STOP ...............................................................................................................................................................................................764 E-3 ENGINE STOPS WHEN TRAVELING.........................................................................................................................................................................................765 E-4 PARKING BRAKE DOES NOT WORK ........................................................................................................................................................................................766 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING............................................................................................................................................................................768 E-6 PARKING BRAKE IS RELEASED WHEN STARTING ............................................................................................................................................................................770 E-7 SHIFT LEVER DOES NOT ENTER NEUTRAL..................................................................................................................................................................................770 E-8 TRANSMISSION DOES NOT WORK NORMALLY.................................................................................................................................................................................772 E-9 KICK-DOWN SWITCH DOES NOT WORK .....................................................................................................................................................................................794 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON ..................................................................................................................................................................797 E-11 KICK-DOWN OPERATION IS NOT CANCELED................................................................................................................................................................................798 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2....................................................................................................................................................................800 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED...........................................................................................................................................................800 E-14 PREHEAT DISPLAY STAYS ON...........................................................................................................................................................................................802 E-15 PREHEAT DOSE NOT STOP..............................................................................................................................................................................................802 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM .............................................................................................................................................................803 POSITION OF CONNECTORS FOR TROUBLESHOOTING ............................................................................................................................................................................804 TROUBLESHOOTING ............................................................................................................................................................................................................816 M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED....................................................................................................................................................................816 M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED...................................................................................................................................................................817 M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED...............................................................................................................................................................818 M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING.....................................................................................................................................................................818 M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING...................................................................................................................................................820 M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING.........................................................................................................................................................................821 M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING.................................................................................................................................................................821 M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING................................................................................................................................................................823 M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING...............................................................................................................................................................823 M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING..............................................................................................................................................................825 M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING..........................................................................................................................................................825 M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING..................................................................................................................................................825 M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP..........................................................................................................................................................827 M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP..........................................................................................................................................................829 M-15 (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP.......................................................................................................................................................................831 M-16 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP................................................................................................................................................................833 M-17 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP................................................................................................................................................................835 M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON....................................................................................................................................................840 M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.........................................................................................................................................................................841 M-20 HOURMETER DISPLAY DOES NOT WORK NORMALLY...........................................................................................................................................................................842 M-21 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PARTS WORKS................................................................................................................................843 M-22 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT............................................................................................................................844 M-23 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED...................................................................................................................................845 M-24 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP.............................................................................................................................847 M-25 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH THE C........................................................................................852 M-26 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS........................................................................................................................................852 M-27 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. T........................................................................................854 M-28 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP.....................................................................................................................................855 M-29 ABNORMALITY IN THE FUEL GAUGE SYSTEM...............................................................................................................................................................................856 M-30 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM.......................................................................................................................................................................858 M-31 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM...........................................................................................................................................................860 M-32 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM...................................................................................................................................................862 83 DISASSEMBLY AND ASSEMBLY ....................................................................................................................................................................................................865 MACHINE MONITOR ...........................................................................................................................................................................................................866 REMOVAL ................................................................................................................................................................................................................866 INSTALLATION ...........................................................................................................................................................................................................867 90 OTHERS...........................................................................................................................................................................................................................869 91 STRUCTURE AND FUNCTION ......................................................................................................................................................................................................869 GENERAL ....................................................................................................................................................................................................................871 BASIC INFORMATION ON AIR CONDITIONERS ..................................................................................................................................................................................871 UNITS RELATED TO REFRIGERATION .....................................................................................................................................................................................871 Heat ...........................................................................................................................................................................................................871 Temperature.....................................................................................................................................................................................................871 Pressure........................................................................................................................................................................................................872 Humidity .......................................................................................................................................................................................................873 PRINCIPLE OF COOLING................................................................................................................................................................................................874 Why do coolers cool?............................................................................................................................................................................................874 Refrigerator using evaporation latent heat......................................................................................................................................................................874 Refrigeration method (Vapor compression)........................................................................................................................................................................874 Refrigerating cycle ............................................................................................................................................................................................875 Heating cycle...................................................................................................................................................................................................877 REFRIGERANTS .......................................................................................................................................................................................................878 SAFETY PRECAUTIONS .............................................................................................................................................................................................878 REFRIGERATOR OIL (LUBE OIL).........................................................................................................................................................................................879 SPECIFICATIONS......................................................................................................................................................................................................880 PIPING DIAGRAM .............................................................................................................................................................................................................881 ELECTRIC WIRING DIAGRAM ....................................................................................................................................................................................................882 COMPRESSOR (CRANK TYPE) ....................................................................................................................................................................................................883 MAGNETIC CLUTCH ............................................................................................................................................................................................................886 CONDENSER ..................................................................................................................................................................................................................887 RECEIVER W/SIGHT GLASS .....................................................................................................................................................................................................889 AIR CONDITIONER UNIT .......................................................................................................................................................................................................891 EXPANSION VALVE ........................................................................................................................................................................................................892 EVAPORATOR .............................................................................................................................................................................................................894 THERMOSTAT .............................................................................................................................................................................................................894 PRESSURE SWITCH ........................................................................................................................................................................................................895 HEATER .................................................................................................................................................................................................................897 BLOWER UNIT ............................................................................................................................................................................................................897 PIPING .................................................................................................................................................................................................................898 AIR CONTROL SYSTEM .....................................................................................................................................................................................................899 CONTROL PANEL ..............................................................................................................................................................................................................900 BLOWER SWITCH...........................................................................................................................................................................................................900 AIR CONDITIONER SWITCH..................................................................................................................................................................................................900 TEMPERATURE CONTROL LEVER...............................................................................................................................................................................................900 AIR SOURCE SELECTOR LEVER...............................................................................................................................................................................................900 92 TESTING AND ADJUSTING........................................................................................................................................................................................................901 SERVICE TOOLS ..............................................................................................................................................................................................................903 GAUGE MANIFOLD .........................................................................................................................................................................................................903 GAS LEAK DETECTOR ......................................................................................................................................................................................................906 HALIDE TORCH LEAK DETECTOR..........................................................................................................................................................................................906 ELECTRIC LEAK TESTER................................................................................................................................................................................................908 VALVE FOR SERVICE CANS .................................................................................................................................................................................................909 MAINTENANCE PROCEDURE ......................................................................................................................................................................................................910 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING ........................................................................................................................................................................910 PROHIBITED WORK.....................................................................................................................................................................................................910 OTHER PRECAUTIONS...................................................................................................................................................................................................910 BLEEDING AIR FROM REFRIGERATION CIRCUIT ...............................................................................................................................................................................912 PURPOSE.............................................................................................................................................................................................................912 CONNECTING GAUGE MANIFOLD...........................................................................................................................................................................................912 EVACUATION..........................................................................................................................................................................................................913 AIR-TIGHTNESS CHECK.................................................................................................................................................................................................913 GAS-LEAK CHECK......................................................................................................................................................................................................913 EVACUATION (REPEATING)..............................................................................................................................................................................................914 CHARGINGTHE REFRIGERATION CIRCUIT WITH REFRIGERANT ....................................................................................................................................................................915 CHARGING FROM THE HIGH-PRESSURE SIDE................................................................................................................................................................................915 CHARGING FROM THE LOW PRESSURE SIDE (REPLENISHING THE REFRIGERATION CIRCUIT)........................................................................................................................................916 WHEN THE AMBIENT TEMPERATURE IS LOW.................................................................................................................................................................................917 WHEN THE AMBIENT TEMPERATURE IS HIGH................................................................................................................................................................................917 REPLACING SERVICE CANS .................................................................................................................................................................................................918 CHECKING THE AMOUNT OF REFRIGERANT .....................................................................................................................................................................................918 REMOVAL OF GAUGE MANIFOLD ..............................................................................................................................................................................................920 DISCHARGING THE REFRIGERANT ............................................................................................................................................................................................920 DAILY CHECKS ...........................................................................................................................................................................................................921 CHECK REFRIGERANT LEVEL.............................................................................................................................................................................................921 CLEANING THE CONDENSER..............................................................................................................................................................................................921 CHECKING THE V-BELT.................................................................................................................................................................................................921 CHECKING OIL LEVEL .....................................................................................................................................................................................................922 PROCEDURE FOR CHECKING..............................................................................................................................................................................................922 PROCEDURE FOR CHECKING OIL LEVEL....................................................................................................................................................................................922 ADDING AND REMOVING OIL.............................................................................................................................................................................................923 ADDING OIL BY EVACUATION............................................................................................................................................................................................923 TROUBLESHOOTING.............................................................................................................................................................................................................924 VISUAL AND ACOUSTICAL CHECKS ...........................................................................................................................................................................................924 DEFECTIVE COOLING ......................................................................................................................................................................................................925 TROUBLESHOOTING TABLES .................................................................................................................................................................................................926 DEFECTIVE HEATING ......................................................................................................................................................................................................928 TROUBLESHOOTING USING GAUGE MANIFOLD .......................................................................................................................................................................................929 PREPARATIONS BEFORE MEASURING...........................................................................................................................................................................................929 INSUFFICIENT REFRIGERANT................................................................................................................................................................................................929 EXCESSIVE REFRIGERANT OR INSUFFICIENT 3. COOLING OF CONDENSER ........................................................................................................................................................930 AIR INSIDE REFRIGERATION SYSTEM ........................................................................................................................................................................................930 MOISTURE IN REFRIGERATING SYSTEM .......................................................................................................................................................................................931 REFRIGERANT DOES NOT CIRCULATE .........................................................................................................................................................................................932 FAILURE OF EXPANSION VALVE .............................................................................................................................................................................................933 DEFECTIVE MOUNTING OF HEAT SENSING TUBE.................................................................................................................................................................................933 DEFECTIVE COMPRESSION BY COMPRESSOR ....................................................................................................................................................................................933 93 DISASSEMBLY AND ASSEMBLY ....................................................................................................................................................................................................935 SPECIAL TOOLS ..............................................................................................................................................................................................................936 MAGNETIC CLUTCH ............................................................................................................................................................................................................937 DISASSEMBLY OF .........................................................................................................................................................................................................937 CHECKS BEFORE DISASSEMBLY...........................................................................................................................................................................................938 REMOVAL OF ROTOR AND STATOR.........................................................................................................................................................................................938 REMOVAL OF CENTER PIECE FROM ROTOR..................................................................................................................................................................................939 REMOVAL OF BEARING FROM ROTOR.......................................................................................................................................................................................940 ASSEMBLY OF ............................................................................................................................................................................................................941 ASSEMBLY OF BEARING TO ROTOR........................................................................................................................................................................................941 ASSEMBLY OF CENTER PIECE TO ROTOR...................................................................................................................................................................................941 ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR..........................................................................................................................................................................942 AIR CONDITIONER UNIT .......................................................................................................................................................................................................943 DISASSEMBLY OF .........................................................................................................................................................................................................943 CHECKS BEFORE DISASSEMBLY...........................................................................................................................................................................................943 REMOVAL OF CONTROL PANEL AND THERMOSTAT.............................................................................................................................................................................947 REMOVAL OF UNIT COVER...............................................................................................................................................................................................949 REMOVAL OF WATER VALVE..............................................................................................................................................................................................949 REMOVAL OF EXPANSION VALVE..........................................................................................................................................................................................951 REMOVAL OF EVAPORATOR...............................................................................................................................................................................................953 REMOVAL OF HEATER CORE .............................................................................................................................................................................................953 REMOVAL OF PRESSURE SWITCHES .......................................................................................................................................................................................953 BLOWER UNIT ................................................................................................................................................................................................................954 DISASSEMBLY OF .........................................................................................................................................................................................................954 CHECKS BEFORE DISASSEMBLY...........................................................................................................................................................................................954 REMOVAL OF BLOWER RESISTOR..........................................................................................................................................................................................954 REMOVAL OF BLOWER MOTOR AND FAN.....................................................................................................................................................................................955 CONDENSER ..................................................................................................................................................................................................................956 DISASSEMBLY OF .........................................................................................................................................................................................................956 CHECKS BEFORE DISASSEMBLY...........................................................................................................................................................................................956 REMOVAL OF CONDENSER, FAN MOTOR.....................................................................................................................................................................................957 REMOVAL OF PRESSURE SWITCH..........................................................................................................................................................................................958 REMOVAL OF RESISTOR ................................................................................................................................................................................................958 97 GEAR PUMP....................................................................................................................................................................................................................959 GENERAL.....................................................................................................................................................................................................................960 PRINCIPLE OF OPERATION .................................................................................................................................................................................................961 PRESSURE LOADED TYPE GEAR PUMP .........................................................................................................................................................................................964 FIXED SIDE PLATE TYPE GEAR PUMP.........................................................................................................................................................................................966 SA SERIES ..................................................................................................................................................................................................................967 STRUCTURE ..............................................................................................................................................................................................................967 TESTING AND ADJUSTING ..................................................................................................................................................................................................971 DISASSEMBLY ............................................................................................................................................................................................................974 ASSEMBLY ...............................................................................................................................................................................................................978 MAINTENANCE STANDARD ...................................................................................................................................................................................................983 99 METRIC CONVERSIONS ..........................................................................................................................................................................................................985
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