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Komatsu WA800-2 Wheel Loader Shop Manual CEBM002400 – PDF DOWNLOAD
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Komatsu WA800-2 Wheel Loader Shop Manual
SERIAL NUMBERS : WA800-2LC- A20020 and up
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Description
Komatsu WA800-2 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA800-2 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA800-2
Serial Number: A20020 and up
Book Code: CEBM002400
Language: English
Pages: 878
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA800-2 Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
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 WA800-2 Wheel Loader Shop Manual
MAIN MENU.................................................................................................................................................................................... 0 CONTENTS..................................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................................... 21 SPECIFICATION DRAWINGS .................................................................................................................................................................. 22 SPECIFICATIONS .......................................................................................................................................................................... 23 WEIGHT TABLE ............................................................................................................................................................................ 26 FUEL, COOLANT, AND LUBRICANTS ........................................................................................................................................................... 28 ENGINE OIL SPECIFICATIONS................................................................................................................................................................ 29 DIESEL FUEL SPECIFICATIONS............................................................................................................................................................... 30 COOLANT SPECIFICATIONS................................................................................................................................................................... 31 10 STRUCTURE AND FUNCTION.................................................................................................................................................................... 39 GENERAL (POWER TRAIN) ................................................................................................................................................................... 44 POWER TRAIN SYSTEM ...................................................................................................................................................................... 45 ENGINE CONTROL .......................................................................................................................................................................... 46 RADIATOR AND HYDRAULIC OIL COOLER ....................................................................................................................................................... 47 DAMPER................................................................................................................................................................................... 48 TORQUE CONVERTER AND TRANSMISSION PIPING ................................................................................................................................................ 49 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM ................................................................................................................................................... 50 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .................................................................................................................................................. 51 TORQUE CONVERTER ........................................................................................................................................................................ 52 TORQUE CONVERTER RELIEF VALVE ........................................................................................................................................................... 55 TORQUE CONVERTER REGULATOR VALVE ........................................................................................................................................................ 56 TORQUE CONVERTER OIL FILTER ............................................................................................................................................................. 57 TRANSMISSION ............................................................................................................................................................................ 59 CLUTCH............................................................................................................................................................................... 62 OUTLINE.......................................................................................................................................................................... 62 OPERATION OF CLUTCH.............................................................................................................................................................. 62 FORWARD 1 st..................................................................................................................................................................... 63 FORWARD 2nd...................................................................................................................................................................... 64 FORWARD 3rd...................................................................................................................................................................... 65 REVERSE 1 st..................................................................................................................................................................... 66 TRANSFER ................................................................................................................................................................................ 67 TRANSMISSION CONTROL VALVE .............................................................................................................................................................. 68 TRANSMISSION SOLENOID VALVE.......................................................................................................................................................... 69 LOWER VALVE.......................................................................................................................................................................... 70 UPPER VALVE.......................................................................................................................................................................... 71 PILOT OIL FILTER..................................................................................................................................................................... 72 MAIN RELIEF VALVE.................................................................................................................................................................... 73 PILOT REDUCING VALVE................................................................................................................................................................. 74 TRANSMISSION SOLENOID VALVE.......................................................................................................................................................... 75 PRIORITY VALVE....................................................................................................................................................................... 76 MODULATING VALVE AND QUICK RETURN VALVE.............................................................................................................................................. 77 REDUCING VALVE....................................................................................................................................................................... 79 EMERGENCY MANUAL SPOOL............................................................................................................................................................... 80 TRANSMISSION LUBRICATION VALVE....................................................................................................................................................... 81 HYDRAULIC CIRCUIT SCHEMATICS......................................................................................................................................................... 82 TORQUE CONVERTER OIL COOLER ............................................................................................................................................................. 84 DRIVE SHAFT ............................................................................................................................................................................. 85 CENTER SUPPORT .......................................................................................................................................................................... 86 AXLES ................................................................................................................................................................................... 87 FRONT AXLE........................................................................................................................................................................... 87 FRONT DIFFERENTIAL................................................................................................................................................................... 88 REAR AXLE............................................................................................................................................................................ 89 REAR DIFFERENTIAL.................................................................................................................................................................... 90 FINAL DRIVE ............................................................................................................................................................................. 92 FLOOR SUPPORT ........................................................................................................................................................................... 93 AXLE MOUNT AND CENTER HINGE PIN ......................................................................................................................................................... 94 STEERING PIPING ......................................................................................................................................................................... 96 STEERING COLUMN ......................................................................................................................................................................... 97 STEERING PUMP ........................................................................................................................................................................... 98 SWITCH PUMP .............................................................................................................................................................................101 SWITCH PUMP (HPV 90 + 90) ...........................................................................................................................................................102 CD NC VALVE .........................................................................................................................................................................104 STEERING DEMAND VALVE ...................................................................................................................................................................106 OVERLOAD RELIEF VALVE ...............................................................................................................................................................107 MAIN RELIEF VALVE ...................................................................................................................................................................109 OPERATION OF STEERING RELIEF VALVE ..................................................................................................................................................110 OPERATION OF DEMAND VALVE ...........................................................................................................................................................111 When steering spool is at neutral................................................................................................................................................111 WHEN STEERING SPOOL IS OPERATED .....................................................................................................................................................112 Engine running at low speed......................................................................................................................................................112 Engine running at high speed ....................................................................................................................................................113 OPERATION OF STEERING VALVE .........................................................................................................................................................114 Neutral..........................................................................................................................................................................114 Turning left.....................................................................................................................................................................115 Turning right....................................................................................................................................................................116 TWO-WAY RESTRICTOR VALVE STRUCTURE AND FUNCTION ........................................................................................................................................117 STEERING UNIT (ORBIT-ROLL VALVE) ........................................................................................................................................................118 OPERATION ...........................................................................................................................................................................120 When turning.....................................................................................................................................................................120 At neutral.......................................................................................................................................................................120 DIVERTER VALVE ..........................................................................................................................................................................121 EMERGENCY STEERING RELIEF VALVE .....................................................................................................................................................122 HYDRAULIC CIRCUIT SCHEMATICS FOR EMERGENCY STEERING .................................................................................................................................123 Pump, engine working normally....................................................................................................................................................123 Failure in pump or engine when machine is traveling..............................................................................................................................124 BRAKE AND AIR PIPING ....................................................................................................................................................................126 BRAKE AND AIR CIRCUIT DIAGRAM ...........................................................................................................................................................128 AIR GOVERNOR ............................................................................................................................................................................130 AIR TANK ................................................................................................................................................................................132 SAFETY VALVE ............................................................................................................................................................................132 BRAKE VALVE .............................................................................................................................................................................134 BRAKE ACTUATED ......................................................................................................................................................................135 OPERATING IN BALANCE ................................................................................................................................................................136 BRAKE RELEASED ......................................................................................................................................................................137 RELAY VALVE .............................................................................................................................................................................138 TWO-WAY VALVE............................................................................................................................................................................139 BRAKE CHAMBER ...........................................................................................................................................................................140 SLACK ADJUSTER ..........................................................................................................................................................................142 BRAKE ...................................................................................................................................................................................145 PARKING BRAKE ...........................................................................................................................................................................146 HYDRAULIC PIPING ........................................................................................................................................................................148 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................150 WORK EQUIPMENT LEVER LINKAGE ............................................................................................................................................................151 HYDRAULIC TANK ..........................................................................................................................................................................152 OIL FILTER BYPASS VALVE..............................................................................................................................................................153 BREATHER.............................................................................................................................................................................153 MAIN PISTON PUMP ........................................................................................................................................................................155 PISTON PUMP (HPVSO + 90) ............................................................................................................................................................156 CONTROL PUMP (BAR025) ...............................................................................................................................................................160 RELIEF VALVE ........................................................................................................................................................................161 ES VALVE (ENGINE SENSING VALVE) .........................................................................................................................................................162 SERVO VALVE .............................................................................................................................................................................165 PPC VALVE ...............................................................................................................................................................................168 PPC RELIEF VALVE ........................................................................................................................................................................172 ACCUMULATOR .............................................................................................................................................................................173 MAIN CONTROL VALVE ......................................................................................................................................................................174 RELIEF VALVE ........................................................................................................................................................................176 SAFETY VALVE (with suction valve) ...................................................................................................................................................177 AS A SAFETY VALVE................................................................................................................................................................177 AS A SUCTION VALVE...............................................................................................................................................................178 SUCTION VALVE .......................................................................................................................................................................178 FLOAT SELECTOR VALVE AND UNLOADER VALVE .............................................................................................................................................179 OPERATION OF HYDRAULIC CIRCUIT ......................................................................................................................................................181 LIFT AND DUMP SPOOLS IN “HOLD”...................................................................................................................................................181 LIFT SPOOL IN “RAISE”............................................................................................................................................................182 LIFT SPOOL IN “LOWER”............................................................................................................................................................183 LIFT SPOOL IN “FLOAT”............................................................................................................................................................184 DUMP SPOOL IN “DUMP”.............................................................................................................................................................185 DUMP SPOOL IN “TILT BACK”........................................................................................................................................................186 LUBRICATION OF WORK EQUIPMENT ...........................................................................................................................................................188 WORK EQUIPMENT LINKAGE ..................................................................................................................................................................190 BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................................................192 BUCKET POSITIONER ...................................................................................................................................................................193 BOOM KICK-OUT .......................................................................................................................................................................193 OPERATION OF PROXIMITY SWITCH .......................................................................................................................................................194 CAB .....................................................................................................................................................................................198 AIR CONDITIONER .........................................................................................................................................................................199 AIR CONDITIONING (GENERAL) ..........................................................................................................................................................200 BASIC INFORMATION ON AIR CONDITIONERS............................................................................................................................................200 PRINCIPLE OF COOLING.............................................................................................................................................................203 REFRIGERANTS.....................................................................................................................................................................208 SAFETY PRECAUTIONS...............................................................................................................................................................208 REFRIGERATOR OIL (LUBE OIL)......................................................................................................................................................209 AIR CONDITIONING PIPING DIAGRAM .........................................................................................................................................................210 AIR CONDITIONING CONDENSER ..............................................................................................................................................................211 RECEIVER W/SIGHT GLASS (LIQUID TANK) ....................................................................................................................................................213 AIR CONDITIONER UNIT ....................................................................................................................................................................215 MACHINE MONITOR SYSTEM ..................................................................................................................................................................216 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ........................................................................................................................................216 INDICATION ON MONITOR PANEL .........................................................................................................................................................218 MONITOR WIRING HARNESS ..............................................................................................................................................................221 ELECTRICAL CIRCUIT SYSTEM (MACHINE MONITOR SYSTEM) ..................................................................................................................................227 ELECTRICAL SCHEMATIC (1/3) ..............................................................................................................................................................228 ELECTRICAL SCHEMATIC (2/3) ..............................................................................................................................................................229 ELECTRICAL SCHEMATIC - JOYSTICK STEERING (3/3) ..........................................................................................................................................230 ENGINE STARTING CIRCUIT .................................................................................................................................................................232 ENGINE STOP CIRCUIT .....................................................................................................................................................................234 PREHEATING CIRCUIT ......................................................................................................................................................................236 PREHEATING AND POST-HEATING USING PREHEATING SWITCH .................................................................................................................................236 PREHEATING WITH STARTING SWITCH .....................................................................................................................................................237 AUTOMATIC PREHEATING ................................................................................................................................................................238 ELECTRICAL TRANSMISSION CONTROL .........................................................................................................................................................240 COMBINATION SWITCH ..................................................................................................................................................................241 TRANSMISSION CUT-OFF SELECTOR SWITCH.................................................................................................................................................242 TRANSMISSION CUT-OFF ELECTRIC CIRCUIT ...............................................................................................................................................243 NEUTRALIZER RELAY ELECTRIC CIRCUIT ..................................................................................................................................................244 KICK-DOWN SWITCH.........................................................................................................................................................................245 KICK-DOWN ELECTRIC CIRCUIT ..........................................................................................................................................................246 Normally ON..........................................................................................................................................................................246 When kick-down switch is operated....................................................................................................................................................247 When kick-down switch is pushed ON...................................................................................................................................................247 Cancellation of kick-down switch I...................................................................................................................................................248 Cancellation of kick-down switch II..................................................................................................................................................249 Cancellation of kick-down switch Ill.................................................................................................................................................250 ELECTRICAL PARKING BRAKE CONTROL ........................................................................................................................................................251 STARING SWITCH OFF ..................................................................................................................................................................254 STARTING SWITCH ON ..................................................................................................................................................................255 When parking brake switch is turned ON, before starting switch is turned ON......................................................................................................255 Parking brake OFF (released), after starting switch is turned ON.................................................................................................................256 Parking brake switch turned OFF (released), before starting switch is turned ON..................................................................................................257 Parking brake switch on (operated)...............................................................................................................................................258 When air pressure drops (emergency brake actuated)...............................................................................................................................259 TRANSMISSION CLUTCH OVERRUN CONTROLLER ..................................................................................................................................................260 ENGINE DIAGNOSTICS ......................................................................................................................................................................262 EXPLANATION OF THE THREE ENGINE DIAGNOSTIC LIGHTS ..................................................................................................................................262 ENGINE FAULT DIAGNOSTICS.............................................................................................................................................................263 FAULT CODES..........................................................................................................................................................................264 ENGINE DIAGNOSTIC ELECTRICAL SCHEMATIC ..................................................................................................................................................267 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................................................................269 TESTING AND ADJUSTING....................................................................................................................................................................274 STANDARD VALUE FOR TABLE ENGINE .....................................................................................................................................................275 STANDARD VALUE TABLE FOR CHASSIS ....................................................................................................................................................276 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ..........................................................................................................................................279 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ....................................................................................................................................282 MEASURING ENGINE PERFORMANCE.........................................................................................................................................................283 ENGINE SPEEDS....................................................................................................................................................................283 ENGINE RATING....................................................................................................................................................................283 INTAKE MANIFOLD PRESSURE.........................................................................................................................................................283 INTAKE AIR RESTRICTION...........................................................................................................................................................283 LUBRICATING OIL PRESSURE.........................................................................................................................................................283 FUEL FILTER INLET RESTRICTION....................................................................................................................................................283 BLOW-BY PRESSURE.................................................................................................................................................................283 EXHAUST BACK PRESSURE............................................................................................................................................................283 COOLANT TEMPERATURE..............................................................................................................................................................283 VALVE CLEARANCE..................................................................................................................................................................283 EXHAUST GAS COLOR................................................................................................................................................................283 ENGINE DRIVE BELT TENSION........................................................................................................................................................283 MEASURING ENGINE STALL SPEEDS .......................................................................................................................................................284 MEASURING TORQUE CONVERTER STALL ................................................................................................................................................284 MEASURING HYDRAULIC STALL .......................................................................................................................................................285 MEASURING FULL STALL ............................................................................................................................................................285 MEASURING ACCELERATOR PEDAL .........................................................................................................................................................286 OPERATING FORCE .................................................................................................................................................................286 OPERATING ANGLE .................................................................................................................................................................286 MEASURING DIRECTIONAL AND SPEED LEVER ..............................................................................................................................................287 MEASURING OPERATING FORCE OF LEVER ..............................................................................................................................................287 MEASURING TRAVEL OF LEVER .......................................................................................................................................................287 MEASURING OIL PRESSURE OF TRANSMISSION AND TORQUE CONVERTER .....................................................................................................................288 TRANSMISSION MAIN RELIEF VALVE PRESSURE .........................................................................................................................................289 MEASURING PILOT REDUCING PRESSURE ...............................................................................................................................................289 MEASURING MODULATING PRESSURE ...................................................................................................................................................289 TORQUE CONVERTER INLET PRESSURE .................................................................................................................................................289 TORQUE CONVERTER OUTLET PRESSURE ................................................................................................................................................289 MEASURING LUBRICATION VALVE PRESSURE ............................................................................................................................................289 MEASURING REDUCING VALVE PRESSURE ...............................................................................................................................................289 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ................................................................................................................................291 WHEEL, TIRE .........................................................................................................................................................................293 MEASURING STEERING WHEEL PERFORMANCE ................................................................................................................................................294 MEASURING STEERING WHEEL PLAY....................................................................................................................................................294 MEASURING OPERATING FORCE OF STEERING WHEEL ....................................................................................................................................295 MEASURING OPERATING TIME FOR STEERING WHEEL ....................................................................................................................................295 MEASURING STEERING OIL PRESSURE .....................................................................................................................................................296 MEASURING MAIN RELIEF PRESSURE ..................................................................................................................................................296 MEASURING EMERGENCY STEERING PRESSURE ...........................................................................................................................................297 ADJUSTING JOYSTICK STEERING .........................................................................................................................................................299 ADJUSTING STOPPER BOLT (FOR STOP VALVE) .........................................................................................................................................299 ADJUSTING JOYSTICK LEVER POTENTIOMETER ..........................................................................................................................................300 ADJUSTING JOYSTICK LEVER NEUTRAL DIRECTION SWITCH................................................................................................................................301 MEASURING BRAKE PEDAL................................................................................................................................................................302 MEASURING AIR PRESSURE...............................................................................................................................................................303 TESTING BRAKE PERFORMANCE............................................................................................................................................................305 CHECKING BRAKE PISTON LEAKAGE .......................................................................................................................................................306 MEASURING WEAR OF BRAKE DISC ........................................................................................................................................................307 BLEEDING AIR FROM BRAKE SYSTEM ......................................................................................................................................................308 TESTING PARKING BRAKE PERFORMANCE ................................................................................................................................................309 CHECKING AND ADJUSTING PARKING BRAKE ...............................................................................................................................................310 MEASURING DUMP AND LIFT CONTROL LEVERS .............................................................................................................................................312 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE ......................................................................................................................................314 AIR BLEEDING FROM PISTON PUMP .......................................................................................................................................................317 MEASURING WORK EQUIPMENT ............................................................................................................................................................318 MEASURING WORK EQUIPMENT HYDRAULIC DRIFT ..........................................................................................................................................319 ADJUSTING BUCKET POSITIONER .........................................................................................................................................................320 ADJUSTING BOOM KICK-OUT .............................................................................................................................................................321 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE) ...................................................................................................................................322 TROUBLESHOOTING..........................................................................................................................................................................323 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................................................................324 SEQUENCE OF EVENTS IN TROUBLESHOOTING ...............................................................................................................................................325 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE ..........................................................................................................................................326 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT ...................................................................................................................................326 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS ......................................................................................................................331 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT ...........................................................................................................................332 CHECKS BEFORE TROUBLESHOOTING .......................................................................................................................................................334 HANDLING CONNECTORS .................................................................................................................................................................335 PRECAUTIONS WHEN TROUBLESHOOTING ....................................................................................................................................................336 PREVENTING RECURRENCE OF TROUBLE ....................................................................................................................................................338 METHOD OF USING TROUBLESHOOTING CHARTS ..............................................................................................................................................339 Category of troubleshooting code number .........................................................................................................................................339 Method of using troubleshooting table for each troubleshooting mode. ............................................................................................................339 Using troubleshooting chart for engine related failure ..........................................................................................................................341 JUDGEMENT ON POWER TRAIN ............................................................................................................................................................347 Judgement flow ..................................................................................................................................................................347 Testing and inspection of transmission solenoid .................................................................................................................................347 Checking directional solenoid circuit ...........................................................................................................................................347 Checking speed solenoid circuit .................................................................................................................................................348 CONNECTOR TYPES AND MOUNTING LOCATIONS ..............................................................................................................................................349 CONNECTOR ARRANGEMENT DIAGRAM .......................................................................................................................................................352 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..........................................................................................................................................354 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................................................................361 S-1 STARTING PERFORMANCE IS POOR (Starting always takes time)........................................................................................................................362 S-2 Engine does not start............................................................................................................................................................363 Engine does not turn.............................................................................................................................................................363 Engine turns but no exhaust gas comes out (Fuel is not being injected)...........................................................................................................364 Exhaust gas comes out but engine does not start. (Fuel is being ejected).........................................................................................................365 S-3 Engine does not pick up smoothly (Follow up is poor).............................................................................................................................366 S-4 Engine stops during operations...................................................................................................................................................367 S-5 Engine does not rotate smoothly (hunting)........................................................................................................................................368 S-6 Engine lacks output (no power)...................................................................................................................................................369 S-7 Exhaust gas is black (incomplete combustion).....................................................................................................................................370 S-8 Oil consumption is excessive (or exhaust gas is blue)............................................................................................................................371 S-9 Oil becomes contaminated quickly.................................................................................................................................................372 S-10 Fuel consumption is excessive...................................................................................................................................................373 S-11 Oil is in cooling water, or water spurts back, or water level goes down.........................................................................................................374 S-12 Oil pressure lamp lights up (drop in oil pressure)..............................................................................................................................375 S-13 Oil level rises.................................................................................................................................................................376 S-14 Water temperature becomes too high..............................................................................................................................................377 S-15 Abnormal noise is made..........................................................................................................................................................378 S-16 Vibration is excessive..........................................................................................................................................................379 TROUBLESHOOTING OF ENGINE, TRANSMISSION, PARKING BRAKE ELECTRIC SYSTEM (E MODE)......................................................................................................381 ELECTRICAL CIRCUIT SYSTEM............................................................................................................................................................382 ENGINE STARTING CIRCUIT SYSTEM...................................................................................................................................................382 ENGINE STOP CIRCUIT SYSTEM.......................................................................................................................................................383 TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM...............................................................................................................................384 PREHEATING CIRCUIT SYSTEM........................................................................................................................................................385 E-1 Engine does not start............................................................................................................................................................386 E-2 Engine does not stop.............................................................................................................................................................390 E-2 Engine stops when traveling .....................................................................................................................................................390 E-4 Parking brake does not work .....................................................................................................................................................391 E-5 Parking brake is not released ...................................................................................................................................................392 E-6 Parking brake is released when starting switch is turned ON .....................................................................................................................394 E-7 Parking brake is applied, transmission does not enter neutral (Parking brake is working normally) ..............................................................................394 E-8 Transmission does not normally .................................................................................................................................................395 E-9 Kick-down switch does not work (1/2) ............................................................................................................................................416 E-9 Kick-down switch does not work (2/2) ............................................................................................................................................418 E-10 Kick-down only works when kick-down switch is ON. (Kick-down switch relay does not carry out self-hold operation) ......................................................419 E-11 Kick-down operation is not canceled ............................................................................................................................................420 E-12 Kick-down works mistake when traveling in F2 ...................................................................................................................................422 E-13 Machine does not travel when kick-down switch is pressed .......................................................................................................................422 E-14 Preheating is not carried out...................................................................................................................................................424 E-15 Preheating stays ON. ...........................................................................................................................................................428 TROUBLESHOOTING OF HYDRAULIC AND AND MECHANICAL SYSTEM (M MODE)......................................................................................................................433 ELECTRICAL CIRCUIT SYSTEM (MACHINE MONITOR SYSTEM)...................................................................................................................................435 ELECTRICAL CIRCUIT SYSTEM............................................................................................................................................................436 M-1 BRAKE OIL LEVEL flashes when engine is stopped...................................................................................................................................438 M-2 ENGINE OIL LEVEL flashes when engine is stopped .................................................................................................................................438 M-3 RADIATOR COOLANT LEVEL flashes when engine is stopped ...........................................................................................................................440 M-4 BATTERY CHARGE flashes when engine is running ...................................................................................................................................440 M-5 TRANSMISSION OIL FILTER CLOGGING flashes when engine is running .................................................................................................................442 M-6 FUEL LEVEL flashes when engine is running ......................................................................................................................................444 M-7 BRAKE LINE FAILURE flashes when engine is running ...............................................................................................................................444 M-8 ENGINE OIL PRESSURE flashes when engine is running...............................................................................................................................446 M-9 FUEL LEVEL flashes when engine is running .......................................................................................................................................446 M-10 DROP IN AIR PRESSURE flashes when engine is running ...........................................................................................................................448 M-11 ENGINE COOLANT TEMPERATURE flashes when engine is running ......................................................................................................................448 M-12 TORQUE CONVERTER OIL TEMPERATURE flashes when engine is running ................................................................................................................448 M-13 PARKING BRAKE lights up abnormally, or does not light up .......................................................................................................................450 M-14 WORKING LAMP lights up abnormally, or does not light up.........................................................................................................................452 M-15 PREHEATING lights up, or does not light up .....................................................................................................................................454 M-16 MAIN STEERING FAILURE lights up, or does not light up...........................................................................................................................456 M-17 TRANSMISSION CUT-OFF lights up, or does not light up............................................................................................................................458 M-18 Turn signal Hi beam light up, or does not light up..............................................................................................................................460 M-19 Turn signal does not flash even when hazard switch is turned ON ................................................................................................................466 M-20 Speedometer display does not work normally .....................................................................................................................................468 M-21 Hourmeter does not work normally ...............................................................................................................................................469 M-22 When starting switch is turned ON, monitor panel does not work, or only part works .............................................................................................470 M-23 When starting switch is turned ON, all monitor panel does not go out............................................................................................................471 M-24 ENGINE OIL PRESSURE flashes or BATTERY CHARGE flashes when engine is stopped ..................................................................................................472 M-25 ENGINE OIL PRESSURE flashes or BATTERY CHARGE flashes when engine is stopped ..................................................................................................475 M-26 When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 second. CAUTION item is flashing but buzzer does not sound. .......................480 M-27 No abnormality is shown on monitor display, but alarm buzzer sounds ............................................................................................................480 M-28 When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 seconds. CAUTION item is flashing but warning lamp does not flash. * ....482 M-29 No abnormality is shown on monitor display, warning lamp lights up .............................................................................................................483 M-30 Abnormality in fuel gauge.......................................................................................................................................................484 M-31 Abnormality in air pressure gauge...............................................................................................................................................485 M-32 Abnormality in engine coolant temperature gauge ................................................................................................................................486 M-33 Abnormality in torque converter oil temperature gauge ..........................................................................................................................488 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE)..........................................................................................................................489 POWER TRAIN..........................................................................................................................................................................490 T-1 Machine does not move .......................................................................................................................................................490 T-2 Machine lacks power or speed ................................................................................................................................................491 T-3 Excessive time lag when starting machine or shifting gear ...................................................................................................................492 T-4 Torque converter oil temperature too high ...................................................................................................................................493 STEERING SYSTEM......................................................................................................................................................................494 T-5 Steering wheel does not turn ................................................................................................................................................494 T-6 Steering wheel is sluggish ..................................................................................................................................................495 T-7 Steering wheel moves unsteadily or is subjected to large shock ..............................................................................................................496 T-8 Machine tends to turn naturally in one particular direction when traveling ..................................................................................................496 BRAKE SYSTEM.........................................................................................................................................................................497 T-9 Air pressure does not rise at all ...........................................................................................................................................497 T-10 Air pressure does not rise to the specified range...........................................................................................................................498 T-11 Brake is ineffective or not very effective .................................................................................................................................499 T-12 Brake does not release, or drags ...........................................................................................................................................500 T-13 Parking brake does not release, or drags ...................................................................................................................................501 WORK EQUIPMENT.......................................................................................................................................................................502 T-14 Lift arm does not rise .....................................................................................................................................................502 T-15 Lift arm moves slowly or does not have sufficient lifting power ............................................................................................................503 T-16 Lift arm movement becomes slow after it reaches a certain height ...........................................................................................................504 T-17 Bucket cannot be held down with lift arm cylinder ..........................................................................................................................504 T-18 Lift arm has large hydraulic drift .........................................................................................................................................504 T-19 Lift arm movement is unsteady during work ..................................................................................................................................505 T-20 Lift arm lowers momentarily when control lever is shifted from “Hold” to “Raise” ...........................................................................................505 T-21 Bucket does not tilt back ..................................................................................................................................................506 T-22 Bucket moves slowly or has insufficient tilt-back power ....................................................................................................................507 T-23 Bucket movement becomes slow during tilt back ..............................................................................................................................508 T-24 Bucket cannot be held down by the bucket cylinder ..........................................................................................................................508 T-25 Bucket has large hydraulic drift ...........................................................................................................................................508 T-26 Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”) ...................................................................................509 T-27 Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” ..........................................................................................509 T-28 Control levers of lift arm and dump move stiffly and sluggishly ............................................................................................................510 TROUBLESHOOTING OF JOYSTICK STEERING (J MODE)........................................................................................................................................511 FUNCTION.........................................................................................................................................................................512 TROUBLESHOOTING..................................................................................................................................................................512 TABLE OF FAILURE CODES...........................................................................................................................................................512 TABLE OF FAILURE MODES AND CAUSES................................................................................................................................................513 J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM ...................................................................................................................514 J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM ...................................................................................................................515 J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM ...................................................................................................................516 J-4 FAILURE CODE [12] ABNORMALITY IN CAUTION LAMP SYSTEM ............................................................................................................................517 J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F, N, R SIGNAL SYSTEM j, ..................................................................................................518 J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING SOLENOID * ..........................................................................................................519 J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID .............................................................................................................520 J-8 FAILURE CODE [32] DISCONNECTION IN L.H. STEERING SOLENOID .......................................................................................................................521 J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID .............................................................................................................522 J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM ..........................................................................................................523 J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM j, ................................................................................................524 J-12 FAILURE CODE [37] ABNORMALITY IN JOYSTICK STEERING LEVER POTENTIOMETER ........................................................................................................525 J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS * ............................................................................................................526 J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE ..........................................................................................................................527 J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM ..........................................................................................................................528 J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM ..................................................................................................................................529 J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM * ...............................................................................................................................530 J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM ..................................................................................................................................531 J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM .............................................................................................................................532 J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM .............................................................................................................................533 J-21 DISCONNECTION JOYSTICK STEERING N SWITCH SYSTEM.................................................................................................................................534 TROUBLESHOOTING OF AIR CONDITIONING..................................................................................................................................................535 AIR CONDITIONER / HEATER (EAGLE) ....................................................................................................................................................536 TROUBLESHOOTING..................................................................................................................................................................536 WIRING DIAGRAM...................................................................................................................................................................540 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................541 METHOD OF USING MANUAL...................................................................................................................................................................546 When removing or installing unit assemblies..........................................................................................................................................546 General precautions..................................................................................................................................................................546 Listing of special tools.............................................................................................................................................................546 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................................................................547 Precautions when carrying out removal work...........................................................................................................................................547 Precautions when carrying out installation work......................................................................................................................................548 Precautions when completing the operations...........................................................................................................................................549 RADIATOR.................................................................................................................................................................................550 REMOVAL..............................................................................................................................................................................550 INSTALLATION.........................................................................................................................................................................553 ENGINE ..................................................................................................................................................................................556 REMOVAL .............................................................................................................................................................................556 INSTALLATION ........................................................................................................................................................................562 DAMPER ..................................................................................................................................................................................568 REMOVAL..............................................................................................................................................................................568 INSTALLATION ........................................................................................................................................................................571 DISASSEMBLY .........................................................................................................................................................................574 ASSEMBLY ............................................................................................................................................................................576 TORQUE CONVERTER, TRANSMISSION ..........................................................................................................................................................580 REMOVAL .............................................................................................................................................................................580 INSTALLATION ........................................................................................................................................................................586 TORQUE CONVERTER ASSEMBLY ...............................................................................................................................................................593 DISASSEMBLY .........................................................................................................................................................................593 ASSEMBLY ............................................................................................................................................................................597 TORQUE CONVERTER VALVE ASSEMBLY .........................................................................................................................................................602 DISASSEMBLY .........................................................................................................................................................................602 ASSEMBLY ............................................................................................................................................................................602 PTO ASSEMBLY ............................................................................................................................................................................603 DISASSEMBLY .........................................................................................................................................................................603 ASSEMBLY ............................................................................................................................................................................605 TRANSMISSION ............................................................................................................................................................................608 DISASSEMBLY .........................................................................................................................................................................608 FINE DISASSEMBLY OF ROTATING CLUTCH ASSEMBLY.....................................................................................................................................621 ASSEMBLY ............................................................................................................................................................................623 FINE ASSEMBLY OF ROTATING CLUTCH ASSEMBLY........................................................................................................................................623 TRANSFER ASSEMBLY .......................................................................................................................................................................639 DISASSEMBLY .........................................................................................................................................................................639 ASSEMBLY ............................................................................................................................................................................647 TRANSMISSION VALVE ......................................................................................................................................................................657 REMOVAL .............................................................................................................................................................................657 INSTALLATION ........................................................................................................................................................................657 TRANSMISSION VALVE.......................................................................................................................................................................658 UPPER VALVE ASSEMBLY.................................................................................................................................................................658 DISASSEMBLY......................................................................................................................................................................659 ASSEMBLY.........................................................................................................................................................................659 LOWER VALVE ASSEMBLY.................................................................................................................................................................660 DISASSEMBLY......................................................................................................................................................................660 ASSEMBLY.........................................................................................................................................................................660 RELIEF VALVE ASSEMBLY................................................................................................................................................................661 DISASSEMBLY......................................................................................................................................................................661 ASSEMBLY.........................................................................................................................................................................661 CENTER SUPPORT ..........................................................................................................................................................................662 REMOVAL .............................................................................................................................................................................662 INSTALLATION ........................................................................................................................................................................663 DISASSEMBLY .........................................................................................................................................................................665 ASSEMBLY ............................................................................................................................................................................667 DRIVE SHAFT .............................................................................................................................................................................670 DISASSEMBLY .........................................................................................................................................................................670 ASSEMBLY ............................................................................................................................................................................672 FRONT AXLE ..............................................................................................................................................................................674 REMOVAL .............................................................................................................................................................................674 INSTALLATION ........................................................................................................................................................................676 REAR AXLE ...............................................................................................................................................................................678 REMOVAL .............................................................................................................................................................................678 INSTALLATION ........................................................................................................................................................................684 DIFFERENTIAL ............................................................................................................................................................................691 REMOVAL .............................................................................................................................................................................691 INSTALLATION ........................................................................................................................................................................693 DISASSEMBLY .........................................................................................................................................................................696 ASSEMBLY ............................................................................................................................................................................699 FINAL DRIVE .............................................................................................................................................................................705 DISASSEMBLY .........................................................................................................................................................................705 ASSEMBLY ............................................................................................................................................................................708 STEERING UNIT ...........................................................................................................................................................................711 REMOVAL .............................................................................................................................................................................711 INSTALLTION .........................................................................................................................................................................712 STEERING DEMAND VALVE ...................................................................................................................................................................713 REMOVAL .............................................................................................................................................................................713 INSTALLATION ........................................................................................................................................................................715 DIVERTER VALVE ..........................................................................................................................................................................717 DISASSEMBLY OF CHECK VALVE ASSEMBLY OF CHECK VALVE ..................................................................................................................................717 ASSEMBLY OF CHECK VALVE..............................................................................................................................................................717 DISASSEMBLY OF SELECTOR VALVE........................................................................................................................................................718 ASSEMBLY OF SELECTOR VALVE...........................................................................................................................................................718 BRAKE VALVE .............................................................................................................................................................................719 DISASSEMBLY .........................................................................................................................................................................719 ASSEMBLY ............................................................................................................................................................................721 BRAKE CHAMBER ...........................................................................................................................................................................723 DISASSEMBLY .........................................................................................................................................................................723 ASSEMBLY ............................................................................................................................................................................726 SLACK ADJUSTER ..........................................................................................................................................................................729 DISASSEMBLY .........................................................................................................................................................................729 ASSEMBLY ............................................................................................................................................................................730 BRAKE ASSEMBLY ..........................................................................................................................................................................731 REMOVAL .............................................................................................................................................................................731 INSTALLATION ........................................................................................................................................................................732 DISASSEMBLY .........................................................................................................................................................................733 ASSEMBLY ............................................................................................................................................................................735 SPRING CYLINDER .........................................................................................................................................................................738 REMOVAL .............................................................................................................................................................................738 INSTALLATION ........................................................................................................................................................................739 DISASSEMBLY .........................................................................................................................................................................740 ASSEMBLY ............................................................................................................................................................................741 PARKING BRAKE CALIPER ...................................................................................................................................................................742 REMOVAL .............................................................................................................................................................................742 INSTALLATION ........................................................................................................................................................................743 DISASSEMBLY .........................................................................................................................................................................744 ASSEMBLY ............................................................................................................................................................................745 PARKING BRAKE PAD .......................................................................................................................................................................746 REMOVAL .............................................................................................................................................................................746 INSTALLATION ........................................................................................................................................................................746 HYDRAULIC TANK AND FILTER CASE ..........................................................................................................................................................747 REMOVAL .............................................................................................................................................................................747 INSTALLATION ........................................................................................................................................................................749 HYDRAULIC PUMP ..........................................................................................................................................................................751 REMOVAL .............................................................................................................................................................................751 INSTALLATION ........................................................................................................................................................................752 SWITCH PUMP .............................................................................................................................................................................753 REMOVAL .............................................................................................................................................................................753 INSTALLATION ........................................................................................................................................................................754 PISTON PUMP .............................................................................................................................................................................755 DISASSEMBLY .........................................................................................................................................................................755 ASSEMBLY.............................................................................................................................................................................760 PPC VALVE ...............................................................................................................................................................................775 REMOVAL .............................................................................................................................................................................775 INSTALLATION ........................................................................................................................................................................777 DISASSEMBLY .........................................................................................................................................................................778 ASSEMBLY ............................................................................................................................................................................778 MAIN CONTROL VALVE ......................................................................................................................................................................779 REMOVAL .............................................................................................................................................................................779 INSTALLATION ........................................................................................................................................................................781 DISASSEMBLY..........................................................................................................................................................................784 ASSEMBLY.............................................................................................................................................................................786 HYDRAULIC CYLINDER ......................................................................................................................................................................788 DISASSEMBLY .........................................................................................................................................................................788 ASSEMBLY ............................................................................................................................................................................790 CENTER HINGE PIN ........................................................................................................................................................................792 REMOVAL .............................................................................................................................................................................792 INSTALLATION ........................................................................................................................................................................800 WORK EQUIPMENT...........................................................................................................................................................................809 REMOVAL..............................................................................................................................................................................809 INSTALLATION.........................................................................................................................................................................814 FUEL TANK................................................................................................................................................................................818 REMOVAL..............................................................................................................................................................................818 INSTALLATION.........................................................................................................................................................................820 40 MAINTENANCE STANDARD......................................................................................................................................................................823 ENGINE MOUNT.............................................................................................................................................................................826 TRANSMISSION MOUNT ......................................................................................................................................................................827 DAMPER ..................................................................................................................................................................................828 TORQUE CONVERTER CHARGING AND PPC PUMP ..................................................................................................................................................830 TORQUE CONVERTER ........................................................................................................................................................................832 TORQUE CONVERTER REGULATOR ..............................................................................................................................................................833 TRANSMISSION (1/2) ......................................................................................................................................................................834 TRANSMISSION (2/2) ......................................................................................................................................................................836 TRANSFER ................................................................................................................................................................................837 TRANSMISSION CONTROL VALVE ..............................................................................................................................................................838 UPPERVALVE...........................................................................................................................................................................838 LOWER VALVE..........................................................................................................................................................................840 SOLENOID VALVE.......................................................................................................................................................................842 DRIVE SHAFT .............................................................................................................................................................................843 CENTER SUPPORT ..........................................................................................................................................................................844 DIFFERENTIAL (1/2) ......................................................................................................................................................................845 DIFFERENTIAL (2/2) ......................................................................................................................................................................846 FINAL DRIVE .............................................................................................................................................................................848 AXLE MOUNT ..............................................................................................................................................................................850 CENTER HINGE PIN ........................................................................................................................................................................851 STEERING COLUMN .........................................................................................................................................................................853 DIVERTER VALVE ..........................................................................................................................................................................854 STEERING CYLINDER MOUNT .................................................................................................................................................................855 EMERGENCY STEERING PUMP .................................................................................................................................................................856 STEERING CYLINDER .......................................................................................................................................................................857 BRAKE CHAMBER ...........................................................................................................................................................................858 BRAKE VALVE .............................................................................................................................................................................860 SLACK ADJUSTER ..........................................................................................................................................................................862 PARKING BRAKE ...........................................................................................................................................................................863 BRAKE ...................................................................................................................................................................................864 SPRING CYLINDER .........................................................................................................................................................................866 CONTROL PUMP (BAR025) ...................................................................................................................................................................867 PPC VALVE ...............................................................................................................................................................................868 MAIN CONTROL VALVE ......................................................................................................................................................................870 BUCKET CYLINDER .........................................................................................................................................................................872 BOOM CYLINDER ...........................................................................................................................................................................873 BUCKET LINKAGE ..........................................................................................................................................................................874 BUCKET POSITIONER AND BOOM KICK-OUT .....................................................................................................................................................876
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