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KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF Download
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- KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:10001 & UP
- PUBLICATION NUMBER:EBM008002
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Description
KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL (SN:10001 & UP)
KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL (SN:10001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use It to full effect at every opportunity.
- This shop manual mainly contains the necessary technical Information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes’ are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component. as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU WA900-1 WHEEL LOADER SERVICE REPAIR MANUAL (SN:10001 & UP)
MAIN MENU...................................................................................................................................... 0 CONTENTS....................................................................................................................................... 2 01 GENERAL..................................................................................................................................... 25 GENERAL ASSEMBLY DRAWING................................................................................................................... 26 SPECIFICATIONS............................................................................................................................. 27 WEIGHT TABLE............................................................................................................................... 30 LIST OF LUBRICANT AND WATER................................................................................................................ 32 10 STRUCTURE AND FUNCTION...................................................................................................................... 35 POWER TRAIN................................................................................................................................ 38 POWER TRAIN SYSTEM......................................................................................................................... 39 ENGINE CONTROL............................................................................................................................. 40 SERVO CYLINDER............................................................................................................................. 41 RADIATOR AND COOLER........................................................................................................................ 45 DAMPER..................................................................................................................................... 46 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................... 47 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...................................................................................................... 48 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM..................................................................................................... 49 TORQUE CONVERTER........................................................................................................................... 50 TORQUE CONVERTER OIL FILTER................................................................................................................ 55 TRANSMISSION............................................................................................................................... 57 TRANSFER................................................................................................................................... 65 TRANSMISSION CONTROL VALVE................................................................................................................. 66 TORQUE CONVERTER OIL COOLER................................................................................................................ 84 DRIVE SHAFT................................................................................................................................ 85 CENTER SUPPORT............................................................................................................................. 86 AXLE....................................................................................................................................... 87 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 STEERING DEMAND VALVE......................................................................................................................106 TWO-WAY RESTRICTOR VALVE...................................................................................................................117 STEERING UNIT (ORBIT-ROLL VALVE)...........................................................................................................118 DIVERTER VALVE.............................................................................................................................121 BRAKE AND AIR PIPING.......................................................................................................................126 BRAKE AND AIR CIRCUIT DIAGRAM..............................................................................................................128 AIR GOVERNOR...............................................................................................................................130 AIR TANK...................................................................................................................................132 SAFETY VALVE...............................................................................................................................132 BRAKE VALVE................................................................................................................................133 RELAY VALVE................................................................................................................................137 TWO-WAY VALVE..............................................................................................................................138 BRAKE CHAMBER..............................................................................................................................139 SLACK ADJUSTER.............................................................................................................................141 BRAKE......................................................................................................................................144 PARKING BRAKE..............................................................................................................................145 HYDRAULIC PIPING...........................................................................................................................148 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................151 WORK EQUIPMENT LEVER LINKAGE...............................................................................................................153 HYDRAULIC TANK.............................................................................................................................154 MAIN PISTON PUMP...........................................................................................................................157 ES VALVE...................................................................................................................................165 SERVO VALVE................................................................................................................................167 PPC VALVE..................................................................................................................................170 PPC RELIEF VALVE...........................................................................................................................174 ACCUMULATOR................................................................................................................................175 MAIN CONTROL VALVE.........................................................................................................................176 LUBRICATION OF WORK EQUIPMENT..............................................................................................................190 WORK EQUIPMENT LINKAGE.....................................................................................................................192 BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................194 CAB........................................................................................................................................200 AIR CONDITIONER............................................................................................................................201 ELECTRIC CIRCUIT DIAGRAM...................................................................................................................206 MACHINE MONITOR SYSTEM.....................................................................................................................209 ENGINE STARTING CIRCUIT....................................................................................................................220 ENGINE STOP CIRCUIT........................................................................................................................221 PREHEATING CIRCUIT.........................................................................................................................222 ELECTRICAL TRANSMISSION CONTROL............................................................................................................226 KICK-DOWN SWITCH...........................................................................................................................231 ELECTRICAL PARKING BRAKE CONTROL...........................................................................................................237 TRANSMISSION CLUTCH OVERRUN CONTROLLER.....................................................................................................246 20 TESTING AND ADJUSTING.......................................................................................................................249 STANDARD VALUE TABLE FOR ENGINE............................................................................................................251 STANDARD VALUE TABLE FOR CHASSIS...........................................................................................................252 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................................................255 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..........................................................................................259 ADJUSTING VALVE CLEARANCE..................................................................................................................260 MEASURING COMPRESSION PRESSURE.............................................................................................................261 TESTING AND ADJUSTING FUEL INJECTION TIMING................................................................................................262 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR..............................................................................................264 MEASURING ACCELERATOR PEDAL OPERATING FORCE................................................................................................265 MEASURING ACCELERATOR PEDAL OPERATING ANGLE................................................................................................267 MEASURING SHIFT LEVER......................................................................................................................269 MEASURING ENGINE STALL SPEED...............................................................................................................270 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION................................................................................272 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.............................................................................................275 TIRE AND WHEEL.............................................................................................................................276 MEASURING STEERING WHEEL PLAY..............................................................................................................277 MEASURING OPERATING FORCE AND TIME OF STEERING WHEEL.......................................................................................278 MEASURING STEERING OIL PRESSURE............................................................................................................279 MEASURING EMERGENCY STEERING PRESSURE......................................................................................................280 ADJUSTING JOYSTICK STEERING................................................................................................................282 MEASURING BRAKE PEDAL......................................................................................................................285 MEASURING AIR PRESSURE.....................................................................................................................286 TESTING BRAKE PERFORMANCE..................................................................................................................288 CHECKING BRAKE PISTON LEAKAGE..............................................................................................................289 MEASURING WEAR OF BRAKE DISC...............................................................................................................290 BLEEDING AIR FROM BRAKE SYSTEM.............................................................................................................291 TESTING PARKING BRAKE PERFORMANCE..........................................................................................................292 CHECKING AND ADJUSTING PARKING BRAKE.......................................................................................................293 MEASURING DUMP AND LIFT CONTROL LEVERS.....................................................................................................295 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT.............................................................................................297 AIR BLEEDING FROM PISTON PUMP..............................................................................................................300 MEASURING WORK EQUIPMENT...................................................................................................................301 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................................................302 ADJUSTING BUCKET POSITIONER................................................................................................................303 ADJUSTING BOOM KICK-OUT....................................................................................................................304 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE).............................................................................................305 TROUBLESHOOTING............................................................................................................................307 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................308 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................309 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................310 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................318 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................320 JUDGMENT ON POWER TRAIN................................................................................................................328 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................330 CONNECTOR ARRANGEMENT DIAGRAM..........................................................................................................331 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................332 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..............................................................................................337 S-1 Starting performance is poor (Starting always takes time)......................................................................338 S-2 Engine does not start..........................................................................................................339 (1) Engine does not turn.......................................................................................................339 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....................................................340 (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...................................................341 S-3 Engine does not pick up smoothly (Follow-up is poor)...........................................................................342 S-4 Engine stops during operations (For V type engine, including cases where one bank stops).......................................343 S-5 Engine does not rotate smoothly (hunting)......................................................................................344 S-6 Engine lacks output (no power).................................................................................................345 S-7 Exhaust gas is black (incomplete combustion)...................................................................................346 S-8 Oil consumption is excessive (or exhaust gas is blue)..........................................................................347 S-9 Oil becomes contaminated quickly...............................................................................................348 S-10 Fuel consumption is excessive.................................................................................................349 S-11 Oil is in cooling water, or water spurts back, or water level goes down.......................................................350 S-12 Oil pressure lamp lights up (drop in oil pressure)............................................................................351 S-13 Oil level rises...............................................................................................................352 S-14 Water temperature becomes too high (overheating)..............................................................................353 S-15 Abnormal noise is made........................................................................................................354 S-16 Vibration is excessive........................................................................................................355 TROUBLESHOOTING OF ENGINE, TRANSMISSION, PARKING BRAKE ELECTRIC SYSTEM (E MODE)........................................................357 ELECTRICAL CIRCUIT SYSTEM..........................................................................................................358 E-1 Engine does not start..........................................................................................................362 a) Inspection of starting circuit..............................................................................................362 b) Inspection of battery - battery relay - starting switch.....................................................................362 c) Inspection of starting switch - engine stop motor...........................................................................364 E-2 Engine does not stop...........................................................................................................366 E-3 Engine stops when traveling....................................................................................................366 E-4 Parking brake does not work....................................................................................................367 a) If parking brake does not work when parking brake switch is ON (applied)....................................................367 b) If parking brake does not work then air pressure has dropped. (does not work as emergency brake)............................367 E-5 Parking brake is not released..................................................................................................368 E-6 Parking brake is released when starting switch is turned.......................................................................370 E-7 When parking brake is applied, transmission does not enter neutral (Parking brake is working normally).........................370 E-8 Transmission does not work normally............................................................................................371 a) Problem in parking brake, transmission cut-off switch, neutral relay circuit................................................372 b) Defective continuity in FORWAED solenoid circuit............................................................................374 c) Defective continuity in REVERCE solenoid circuit............................................................................376 d) Contact in F-R circuit (1/2)................................................................................................378 e) Problem in speed solenoid circuit (1/2).....................................................................................382 f) Contact in speed circuit (1/31).............................................................................................386 E-9 Kick-down switch does not work (1/2) (normal F1 - F3 switches correctly).......................................................392 E-10 Kick-down only works when kick-down switch is ON. (Kick-down switch relay does not carry out self-hold operation).............395 E-11 Kick-down operation is not canceled...........................................................................................396 E-12 Kick-down works mistake when traveling in F2..................................................................................398 E-13 Machine does not travel when kick-down switch is pressed......................................................................398 E-14 Preheating is not carried out.................................................................................................400 a) Preheating is not carried out automatically.................................................................................401 b) Preheating is not carried out normally or automatically.....................................................................402 E-15 Preheating stays ON...........................................................................................................404 a) Automatic preheating is not canceled........................................................................................404 b) Preheating continues even when heater switch is turned OFF..................................................................406 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................409 ELECTRICAL CIRCUIT SYSTEM..........................................................................................................411 M-1 BRAKE OIL LEVEL flashes when engine is stopped.................................................................................413 M-2 ENGINE OIL LEVEL engine is stopped flashes when................................................................................413 M-3 RADIATOR WATER LEVEL flashes when engine is stopped............................................................................415 M-4 BATTERY CHARGE flashes when engine is running..................................................................................415 M-5 TRANSMISSION OIL FILTER CLOGGING flashes when engine is running................................................................417 M-6 FUEL LEVEL flashes when engine is running......................................................................................418 M-7 BRAKE LINE FAILURE flashes when engine is running..............................................................................418 M-8 ENGINE OIL PRESSURE flashes when engine is running.............................................................................420 M-9 RADIATOR WATER LEVEL flashes when engine is running............................................................................420 M-10 DROP IN AIR PRESSURE flashes when engine is running...........................................................................422 M-11 ENGINE WATER TEMPERATURE flashes when engine is running.......................................................................422 M-12 TORQUE CONVERTER OIL TEMPERATURE flashes when engine is running...............................................................422 M-13 PARKING BRAKE lights up abnormally, or does not light up......................................................................424 a) If (PARKING BRAKE) stays lighted up.........................................................................................424 b) if (PARKING BRAKE) does not light up........................................................................................424 M-14 WORKING LAMP lights up abnormally, or does not light up.......................................................................426 a) If WORKING LAMP stays lighted up............................................................................................426 b) If WORKING LAMP does not light up...........................................................................................426 M-15 PREHEATING lights up, or does not light up....................................................................................428 a) PREHEATING lights up........................................................................................................428 b) PREHEATING does not light up................................................................................................428 M-16 MAIN STEERING FAILURE lights up, or does not light up.........................................................................430 a) MAIN STEERING FAILURE lights up.............................................................................................430 b) MAIN STEERING FAILURE does not light up.....................................................................................430 M-17 TRANSMISSION CUT-OFF lights up, or does not light up..........................................................................432 a) TRANSMISSION CUT-OFF lights up..............................................................................................432 b) TRANSMISSION CUT-OFF does not light up......................................................................................432 M-18 Turn signal Hi beam light up, or do not light up..............................................................................434 a) Turn signal (right) pilot display lights up.................................................................................434 b) Turn signal (left) pilot display lights up..................................................................................435 c) Turn signal (right) pilot display does not light up.........................................................................436 d) Turn signal (left) pilot display does not light up..........................................................................436 e) Hi beam pilot does not light up.............................................................................................437 f) Hi beam pilot stays lighted up..............................................................................................437 M-19 Turn signal does not flash even when hazard switch is turned ON...............................................................439 M-20 Speedometer display does not work normally....................................................................................441 M-21 Hourmeter does not work normally..............................................................................................442 M-22 When starting switch is turned ON, monitor panel does not work, or only part works............................................443 a) None of monitor panel lights up.............................................................................................443 b) Except for speedometer module, none of monitor panel lights up..............................................................443 c) Non of CAUTION items light up...............................................................................................444 d) Some other parts do not light up............................................................................................444 M-23 When starting switch is turned ON, all monitor panel lights up, but does not go out...........................................444 M-24 ENGINE OIL PRESSURE flashes or BATTERY CHARGE flashes when engine is stopped..................................................445 a) ENGINE OIL PRESSURE flashes, and alarm buzzer and warning lamp are actuated.................................................445 b) BATTERY CHARGE flashes, and warning lamp lights up but does not go out......................................................445 M-25 None of machine monitor panel lighting lights up, or part does not light up...................................................447 a) Even when combination lamp is placed at SMALL, none of panel lighting lights up.............................................447 b) Even when working lamp switched ON, none of monitor panel lights up.........................................................448 c) Even when starting switch is turned ON, none of monitor panel lights up.....................................................450 d) Part of panel does not light up.............................................................................................450 M-26 When starting switch is turned to ON position (engine stopped), buzzer does not sound for 1 sec. CAUTION item is flashing.....452 M-27 No abnormality is shown on monitor display, but alarm buzzer sounds...........................................................452 M-28 When starting switch is turned to ON position (engine stopped), warning lamp does not light up for 2 sec. CAUTION item is ....454 M-29 No abnormality is shown on monitor display, but warning lamp lights up .......................................................455 M-30 Abnormality in fuel gauge.....................................................................................................456 a) lf nothing is displayed in display area.....................................................................................456 b) lf indicator remains at FULL................................................................................................456 M-31 Abnormality in air pressure gauge.............................................................................................457 a) If nothing is displayed in display area.....................................................................................457 b) If indicator remains at maximum level.......................................................................................457 M-32 Abnormality in engine water temperature gauge.................................................................................458 a) If nothing is displayed in display area.....................................................................................458 b) If indicator remains at minimum level.......................................................................................458 M-33 Abnormality in torque converter oil temperature gauge.........................................................................460 a) If nothing is displayed in display area.....................................................................................460 b) lf indicator remains at minimum level.......................................................................................460 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE)............................................................................461 POWER TRAIN........................................................................................................................462 T-1 Machine does not move......................................................................................................462 T-2 Machine lacks power or speed...............................................................................................463 T-3 Excessive time lag when starting machine or shifting gear..................................................................464 T-4 Torque converter oil, temperature too high.................................................................................465 STEERING SYSTEM....................................................................................................................466 T-5 Steering wheel does not turn...............................................................................................466 T-6 Steering wheel is sluggish.................................................................................................467 T-7 Steering wheel moves unsteadily or is subjected to large shock.............................................................468 T-8 Machine tends to turn naturally in one particular direction when traveling.................................................468 BRAKE SYSTEM.......................................................................................................................469 T-9 Air pressure does not rise at all..........................................................................................469 T-10 Air pressure does not rise to the specified range.........................................................................470 T-11 Brake is ineffective or not very effective................................................................................471 T-12 Brake does not release, or drags..........................................................................................472 T-13 Parking brake does not release, or drags..................................................................................473 WORK EQUIPMENT.....................................................................................................................474 T-14 Lift arm does not rise....................................................................................................474 T-15 Lift arm moves slowly or does not have sufficient lifting power...........................................................475 T-16 Lift arm movement becomes slow after it reaches a certain height..........................................................476 T-17 Bucket cannot be held down with lift arm cylinder.........................................................................476 T-18 Lift arm has large hydraulic drift........................................................................................476 T-19 Lift arm movement is unsteady during work.................................................................................477 T-20 Lift arm lowers momentarily when control lever is shifted from "Hold" to "Raise"..........................................477 T-21 Bucket does not tilt back.................................................................................................478 T-22 Bucket moves slowly or has insufficient tilt back power...................................................................479 T-23 Bucket movement becomes slow during tilt back.............................................................................480 T-24 Bucket cannot be held down by the bucket cylinder.........................................................................480 T-25 Bucket has large hydraulic drift..........................................................................................480 T-26 Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")...................................481 T-27 Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".........................................481 T-28 Control levers of lift arm and dump move stiffly and sluggishly...........................................................482 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)........................................................................483 1. FUNCTION........................................................................................................................485 2. TROUBLESHOOTING.................................................................................................................485 3. TABLE OF FAILURE CODES..........................................................................................................485 4. TABLE OF FAILURE MODES AND CAUSES...............................................................................................486 J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM...................................................................487 J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM...................................................................488 J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY SYSTEM...................................................................489 J-4 FAILURE CODE [19] ABNORMALITY IN CAUTION LAMP SYSTEM...........................................................................490 J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R SYSTEM................................................................491 J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING SOLENOID.............................................................492 J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID.............................................................493 J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L.H. STEERING SOLENOID.............................................................494 J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID.............................................................495 J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM...........................................................496 J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM......................................................497 J-12 FAILURE CODE [37] ABNORMALITY IN JOYSTICK STEERING POTENTIOMETER..............................................................498 J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS...............................................................499 J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE.........................................................................500 J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM.........................................................................501 J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM.................................................................................502 J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM.................................................................................503 J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM.................................................................................504 J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM............................................................................505 J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM............................................................................506 J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM............................................................................507 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................509 METHOD OF USING MANUAL.....................................................................................................................511 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................513 FUEL INJECTION PUMP FOR RIGHT BANK.........................................................................................................516 Removal and Installation...............................................................................................................516 FUEL INJECTION PUMP FOR LEFT BANK..........................................................................................................517 Removal and Installation...............................................................................................................517 ENGINE OIL COOLER .........................................................................................................................518 Removal and Installatioin..............................................................................................................518 WATER PUMP.................................................................................................................................519 Removal and Installation...............................................................................................................519 NOZZLE HOLDER..............................................................................................................................520 Removal and Installation...............................................................................................................520 CYLINDER HEAD..............................................................................................................................521 Removal................................................................................................................................521 Installation...........................................................................................................................523 RADIATOR...................................................................................................................................526 Removal................................................................................................................................526 Installation...........................................................................................................................529 ENGINE.....................................................................................................................................532 Removal................................................................................................................................532 Installation...........................................................................................................................538 DAMPER.....................................................................................................................................545 Removal................................................................................................................................545 Installation...........................................................................................................................545 Disassembly............................................................................................................................551 Assembly...............................................................................................................................553 TORQUE CONVERTER, TRANSMISSION.............................................................................................................557 Removal................................................................................................................................557 Installation...........................................................................................................................563 TORQUE CONVERTER...........................................................................................................................570 Disassembly............................................................................................................................570 Assembly...............................................................................................................................574 TORQUE CONVERTER VALVE.....................................................................................................................579 Disassembly and Assembly...............................................................................................................579 PTO........................................................................................................................................580 Disassembly............................................................................................................................580 Assembly...............................................................................................................................582 TRANSMISSION...............................................................................................................................585 Disassembly............................................................................................................................585 Assembly...............................................................................................................................600 TRANSFER...................................................................................................................................616 Disassembly............................................................................................................................616 Assembly...............................................................................................................................624 TRANSMISSION VALVE.........................................................................................................................636 Disassembly and Assembly...............................................................................................................636 CENTER SUPPORT.............................................................................................................................640 Removal................................................................................................................................640 Installation...........................................................................................................................641 Disassembly............................................................................................................................643 Assembly...............................................................................................................................645 DRIVE SHAFT................................................................................................................................648 Disassembly............................................................................................................................648 Assembly...............................................................................................................................650 FRONT AXLE.................................................................................................................................652 Removal................................................................................................................................652 Installation...........................................................................................................................654 REAR AXLE..................................................................................................................................656 Removal................................................................................................................................656 Installation...........................................................................................................................662 DIFFERENTIAL...............................................................................................................................669 Removal................................................................................................................................669 Installation...........................................................................................................................671 Disassembly............................................................................................................................674 Assembly...............................................................................................................................677 FINAL DRIVE................................................................................................................................683 Disassembly............................................................................................................................683 Assembly...............................................................................................................................686 STEERING UNIT..............................................................................................................................689 Removal................................................................................................................................689 Installation...........................................................................................................................690 STEERING DEMAND VALVE......................................................................................................................691 Removal................................................................................................................................691 Installation...........................................................................................................................693 DIVERTER VALVE.............................................................................................................................695 Disassembly and Assembly...............................................................................................................695 BRAKE VALVE................................................................................................................................697 Disassembly............................................................................................................................697 Assembly...............................................................................................................................699 BRAKE CHAMBER..............................................................................................................................701 Disassembly............................................................................................................................701 Assembly...............................................................................................................................704 SLACK ADJUSTER.............................................................................................................................707 Disassembly............................................................................................................................707 Assembly...............................................................................................................................708 BRAKE......................................................................................................................................709 Removal................................................................................................................................709 Installation...........................................................................................................................710 Disassembly............................................................................................................................711 Assembly...............................................................................................................................713 SPRING CYLINDER............................................................................................................................716 Removal................................................................................................................................716 Installation...........................................................................................................................717 Disassembly............................................................................................................................718 Assembly...............................................................................................................................719 PARKING BRAKE CALIPER......................................................................................................................720 Removal................................................................................................................................720 Installation...........................................................................................................................721 Disassembly............................................................................................................................722 Assembly...............................................................................................................................723 PARKING BRAKE PAD..........................................................................................................................724 Removal and Installation...............................................................................................................724 HYDRAULIC TANK AND FILTER CASE.............................................................................................................725 Removal................................................................................................................................725 Installation...........................................................................................................................727 HYDRAULIC PUMP ............................................................................................................................729 Removal................................................................................................................................729 Installation...........................................................................................................................730 SWITCH PUMP................................................................................................................................731 Removal................................................................................................................................731 Installation...........................................................................................................................732 PISTON PUMP................................................................................................................................733 Disassembly............................................................................................................................733 Assembly...............................................................................................................................738 PPC VALVE..................................................................................................................................753 Removal................................................................................................................................753 Installation...........................................................................................................................755 Disassembly and Assembly...............................................................................................................756 MAIN CONTROL VALVE.........................................................................................................................757 Removal................................................................................................................................757 Installation...........................................................................................................................759 Disassembly............................................................................................................................762 Assembly...............................................................................................................................764 HYDRAULIC CYLINDER.........................................................................................................................766 Disassembly............................................................................................................................766 Assembly...............................................................................................................................768 CENTER HINGE PIN...........................................................................................................................770 Removal................................................................................................................................770 Installation...........................................................................................................................778 WORK EQUIPMENT.............................................................................................................................787 Removal................................................................................................................................787 Installation...........................................................................................................................792 FUEL TANK..................................................................................................................................796 Removal................................................................................................................................796 Installation...........................................................................................................................798 40 MAINTENANCE STANDARD........................................................................................................................801 ENGINE MOUNT...............................................................................................................................802 TRANSMISSION MOUNT.........................................................................................................................803 DAMPER.....................................................................................................................................804 TORQUE CONVERTER CHARGING PUMP AND PPC PUMP................................................................................................805 TORQUE CONVERTER...........................................................................................................................806 TORQUE CONVERTER REGULATOR VALVE...........................................................................................................807 TRANSMISSION...............................................................................................................................808 TRANSFER...................................................................................................................................811 TRANSMISSION CONTROL VALVE.................................................................................................................812 DRIVE SHAFT................................................................................................................................817 CENTER SUPPORT.............................................................................................................................818 DIFFERENTIAL...............................................................................................................................819 FINAL DRIVE................................................................................................................................822 AXLE MOUNT.................................................................................................................................824 CENTER HINGE PIN...........................................................................................................................826 STEERING COLUMN............................................................................................................................828 DIVERTER VALVE.............................................................................................................................829 STEERING CYLINDER MOUNT....................................................................................................................830 EMERGENCY STEERING PUMP....................................................................................................................831 STEERING CYLINDER..........................................................................................................................832 BRAKE CHAMBER..............................................................................................................................833 BRAKE VALVE................................................................................................................................834 SLACK ADJUSTER.............................................................................................................................836 PARKING BRAKE..............................................................................................................................837 BRAKE......................................................................................................................................838 SPRING CYLINDER............................................................................................................................840 CONTROL PUMP...............................................................................................................................841 PPC VALVE..................................................................................................................................842 MAIN CONTROL VALVE.........................................................................................................................844 DUMP CYLINDER..............................................................................................................................846 LIFT CYLINDER..............................................................................................................................847 BUCKET LINKAGE.............................................................................................................................848 BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................................850 90 OTHERS......................................................................................................................................851 HYDRAULIC PIPING...........................................................................................................................855 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................856 WORK EQUIPMENT HYDRAULIC CIRCUIT MACHINE WITH JOYSTICK STEERING............................................................................857 ELECTRIC CIRCUIT DIAGRAM...................................................................................................................858 ELECTRIC CIRCUIT DIAGRAM...................................................................................................................859 ELECTRIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING)..................................................................................860 CONNECTOR ARRANGEMENT DIAGRAM..............................................................................................................861 ELECTRICAL CIRCUIT SYSTEM .................................................................................................................862 ELECTRICAL CIRCUIT SYSTEM..................................................................................................................863
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