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Komatsu Wheel Loader WA600-1LC Shop Manual CEBMW26030 – PDF DOWNLOAD
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Komatsu Wheel Loader WA600-1LC Shop Manual
MACHINE MODEL SERIAL NUMBERS
WA600-1 LC A50001 and up
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Description
Komatsu Wheel Loader WA600-1LC Shop Manual
FILE DETAILS:
Komatsu Wheel Loader WA600-1LC Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA600-1LC
Serial Number: A50001 and up
Book Code: CEBMW26030
Language: English
Pages: 1018
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Wheel Loader WA600-1LC Shop Manual
1 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, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It 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.
TABLE OF CONTENTS:
Komatsu Wheel Loader WA600-1LC Shop Manual
MAIN MENU..................................................................................................................................................................................................................................................................... 0 CONTENTS...................................................................................................................................................................................................................................................................... 5 10 ENGINE .................................................................................................................................................................................................................................................................... 19 12 TESTING AND ADJUSTING ................................................................................................................................................................................................................................................. 19 STANDARD VALUE TABLE ................................................................................................................................................................................................................................................. 20 TOOL LIST ............................................................................................................................................................................................................................................................ 21 VALVE CLEARANCE ...................................................................................................................................................................................................................................................... 22 FUEL INJECTION ....................................................................................................................................................................................................................................................... 23 BLOW-BY PRESSURE ..................................................................................................................................................................................................................................................... 24 ALTERNATOR FAN BELT .................................................................................................................................................................................................................................................. 25 FAN BELT TENSIONER ................................................................................................................................................................................................................................................... 26 EXHAUST GAS COLOR .................................................................................................................................................................................................................................................... 27 OIL PRESSURE ......................................................................................................................................................................................................................................................... 29 OIL TEMPERATURE ...................................................................................................................................................................................................................................................... 30 ACCELERATOR PEDAL .................................................................................................................................................................................................................................................... 31 OPERATING FORCE................................................................................................................................................................................................................................................... 31 OPERATING ANGLE................................................................................................................................................................................................................................................... 32 13 DISASSEMBLY AND ASSEMBLY .............................................................................................................................................................................................................................................. 35 STARTING MOTOR ....................................................................................................................................................................................................................................................... 37 REMOVAL........................................................................................................................................................................................................................................................... 37 INSTALLATION ..................................................................................................................................................................................................................................................... 37 ALTERNATOR .......................................................................................................................................................................................................................................................... 38 REMOVAL........................................................................................................................................................................................................................................................... 38 INSTALLATION ..................................................................................................................................................................................................................................................... 38 OIL COOLER ........................................................................................................................................................................................................................................................... 39 REMOVAL........................................................................................................................................................................................................................................................... 39 INSTALLATION ..................................................................................................................................................................................................................................................... 39 FUEL INJECTION PUMP .................................................................................................................................................................................................................................................. 40 REMOVAL .......................................................................................................................................................................................................................................................... 40 INSTALLATION ..................................................................................................................................................................................................................................................... 40 WATER PUMP ........................................................................................................................................................................................................................................................... 41 REMOVAL .......................................................................................................................................................................................................................................................... 41 INSTALLATION ..................................................................................................................................................................................................................................................... 41 NOZZLE HOLDER ........................................................................................................................................................................................................................................................ 42 REMOVAL........................................................................................................................................................................................................................................................... 42 INSTALLATION ..................................................................................................................................................................................................................................................... 42 TURBOCHARGER ......................................................................................................................................................................................................................................................... 43 REMOVAL........................................................................................................................................................................................................................................................... 43 INSTALLATION ..................................................................................................................................................................................................................................................... 43 AIR COMPRESSOR ....................................................................................................................................................................................................................................................... 44 REMOVAL........................................................................................................................................................................................................................................................... 44 INSTALLATION ..................................................................................................................................................................................................................................................... 45 CYLINDER HEAD ........................................................................................................................................................................................................................................................ 46 REMOVAL........................................................................................................................................................................................................................................................... 46 INSTALLATION ..................................................................................................................................................................................................................................................... 48 RADIATOR ............................................................................................................................................................................................................................................................. 50 REMOVAL........................................................................................................................................................................................................................................................... 50 INSTALLATION ..................................................................................................................................................................................................................................................... 53 ENGINE................................................................................................................................................................................................................................................................ 56 REMOVAL........................................................................................................................................................................................................................................................... 56 INSTALLATION ..................................................................................................................................................................................................................................................... 64 FUEL TANK ............................................................................................................................................................................................................................................................ 72 REMOVAL........................................................................................................................................................................................................................................................... 72 INSTALLATION ..................................................................................................................................................................................................................................................... 74 14 MAINTENANCE STANDARD .................................................................................................................................................................................................................................................. 77 ENGINE MOUNT ......................................................................................................................................................................................................................................................... 78 20 POWER TRAIN................................................................................................................................................................................................................................................................ 79 21 STRUCTURE AND FUNCTION ................................................................................................................................................................................................................................................ 79 GENERAL .............................................................................................................................................................................................................................................................. 81 POWER TRAIN....................................................................................................................................................................................................................................................... 82 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................................................................................................................................................. 84 HYDRAULIC ClRCUli DIAGRAM FOR POWER TRAIN......................................................................................................................................................................................................................... 85 TORQUE CONVERTER AND TRANSMISSION PIPING ............................................................................................................................................................................................................................. 86 TORQUE CONVERTER OIL COOLER .......................................................................................................................................................................................................................................... 87 TORQUE CONVERTER...................................................................................................................................................................................................................................................... 88 TORQUE CONVERTER RELIEF VALVE ....................................................................................................................................................................................................................................... 91 TORQUE CONVERTER REGULATOR VALVE ..................................................................................................................................................................................................................................... 92 TORQUE CONVERTER OIL FILTER .......................................................................................................................................................................................................................................... 94 LUBRICATION BY-PASS VALVE ............................................................................................................................................................................................................................................ 95 TRANSMISSION MOUNT ................................................................................................................................................................................................................................................... 96 TRANSMISSION ......................................................................................................................................................................................................................................................... 97 TRANSMISSION foldout # 5 ......................................................................................................................................................................................................................................... 98 FORWARD 1 st...................................................................................................................................................................................................................................................... 100 Power pass.................................................................................................................................................................................................................................................... 100 Hydraulic circuit schematics.................................................................................................................................................................................................................................. 102 TRANSMISSION CONTROL VALVE ........................................................................................................................................................................................................................................... 104 UPPER VALVE....................................................................................................................................................................................................................................................... 105 LOWER VALVE....................................................................................................................................................................................................................................................... 106 MAIN RELIEF VALVE................................................................................................................................................................................................................................................. 107 PRIORITY VALVE.................................................................................................................................................................................................................................................... 108 MODULATING VALVE AND QUICK RETURN VALVE........................................................................................................................................................................................................................... 109 REDUCING VALVE.................................................................................................................................................................................................................................................... 112 ACCUMULATOR VALVE................................................................................................................................................................................................................................................. 113 PILOT REDUCING VALVE.............................................................................................................................................................................................................................................. 115 TRANSMISSION SOLENOID VALVE .......................................................................................................................................................................................................................................... 116 EMERGENCY MANUAL SPOOL ............................................................................................................................................................................................................................................... 118 TRANSMISSION PILOT OIL FILTER ........................................................................................................................................................................................................................................ 119 TRANSFER ............................................................................................................................................................................................................................................................. 120 DRIVE SHAFT .......................................................................................................................................................................................................................................................... 121 CENTER SUPPORT ....................................................................................................................................................................................................................................................... 122 AXLE MOUNT ........................................................................................................................................................................................................................................................... 124 AXLES ................................................................................................................................................................................................................................................................ 126 FRONT............................................................................................................................................................................................................................................................. 126 REAR.............................................................................................................................................................................................................................................................. 127 DIFFERENTIAL ......................................................................................................................................................................................................................................................... 128 FRONT............................................................................................................................................................................................................................................................. 128 REAR.............................................................................................................................................................................................................................................................. 129 TORQUE PROPORTIONING DIFFERENTIAL................................................................................................................................................................................................................................. 131 FINAL DRIVE........................................................................................................................................................................................................................................................... 132 TIRE AND WHEEL ....................................................................................................................................................................................................................................................... 133 22 TESTING AND ADJUSTING ................................................................................................................................................................................................................................................. 135 STANDARD VALUE TABLE ................................................................................................................................................................................................................................................. 136 TOOL LIST FOR TESTING AND ADJUSTING .................................................................................................................................................................................................................................. 137 MEASURING ENGINE STALL SPEED ......................................................................................................................................................................................................................................... 138 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION ......................................................................................................................................................................................................... 140 MEASURING SHIFT LEVER ................................................................................................................................................................................................................................................ 142 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ...................................................................................................................................................................................................................... 144 TIRE AND WHEEL ....................................................................................................................................................................................................................................................... 146 TROUBLESHOOTING ...................................................................................................................................................................................................................................................... 147 PRECAUTIONS WHEN TROUBLESHOOTING.................................................................................................................................................................................................................................. 148 METHOD OF READING TROUBLESHOOTING TABLES.......................................................................................................................................................................................................................... 150 PREVENTING RECURRENCE OF TROUBLE.................................................................................................................................................................................................................................. 152 JUDGEMENT ON POWER TRAIN.......................................................................................................................................................................................................................................... 153 TROUBLESHOOTING TABLE............................................................................................................................................................................................................................................. 155 Machine does not move......................................................................................................................................................................................................................................... 155 Machine lacks power or speed.................................................................................................................................................................................................................................. 157 Excessive time lag when starting machine or shifting gear..................................................................................................................................................................................................... 158 Torque converter oil temperature too high..................................................................................................................................................................................................................... 159 23 DISASSEMBLY AND ASSEMBLY .............................................................................................................................................................................................................................................. 161 HYDRAULIC PUMP........................................................................................................................................................................................................................................................ 166 REMOVAL........................................................................................................................................................................................................................................................... 163 TRANSMISSION LUBRICATING AND TORQUE CONVERTER CHARGING AND PPC PUMP........................................................................................................................................................................................... 163 INSTALLATION...................................................................................................................................................................................................................................................... 166 TRANSMISSION LUBRICATING AND TORQUE CONVERTER CHARGING AND PPC PUMP........................................................................................................................................................................................... 166 TORQUE CONVERTER ..................................................................................................................................................................................................................................................... 169 REMOVAL........................................................................................................................................................................................................................................................... 169 lNSTALlATlON...................................................................................................................................................................................................................................................... 173 DISASSEMBLY....................................................................................................................................................................................................................................................... 178 ASSEMBLY.......................................................................................................................................................................................................................................................... 183 TRANSMISSION ......................................................................................................................................................................................................................................................... 189 REMOVAL .......................................................................................................................................................................................................................................................... 189 INSTALLATION ..................................................................................................................................................................................................................................................... 194 DISASSEMBLY ...................................................................................................................................................................................................................................................... 200 ASSEMBLY ......................................................................................................................................................................................................................................................... 215 TRANSFER ASSEMBLY..................................................................................................................................................................................................................................................... 231 DISASSEMBLY ...................................................................................................................................................................................................................................................... 231 ASSEMBLY ......................................................................................................................................................................................................................................................... 240 TRANSMISSION CONTROL VALVE............................................................................................................................................................................................................................................ 166 REMOVAL .......................................................................................................................................................................................................................................................... 251 INSTALLATION ..................................................................................................................................................................................................................................................... 252 DISASSEMBLY AND ASSEMBLY OF SPEED VALVE ASSEMBLY ................................................................................................................................................................................................................. 253 DISASSEMBLY OF SPEED VALVE ASSEMBLY........................................................................................................................................................................................................................... 254 ASSEMBLY OF SPEED VALVE ASSEMBLY.............................................................................................................................................................................................................................. 254 DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE ASSEMBLY ............................................................................................................................................................................................................ 255 DISASSEMBLY OF MODULATINGVALVEASSEMBLY........................................................................................................................................................................................................................ 256 ASSEMBLY OF MODULATING VALVE ASSEMBLY......................................................................................................................................................................................................................... 256 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..................................................................................................................................................................................................................... 256 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY........................................................................................................................................................................................................................ 256 FRONT DIFFERENTIAL ................................................................................................................................................................................................................................................... 259 REMOVAL .......................................................................................................................................................................................................................................................... 262 INSTALLATION ..................................................................................................................................................................................................................................................... 259 REAR DIFFERENTIAL..................................................................................................................................................................................................................................................... 262 REMOVAL........................................................................................................................................................................................................................................................... 262 INSTALLATION...................................................................................................................................................................................................................................................... 265 DIFFERENTIAL GEAR ASSEMBLY ........................................................................................................................................................................................................................................... 269 DISASSEMBLY ...................................................................................................................................................................................................................................................... 269 FINE DISASSEMBLY OF PINION ASSEMBLY........................................................................................................................................................................................................................... 271 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY........................................................................................................................................................................................................... 272 ASSEMBLY.......................................................................................................................................................................................................................................................... 273 FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY.............................................................................................................................................................................................................. 273 FINE ASSEMBLY OF PINION ASSEMBLY.............................................................................................................................................................................................................................. 274 ASSEMBLY OF DIFFERENTIAL ASSEMBLY............................................................................................................................................................................................................................. 275 FRONT AXLE ........................................................................................................................................................................................................................................................... 280 REMOVAL .......................................................................................................................................................................................................................................................... 280 INSTALIATION ..................................................................................................................................................................................................................................................... 282 REAR AXLE............................................................................................................................................................................................................................................................. 284 REMOVAL .......................................................................................................................................................................................................................................................... 284 INSTALLATION...................................................................................................................................................................................................................................................... 288 CENTER SUPPORT ....................................................................................................................................................................................................................................................... 292 REMOVAL .......................................................................................................................................................................................................................................................... 292 INSTALLATION ..................................................................................................................................................................................................................................................... 293 DISASSEMBLY ...................................................................................................................................................................................................................................................... 295 ASSEMBLY ......................................................................................................................................................................................................................................................... 297 DRIVE SHAFT........................................................................................................................................................................................................................................................... 300 DISASSEMBLY ...................................................................................................................................................................................................................................................... 300 ASSEMBLY.......................................................................................................................................................................................................................................................... 302 FINAL DRIVE........................................................................................................................................................................................................................................................... 304 DISASSEMBLY ...................................................................................................................................................................................................................................................... 304 ASSEMBLY ......................................................................................................................................................................................................................................................... 307 24 MAINTENANCE STANDARD................................................................................................................................................................................................................................................... 311 TRANSMISSION MOUNT ................................................................................................................................................................................................................................................... 312 TORQUE CONVERTER ..................................................................................................................................................................................................................................................... 314 TORQUE CONVERTER REGULATOR VALVE ..................................................................................................................................................................................................................................... 316 TRANSMISSION ......................................................................................................................................................................................................................................................... 318 TRANSMISSION CONTROL VALVE ........................................................................................................................................................................................................................................... 322 UPPER VALVE....................................................................................................................................................................................................................................................... 322 LOWER VALVE....................................................................................................................................................................................................................................................... 326 SOLENOID VALVE.................................................................................................................................................................................................................................................... 328 TRANSFER ............................................................................................................................................................................................................................................................. 330 DRIVE SHAFT .......................................................................................................................................................................................................................................................... 332 CENTER SUPPORT ....................................................................................................................................................................................................................................................... 334 AXLE MOUNT............................................................................................................................................................................................................................................................ 336 DIFFERENTIAL ......................................................................................................................................................................................................................................................... 338 FINAL DRIVE .......................................................................................................................................................................................................................................................... 342 40 STEERING SYSTEM............................................................................................................................................................................................................................................................ 345 41 STRUCTURE AND FUNCTION................................................................................................................................................................................................................................................. 345 GENERAL .............................................................................................................................................................................................................................................................. 346 STEERING COLUMN, GEAR BOX, AND LINKAGE ............................................................................................................................................................................................................................. 348 HYDRAULIC CIRCUIT FOR STEERING ....................................................................................................................................................................................................................................... 350 HYDRAULIC CIRCUIT SCHEMATIC....................................................................................................................................................................................................................................... 350 HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................................................................................... 351 STEERING CONTROL SYSTEM .............................................................................................................................................................................................................................................. 352 STEERING VALVE.................................................................................................................................................................................................................................................... 352 STEERING RELIEF VALVE............................................................................................................................................................................................................................................. 354 SAFETY VALVE WITH SUCTION VALVE).................................................................................................................................................................................................................................. 356 OPERATION OF DEMAND SPOOL......................................................................................................................................................................................................................................... 358 OPERATION OF THE STEERING VALVE................................................................................................................................................................................................................................... 361 TWO-WAY RESTRICTOR VALVE ............................................................................................................................................................................................................................................. 362 STEERING CYLINDER .................................................................................................................................................................................................................................................... 363 CENTER HINGE PIN ..................................................................................................................................................................................................................................................... 364 42 TESTING AND ADJUSTING.................................................................................................................................................................................................................................................. 371 STANDARD VALUE TABLE ................................................................................................................................................................................................................................................. 372 TOOL LIST FOR TESTING AND ADJUSTMENT ................................................................................................................................................................................................................................. 372 MEASURING STEERING WHEEL PLAY ........................................................................................................................................................................................................................................ 373 MEASURING OPERATING FORCE OF STEERING WHEEL .......................................................................................................................................................................................................................... 374 OPERATING TIME OF STEERING WHEEL ..................................................................................................................................................................................................................................... 375 STEERING OIL PRESSURE ................................................................................................................................................................................................................................................ 376 STEERING LINKAGE ..................................................................................................................................................................................................................................................... 378 TROUBLESHOOTING TABLES ............................................................................................................................................................................................................................................... 382 1. Steering wheel does not turn................................................................................................................................................................................................................................... 383 2. Steering wheel is sluggish..................................................................................................................................................................................................................................... 384 3. Steering wheel moves unsteadily or is subject to large shock................................................................................................................................................................................................... 385 4. Machine tends to turn naturally in one particular direction when traveling..................................................................................................................................................................................... 385 5. Left and right turning radii are different..................................................................................................................................................................................................................... 385 43 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................................... 387 STEERING, SWITCH PUMP ................................................................................................................................................................................................................................................ 389 REMOVAL........................................................................................................................................................................................................................................................... 389 INSTALLATION...................................................................................................................................................................................................................................................... 391 STEERING GEAR......................................................................................................................................................................................................................................................... 394 REMOVAL........................................................................................................................................................................................................................................................... 394 INSTALLATION...................................................................................................................................................................................................................................................... 396 STEERING GEAR BOX .................................................................................................................................................................................................................................................... 397 DISASSEMBLY....................................................................................................................................................................................................................................................... 397 ASSEMBLY.......................................................................................................................................................................................................................................................... 398 STEERING VALVE ....................................................................................................................................................................................................................................................... 400 REMOVAL........................................................................................................................................................................................................................................................... 400 INSTALLATION...................................................................................................................................................................................................................................................... 402 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................................................... 406 STEERING CYLINDER..................................................................................................................................................................................................................................................... 408 REMOVAL........................................................................................................................................................................................................................................................... 408 INSTALLATION...................................................................................................................................................................................................................................................... 410 DISASSEMBLY....................................................................................................................................................................................................................................................... 412 ASSEMBLY.......................................................................................................................................................................................................................................................... 414 CENTER HINGE PIN ..................................................................................................................................................................................................................................................... 417 REMOVAL .......................................................................................................................................................................................................................................................... 417 INSTALLATION ..................................................................................................................................................................................................................................................... 426 44 MAINTENANCE STANDARD................................................................................................................................................................................................................................................... 437 STEERING COLUMN AND GEAR BOX.......................................................................................................................................................................................................................................... 438 STEERING VALVE ....................................................................................................................................................................................................................................................... 440 STEERING CYLINDER MOUNT .............................................................................................................................................................................................................................................. 441 STEERING CYLINDER .................................................................................................................................................................................................................................................... 442 CENTER HINGE PIN ..................................................................................................................................................................................................................................................... 444 GROUND DRIVEN STEERING PUMP .......................................................................................................................................................................................................................................... 447 DIVERTER VALVE ....................................................................................................................................................................................................................................................... 448 50 BRAKE AND AIR SYSTEM....................................................................................................................................................................................................................................................... 449 51 STRUCTURE AND FUNCTION................................................................................................................................................................................................................................................. 449 GENERAL .............................................................................................................................................................................................................................................................. 450 AIR SYSTEM........................................................................................................................................................................................................................................................ 450 BRAKE CIRCUIT..................................................................................................................................................................................................................................................... 450 BRAKE AND AIR PIPING ................................................................................................................................................................................................................................................. 451 BRAKE AND AIR CIRCUIT SYSTEM ......................................................................................................................................................................................................................................... 452 AIR TANK ............................................................................................................................................................................................................................................................. 453 WET TANK.......................................................................................................................................................................................................................................................... 453 DRY TANK.......................................................................................................................................................................................................................................................... 453 SAFETY VALVE ......................................................................................................................................................................................................................................................... 453 BRAKE VALVE .......................................................................................................................................................................................................................................................... 454 BRAKE ACTUATED.................................................................................................................................................................................................................................................... 455 OPERATING IN BALANCE.............................................................................................................................................................................................................................................. 456 BRAKE RELEASED.................................................................................................................................................................................................................................................... 457 TWO-WAY VALVE ........................................................................................................................................................................................................................................................ 458 RELAY VALVE .......................................................................................................................................................................................................................................................... 459 BRAKE CHAMBER ........................................................................................................................................................................................................................................................ 460 SLACK ADJUSTER ....................................................................................................................................................................................................................................................... 462 BRAKE ................................................................................................................................................................................................................................................................ 465 PARKING BRAKE ........................................................................................................................................................................................................................................................ 467 BRAKE CALIPER ........................................................................................................................................................................................................................................................ 469 PARKING BRAKE SOLENOID VALVE ......................................................................................................................................................................................................................................... 470 SPRING CYLINDER ...................................................................................................................................................................................................................................................... 471 HYDRAULIC TANK PRESSURIZING VALVE .................................................................................................................................................................................................................................... 472 52 TESTING AND ADJUSTING.................................................................................................................................................................................................................................................. 473 STANDARD VALUE TABLE ................................................................................................................................................................................................................................................. 475 TOOL LIST ............................................................................................................................................................................................................................................................ 476 MEASURING BRAKE PEDAL ................................................................................................................................................................................................................................................ 477 MEASURING AIR PRESSURE ............................................................................................................................................................................................................................................... 478 BRAKE PERFORMANCE .................................................................................................................................................................................................................................................... 480 CHECKING BRAKE OIL PRESSURE .......................................................................................................................................................................................................................................... 481 MEASURING WEAR OF BRAKE DISC ........................................................................................................................................................................................................................................ 482 AIR BLEEDING FROM BRAKE LINE ......................................................................................................................................................................................................................................... 483 PARKING BRAKE PERFORMANCE ............................................................................................................................................................................................................................................ 484 CHECKING AND ADJUSTING PARKING BRAKE................................................................................................................................................................................................................................. 485 TROUBLESHOOTING....................................................................................................................................................................................................................................................... 487 TROUBLESHOOTING TABLE............................................................................................................................................................................................................................................. 488 1. Air pressure does not rise at all.............................................................................................................................................................................................................................. 488 2. Air pressure does not rise to the specified range.............................................................................................................................................................................................................. 489 3. Brake is ineffective or not very effective..................................................................................................................................................................................................................... 490 4. Brake does not release, or drags............................................................................................................................................................................................................................... 491 5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.)................................................................................................................................................................ 492 53 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................................... 493 BRAKE VALVE .......................................................................................................................................................................................................................................................... 495 REMOVAL........................................................................................................................................................................................................................................................... 495 INSTALLATION...................................................................................................................................................................................................................................................... 497 DISASSEMBLY....................................................................................................................................................................................................................................................... 499 ASSEMBLY.......................................................................................................................................................................................................................................................... 501 BRAKE CHAMBER......................................................................................................................................................................................................................................................... 503 REMOVAL........................................................................................................................................................................................................................................................... 503 INSTALLATION...................................................................................................................................................................................................................................................... 506 DISASSEMBLY....................................................................................................................................................................................................................................................... 509 ASSEMBLY.......................................................................................................................................................................................................................................................... 512 SLACK ADJUSTER........................................................................................................................................................................................................................................................ 515 REMOVAL........................................................................................................................................................................................................................................................... 515 INSTALLATION...................................................................................................................................................................................................................................................... 515 DISASSEMBLY....................................................................................................................................................................................................................................................... 516 ASSEMBLY.......................................................................................................................................................................................................................................................... 517 BRAKE ASSEMBLY ....................................................................................................................................................................................................................................................... 518 REMOVAL........................................................................................................................................................................................................................................................... 518 INSTALLATION...................................................................................................................................................................................................................................................... 521 DISASSEMBLY (FRONT, REAR)......................................................................................................................................................................................................................................... 524 ASSEMBLY (FRONT, REAR)............................................................................................................................................................................................................................................ 527 SPRING CYLINDER....................................................................................................................................................................................................................................................... 530 REMOVAL........................................................................................................................................................................................................................................................... 530 INSTALIATION...................................................................................................................................................................................................................................................... 531 DISASSEMBLY....................................................................................................................................................................................................................................................... 532 ASSEMBLY.......................................................................................................................................................................................................................................................... 533 PARKING BRAKE ........................................................................................................................................................................................................................................................ 534 REMOVAL........................................................................................................................................................................................................................................................... 534 INSTALLATION...................................................................................................................................................................................................................................................... 537 PARKING BRAKE PAD..................................................................................................................................................................................................................................................... 540 REMOVAL........................................................................................................................................................................................................................................................... 540 INSTALLATION...................................................................................................................................................................................................................................................... 540 54 MAINTENANCE STANDARD................................................................................................................................................................................................................................................... 541 BRAKE VALVE .......................................................................................................................................................................................................................................................... 542 BRAKE CHAMBER ........................................................................................................................................................................................................................................................ 544 SLACK ADJUSTER ....................................................................................................................................................................................................................................................... 545 BRAKE ................................................................................................................................................................................................................................................................ 546 PARKING BRAKE ........................................................................................................................................................................................................................................................ 548 SPRING CYLINDER ...................................................................................................................................................................................................................................................... 550 60 WORK EQUIPMENT SYSTEM...................................................................................................................................................................................................................................................... 553 61 STRUCTURE AND FUNCTION................................................................................................................................................................................................................................................. 553 GENERAL .............................................................................................................................................................................................................................................................. 556 HYDRAULIC PIPING ..................................................................................................................................................................................................................................................... 557 HYDRAULIC CIRCUIT..................................................................................................................................................................................................................................................... 558 SCHEMATICS ....................................................................................................................................................................................................................................................... 558 DIAGRAM .......................................................................................................................................................................................................................................................... 560 HYDRAULIC TANK ....................................................................................................................................................................................................................................................... 562 OIL FILTER BYPASS VALVE .......................................................................................................................................................................................................................................... 564 BREATHER ......................................................................................................................................................................................................................................................... 565 HYDRAULIC PUMPS ...................................................................................................................................................................................................................................................... 566 TRANSMISSION LUBRICATION + TORQUE CONVERTER CHARGING + PPC PUMP................................................................................................................................................................................................... 566 STEERING + SWITCH PUMP............................................................................................................................................................................................................................................ 567 PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE) ...................................................................................................................................................................................................................... 568 FUNCTION OF PPC VALVE ............................................................................................................................................................................................................................................ 570 PPC RELIEF VALVE ................................................................................................................................................................................................................................................. 572 MAIN CONTROL VALVE ................................................................................................................................................................................................................................................... 573 RELIEF VALVE...................................................................................................................................................................................................................................................... 576 SAFETY VALVE (with suction valve)................................................................................................................................................................................................................................. 577 SUCTION VALVE..................................................................................................................................................................................................................................................... 578 FLOAT SELECTOR VALVE AND UNLOADER VALVE .......................................................................................................................................................................................................................... 579 ACCUMULATOR .......................................................................................................................................................................................................................................................... 581 HYDRAULIC CIRCUIT OPERATION .......................................................................................................................................................................................................................................... 582 LIFT AND DUMP SPOOLS AT “HOLD".................................................................................................................................................................................................................................... 582 LIFT SPOOL AT “RAISE”............................................................................................................................................................................................................................................. 584 LIFT SPOOL AT “FLOAT”............................................................................................................................................................................................................................................. 586 DUMP SPOOL AT “TILT BACK”......................................................................................................................................................................................................................................... 588 HYDRAULIC CYLINDER ................................................................................................................................................................................................................................................... 590 LIFT CYLINDER..................................................................................................................................................................................................................................................... 590 DUMP CYLINDER..................................................................................................................................................................................................................................................... 591 BUCKET LINKAGE ....................................................................................................................................................................................................................................................... 592 BUCKET POSITIONER AND BOOM KICK-OUT .................................................................................................................................................................................................................................. 594 WORK EQUIPMENT LEVER LINKAGE ......................................................................................................................................................................................................................................... 596 62 TESTING AND ADJUSTING.................................................................................................................................................................................................................................................. 597 STANDARD VALUE TABLE ................................................................................................................................................................................................................................................. 599 TOOL LIST ............................................................................................................................................................................................................................................................ 600 DUMP AND LIFT CONTROL LEVERS.......................................................................................................................................................................................................................................... 601 MEASURING......................................................................................................................................................................................................................................................... 601 ADJUSTING ........................................................................................................................................................................................................................................................ 602 HYDRAULIC CIRCUIT FLUSHING............................................................................................................................................................................................................................................ 604 PPC RELIEF VALVE ..................................................................................................................................................................................................................................................... 607 MEASURING PRESSURE................................................................................................................................................................................................................................................ 607 ADJUSTING ........................................................................................................................................................................................................................................................ 609 WORK EQUIPMENT........................................................................................................................................................................................................................................................ 610 RELIEF VALVE...................................................................................................................................................................................................................................................... 610 MEASURING TIME.................................................................................................................................................................................................................................................... 612 HYDRAULIC DRIFT................................................................................................................................................................................................................................................... 613 BUCKET POSITIONER .................................................................................................................................................................................................................................................... 614 BOOM KICK-OUT ........................................................................................................................................................................................................................................................ 615 TROUBLESHOOTING ...................................................................................................................................................................................................................................................... 616 TROUBLESHOOTING TABLE ............................................................................................................................................................................................................................................ 616 1. Lift arm does not rise. ....................................................................................................................................................................................................................................... 616 2. Lift arm moves slowly or does not have sufficient lifting power. ............................................................................................................................................................................................. 617 3. Lift arm movement becomes slow after it reaches 0. Lift arm movement is unsteady during work. During excavation or ground leveling when the a certain height. lift arm control lever is in the “Hold” position, the bucket and lift arm move up and dow.... 618 4. Bucket cannot be held down with lift arm cylinder.............................................................................................................................................................................................................. 618 5. Lift arm has large hydraulic drift............................................................................................................................................................................................................................. 618 6. Lift arm movement is unsteady during work...................................................................................................................................................................................................................... 618 7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"............................................................................................................................................................................. 618 8. Bucket does not tilt back...................................................................................................................................................................................................................................... 619 9. Bucket moves slowly ur has insufficient tilt back power. ..................................................................................................................................................................................................... 620 10. Bucket movement becomes stow during tilt back................................................................................................................................................................................................................. 621 11. Bucket cannot be held down by the bucket cylinder............................................................................................................................................................................................................. 621 12. Bucket has large hydraulic drift. ............................................................................................................................................................................................................................ 621 13. Bucket moves unsteadily when machine travels 10. Bucket movement becomes stow during tilt back. under load. (Main control valve in “Hold”). Checks before troubleshooting Checks before troubleshooting External deformation of dump cylinder Is oil.... 621 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"............................................................................................................................................................................. 621 15. Control levers of lift arm and dump move stiffly and sluggishly. ............................................................................................................................................................................................ 622 63 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................................... 623 HYDRAULIC TANK........................................................................................................................................................................................................................................................ 625 REMOVAL........................................................................................................................................................................................................................................................... 625 INSTALLATION...................................................................................................................................................................................................................................................... 627 HYDRAULIC FILTER ..................................................................................................................................................................................................................................................... 629 REMOVAL........................................................................................................................................................................................................................................................... 629 INSTALIATION...................................................................................................................................................................................................................................................... 630 WORK EQUIPMENT PUMP .................................................................................................................................................................................................................................................. 633 REMOVAL........................................................................................................................................................................................................................................................... 631 INSTALLATION...................................................................................................................................................................................................................................................... 634 PPC VALVE ASSEMBLY.................................................................................................................................................................................................................................................... 637 REMOVAL........................................................................................................................................................................................................................................................... 637 INSTALLATION...................................................................................................................................................................................................................................................... 639 DISASSEMBLY ...................................................................................................................................................................................................................................................... 641 ASSEMBLY.......................................................................................................................................................................................................................................................... 641 MAIN CONTROL VALVE.................................................................................................................................................................................................................................................... 642 REMOVAL........................................................................................................................................................................................................................................................... 642 INSTALLATION...................................................................................................................................................................................................................................................... 645 DISASSEMBLY....................................................................................................................................................................................................................................................... 648 ASSEMBLY ......................................................................................................................................................................................................................................................... 650 DUMP CYLINDER ........................................................................................................................................................................................................................................................ 652 REMOVAL .......................................................................................................................................................................................................................................................... 652 INSTALIATION ..................................................................................................................................................................................................................................................... 655 LIFT CYLINDER ........................................................................................................................................................................................................................................................ 657 REMOVAL .......................................................................................................................................................................................................................................................... 657 INSTALLATION ..................................................................................................................................................................................................................................................... 660 LIFT AND DUMP CYLINDERS .............................................................................................................................................................................................................................................. 663 DISASSEMBLY....................................................................................................................................................................................................................................................... 663 ASSEMBLY ......................................................................................................................................................................................................................................................... 665 WORK EQUIPMENT ....................................................................................................................................................................................................................................................... 667 REMOVAL .......................................................................................................................................................................................................................................................... 667 INSTALLATION...................................................................................................................................................................................................................................................... 673 COUNTERWEIGHT ........................................................................................................................................................................................................................................................ 679 REMOVAL .......................................................................................................................................................................................................................................................... 679 INSTALIATION ..................................................................................................................................................................................................................................................... 681 64 MAINTENANCE STANDARD................................................................................................................................................................................................................................................... 683 MAIN CONTROL VALVE ................................................................................................................................................................................................................................................... 684 TRANSMISSION LUBRICATION (SAL125) + TORQUE CONVERTER CHARG- ING (SALIOO) + PPC PUMP (SAL20) ......................................................................................................................................................................... 686 STEERING (SAL 125) SWITCH PUMP (SAL 100) ............................................................................................................................................................................................................................. 688 PPC VALVE ............................................................................................................................................................................................................................................................ 690 DUMP CYLINDER ........................................................................................................................................................................................................................................................ 692 LIFT CYLINDER ........................................................................................................................................................................................................................................................ 694 BUCKET LINKAGE ....................................................................................................................................................................................................................................................... 696 BUCKET POSITIONER AND BOOM KICK-OUT .................................................................................................................................................................................................................................. 698 BUCKET ............................................................................................................................................................................................................................................................... 699 80 ELECTRIC AND ELECTRONIC SYSTEM............................................................................................................................................................................................................................................. 701 81 STRUCTURE AND FUNCTION................................................................................................................................................................................................................................................. 701 ELECTRICAL WIRING DIAGRAM ............................................................................................................................................................................................................................................ 703 ENGINE STARTING CIRCUIT .............................................................................................................................................................................................................................................. 704 ENGINE STOP CIRCUIT................................................................................................................................................................................................................................................... 706 COMBINATION SWITCH ............................................................................................................................................................................................................................................... 708 TRANSMISSION CUT-OFF SWITCH ...................................................................................................................................................................................................................................... 709 TRANSMISSION CUT-OFF SELECTOR SWITCH ............................................................................................................................................................................................................................. 710 NEUTRALIZER RELAY ................................................................................................................................................................................................................................................ 711 KICK-DOWN SWITCH ................................................................................................................................................................................................................................................. 712 KICK-DOWN ELECTRIC CIRCUIT ....................................................................................................................................................................................................................................... 713 ELECTRICAL PARKING BRAKE CONTROL ..................................................................................................................................................................................................................................... 719 PARKING BRAKE VALVE............................................................................................................................................................................................................................................... 721 PARKING SAFETY RELAY.............................................................................................................................................................................................................................................. 721 NEUTRALIZER RELAY................................................................................................................................................................................................................................................. 721 EMERGENCY BRAKE SWITCH............................................................................................................................................................................................................................................ 721 CONDITIONS........................................................................................................................................................................................................................................................ 722 1. STARTING SWITCH OFF........................................................................................................................................................................................................................................ 722 2. STARTING SWITCH ON......................................................................................................................................................................................................................................... 723 2-1. When parking brake switch is turned ON before starting switch is turned ON........................................................................................................................................................................... 723 2-2. Parking brake switch turned OFF (released) before starting switch is turned ON....................................................................................................................................................................... 724 3. PARKING BRAKE SWITCH TURNED OFF (Released) AFTER STARTING SWITCH IS TURNED ON.............................................................................................................................................................................. 725 4. PARKING BRAKE SWITCH ON (operated)......................................................................................................................................................................................................................... 726 5. WHEN AIR PRESSURE DROPS. (Emergency brake actuated)....................................................................................................................................................................................................... 727 PROXIMITY SWITCH ..................................................................................................................................................................................................................................................... 728 OPERATION......................................................................................................................................................................................................................................................... 729 Lift arm RAISE................................................................................................................................................................................................................................................ 729 Kick-out...................................................................................................................................................................................................................................................... 731 BUCKET “TILT’..................................................................................................................................................................................................................................................... 732 Hold.......................................................................................................................................................................................................................................................... 732 Tilt.......................................................................................................................................................................................................................................................... 733 Positioned.................................................................................................................................................................................................................................................... 734 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)........................................................................................................................................................................................................................... 735 INDICATION ON MONITOR PANEL ...................................................................................................................................................................................................................................... 737 MONITOR WIRING HARNESS ........................................................................................................................................................................................................................................... 741 SENSORS .............................................................................................................................................................................................................................................................. 742 ENGINE OIL LEVEL.................................................................................................................................................................................................................................................. 742 BRAKE OIL LEVEL................................................................................................................................................................................................................................................... 743 COOLANT LEVEL..................................................................................................................................................................................................................................................... 743 FUEL GAUGE........................................................................................................................................................................................................................................................ 744 ENGINE OIL PRESSURE............................................................................................................................................................................................................................................... 745 PARKING BRAKE..................................................................................................................................................................................................................................................... 746 AIR PRESSURE...................................................................................................................................................................................................................................................... 746 TORQUE CONVERTER OIL TEMPERATURE.................................................................................................................................................................................................................................. 748 COOLANT TEMPERATURE............................................................................................................................................................................................................................................... 748 ROTATIONAL SPEED.................................................................................................................................................................................................................................................. 750 BRAKE LINE FAILURE................................................................................................................................................................................................................................................ 750 TRANSMISSION OIL FILTER CLOGGING ................................................................................................................................................................................................................................. 751 GROUND DRIVEN STEERING OPERATION.................................................................................................................................................................................................................................. 751 82 TESTING AND ADJUSTING.................................................................................................................................................................................................................................................. 753 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ........................................................................................................................................................................................................................... 756 MACHINE MONITOR (SPEEDOMETER MODULE) ................................................................................................................................................................................................................................. 759 TROUBLESHOOTING....................................................................................................................................................................................................................................................... 761 CHECKS BEFORE TROUBLESHOOTING .................................................................................................................................................................................................................................... 762 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART ................................................................................................................................................................................................................ 763 CONNECTOR TERMINAL NUMBERS ....................................................................................................................................................................................................................................... 765 PRECAUTION WHEN HANDLING CONNECTOR ............................................................................................................................................................................................................................... 771 ELECTRICAL WIRING DIAGRAM ........................................................................................................................................................................................................................................ 773 ELECTRICAL CONNECTOR (CN) DIAGRAM ................................................................................................................................................................................................................................ 773 ELECTRICAL CIRCUIT SYSTEM ........................................................................................................................................................................................................................................ 774 ENGINE STARTING AND STOP CIRCUIT SYSTEM....................................................................................................................................................................................................................... 774 TRANSMISSION CONTROL, PARKING CIRCUIT SYSTEM.................................................................................................................................................................................................................. 775 PARKING BRAKE SYSTEM.......................................................................................................................................................................................................................................... 776 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM............................................................................................................................................................................................................................. 777 POSITION OF CONNECTORS FOR TROUBLESHOOTING ...................................................................................................................................................................................................................... 778 E-1 ENGINE DOES NOT START......................................................................................................................................................................................................................................... 784 E-2 DOES NOT STOP................................................................................................................................................................................................................................................. 786 E-3 ENGINE STOPS WHEN TRAVELING................................................................................................................................................................................................................................... 787 E-4 PARKING BRAKE DOES NOT WORK................................................................................................................................................................................................................................... 788 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING....................................................................................................................................................................................................................... 790 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON................................................................................................................................................................................................... 793 E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED......................................................................................................................................................................................... 794 E-8 TRANSMISSION DOES NOT WORK NORMALLY........................................................................................................................................................................................................................... 796 E-9 KICK-DOWN SWITCH DOES NOT WORK (1/2)......................................................................................................................................................................................................................... 818 E-10 KICK-DOWN WORKS WHEN KICK-DOWN SWITCH IS ON ................................................................................................................................................................................................................. 821 E-11 KICK-DOWN OPERATION IS NOT CANCELED.......................................................................................................................................................................................................................... 822 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.............................................................................................................................................................................................................. 824 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED..................................................................................................................................................................................................... 824 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM........................................................................................................................................................................................................ 827 POSITION OF CONNECTORS FOR TROUBLESHOOTING........................................................................................................................................................................................................................ 828 M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.............................................................................................................................................................................................................. 835 M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED............................................................................................................................................................................................................. 835 M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED......................................................................................................................................................................................................... 837 M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING............................................................................................................................................................................................................... 837 M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING............................................................................................................................................................................................. 839 M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING................................................................................................................................................................................................................... 840 M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING........................................................................................................................................................................................................... 840 M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING.......................................................................................................................................................................................................... 842 M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING......................................................................................................................................................................................................... 842 M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING........................................................................................................................................................................................................ 844 M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING.................................................................................................................................................................................................... 844 M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING............................................................................................................................................................................................ 844 M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP.................................................................................................................................................................................................... 846 M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.................................................................................................................................................................................................... 848 M-15 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP.......................................................................................................................................................................................................... 850 M-16 TURN SIGNAL HI BEAM UGHTS UP, OR DOES NOT LIGHT UP........................................................................................................................................................................................................... 852 M-17 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON.............................................................................................................................................................................................. 857 M-18 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY................................................................................................................................................................................................................... 858 M-19 HOURMETER DISPLAY DOES NOT WORK NORMALLY..................................................................................................................................................................................................................... 859 M-20 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS........................................................................................................................................................................... 860 M-21 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT...................................................................................................................................................................... 861 M-22 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED............................................................................................................................................................................. 862 M-23 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP....................................................................................................................................................................... 864 M-24 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH THE C.................................................................................................................................. 868 M-25 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS.................................................................................................................................................................................. 868 M-26 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. T.................................................................................................................................. 870 M-27 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP............................................................................................................................................................................... 871 M-28 ABNORMALITY IN THE FUEL GAUGE SYSTEM......................................................................................................................................................................................................................... 872 M-29 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM................................................................................................................................................................................................................. 874 M-30 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM..................................................................................................................................................................................................... 876 M-31 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM............................................................................................................................................................................................. 878 83 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................................... 881 MACHINE MONITOR....................................................................................................................................................................................................................................................... 882 REMOVAL........................................................................................................................................................................................................................................................... 882 INSTALLATION...................................................................................................................................................................................................................................................... 883 90 OTHERS..................................................................................................................................................................................................................................................................... 885 91 AIR CONDITIONER STRUCTURE AND FUNCTION................................................................................................................................................................................................................................. 885 GENERAL .............................................................................................................................................................................................................................................................. 887 BASIC INFORMATION ON AIR CONDITIONERS ............................................................................................................................................................................................................................ 887 UNITS RELATED TO REFRIGERATION ............................................................................................................................................................................................................................... 887 Heat ................................................................................................................................................................................................................................................... 887 Temperature............................................................................................................................................................................................................................................... 887 Pressure.................................................................................................................................................................................................................................................. 888 Humidity.................................................................................................................................................................................................................................................. 889 PRINCIPLE OF COOLING.......................................................................................................................................................................................................................................... 890 Why do coolers cool? ..................................................................................................................................................................................................................................... 890 Refrigerator using evaporation latent heat ............................................................................................................................................................................................................... 890 Refrigeration method (Vapor compression) ................................................................................................................................................................................................................. 890 Refrigerating cycle....................................................................................................................................................................................................................................... 891 Heating cycle............................................................................................................................................................................................................................................. 893 REFRIGERANTS ................................................................................................................................................................................................................................................. 894 SAFETY PRECAUTIONS ....................................................................................................................................................................................................................................... 894 REFRIGERATOR OIL (LUBE OIL) .................................................................................................................................................................................................................................. 895 SPECIFICATIONS................................................................................................................................................................................................................................................ 896 PIPING DIAGRAM ....................................................................................................................................................................................................................................................... 897 ELECTRIC WIRING DIAGRAM .............................................................................................................................................................................................................................................. 898 COMPRESSOR (CRANK TYPE) .............................................................................................................................................................................................................................................. 899 MAGNETIC CLUTCH ...................................................................................................................................................................................................................................................... 902 CONDENSER ............................................................................................................................................................................................................................................................ 903 RECEIVER W/SIGHT GLASS (LIQUID TANK) ................................................................................................................................................................................................................................ 905 AIR CONDITIONER UNIT ................................................................................................................................................................................................................................................. 907 EXPANSION VALVE .................................................................................................................................................................................................................................................. 908 EVAPORATOR ....................................................................................................................................................................................................................................................... 910 THERMOSTAT ....................................................................................................................................................................................................................................................... 910 PRESSURE SWITCH................................................................................................................................................................................................................................................... 911 HEATER ........................................................................................................................................................................................................................................................... 913 BLOWER UNIT ...................................................................................................................................................................................................................................................... 913 PIPING ........................................................................................................................................................................................................................................................... 914 AIR CONTROL SYSTEM ............................................................................................................................................................................................................................................... 915 CONTROL PANEL ........................................................................................................................................................................................................................................................ 916 BLOWER SWITCH..................................................................................................................................................................................................................................................... 916 AIR CONDITIONER SWITCH ........................................................................................................................................................................................................................................... 916 TEMPERATURE CONTROL LEVER ........................................................................................................................................................................................................................................ 916 AIR SOURCE SELECTOR LEVER ........................................................................................................................................................................................................................................ 916 92 AIR CONDITIONER TESTING AND ADJUSTING.................................................................................................................................................................................................................................. 917 SERVICE TOOLS ........................................................................................................................................................................................................................................................ 919 GAUGE MANIFOLD ................................................................................................................................................................................................................................................... 919 GAS LEAK DETECTOR ................................................................................................................................................................................................................................................ 922 HALIDE TORCH LEAK DETECTOR.................................................................................................................................................................................................................................... 922 ELECTRIC LEAK TESTER.......................................................................................................................................................................................................................................... 924 VALVE FOR SERVICE CANS ........................................................................................................................................................................................................................................... 925 MAINTENANCE PROCEDURE................................................................................................................................................................................................................................................. 926 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING .................................................................................................................................................................................................................. 926 PROHIBITED WORK .............................................................................................................................................................................................................................................. 926 OTHER PRECAUTIONS ............................................................................................................................................................................................................................................ 926 BLEEDING AIR FROM REFRIGERATION CIRCUIT ......................................................................................................................................................................................................................... 928 PURPOSE ...................................................................................................................................................................................................................................................... 928 CONNECTING GAUGE MANIFOLD .................................................................................................................................................................................................................................... 928 EVACUATION ................................................................................................................................................................................................................................................... 929 AIR-TIGHTNESS CHECK .......................................................................................................................................................................................................................................... 929 GAS-LEAK CHECK ............................................................................................................................................................................................................................................... 929 EVACUATION (REPEATING) ....................................................................................................................................................................................................................................... 930 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT............................................................................................................................................................................................................... 931 CHARGING FROM THE HIGH-PRESSURE SIDE.......................................................................................................................................................................................................................... 931 CHARGING FROM THE SIDE (REPLENISHINGTHEREFRIGERATIONCIRCUIT) ................................................................................................................................................................................................ 932 WHEN THE AMBIENT TEMPERATURE IS LOW........................................................................................................................................................................................................................... 933 WHEN THE AMBIENT TEMPERATURE IS HIGH.......................................................................................................................................................................................................................... 933 REPLACING SERVICE CANS ........................................................................................................................................................................................................................................... 934 CHECKING THE AMOUNT OF REFRIGERANT ............................................................................................................................................................................................................................... 934 REMOVAL OF GAUGE MANIFOLD ........................................................................................................................................................................................................................................ 936 DISCHARGING THE REFRIGERANT ...................................................................................................................................................................................................................................... 936 DAILY CHECKS ..................................................................................................................................................................................................................................................... 937 CHECK REFRIGERANT LEVEL ...................................................................................................................................................................................................................................... 937 CLEANING THE CONDENSER........................................................................................................................................................................................................................................ 937 CHECKING THE V-BELT........................................................................................................................................................................................................................................... 937 CHECKING OIL LEVEL ............................................................................................................................................................................................................................................... 938 PROCEDURE FOR CHECKING........................................................................................................................................................................................................................................ 938 PROCEDURE FOR CHECKING OIL LEVEL.............................................................................................................................................................................................................................. 938 ADDING AND REMOVING OIL ...................................................................................................................................................................................................................................... 939 ADDING OIL BY EVACUATION...................................................................................................................................................................................................................................... 939 TROUBLESHOOTING ...................................................................................................................................................................................................................................................... 940 VISUAL AND ACOUSTICAL CHECKS ..................................................................................................................................................................................................................................... 940 DEFECTIVE COOLING ................................................................................................................................................................................................................................................ 941 TROUBLESHOOTING TABLES ........................................................................................................................................................................................................................................... 942 DEFECTIVE HEATING ................................................................................................................................................................................................................................................ 944 TROUBLESHOOTING USING GAUGE MANIFOLD ................................................................................................................................................................................................................................. 945 PREPARATIONS BEFORE MEASURING..................................................................................................................................................................................................................................... 945 INSUFFICIENT REFRIGERANT.......................................................................................................................................................................................................................................... 945 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER ....................................................................................................................................................................................................... 946 AIR INSIDE REFRIGERATION SYSTEM .................................................................................................................................................................................................................................. 946 MOISTURE IN REFRIGERATING SYSTEM ................................................................................................................................................................................................................................. 947 REFRIGERANT DOES NOT CIRCULATE ................................................................................................................................................................................................................................... 948 FAILURE OF EXPANSION VALVE (OPEN TO FAR).......................................................................................................................................................................................................................... 949 DEFECTIVE MOUNTING OF HEAT SENSING TUBE........................................................................................................................................................................................................................... 949 DEFECTIVE COMPRESSION BY COMPRESSOR .............................................................................................................................................................................................................................. 949 93 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................... 951 SPECIAL TOOLS ........................................................................................................................................................................................................................................................ 952 MAGNETIC CLUTCH ...................................................................................................................................................................................................................................................... 953 DISASSEMBLY....................................................................................................................................................................................................................................................... 953 CHECKS BEFORE DISASSEMBLY..................................................................................................................................................................................................................................... 954 REMOVAL OF ROTOR AND STATOR................................................................................................................................................................................................................................... 954 REMOVAL OF CENTER PIECE FROM ROTOR............................................................................................................................................................................................................................ 955 REMOVAL OF BEARING FROM ROTOR................................................................................................................................................................................................................................. 956 ASSEMBLY.......................................................................................................................................................................................................................................................... 957 ASSEMBLY OF BEARING TO ROTOR.................................................................................................................................................................................................................................. 957 ASSEMBLY OF CENTER PIECE TO ROTOR............................................................................................................................................................................................................................. 957 ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR.................................................................................................................................................................................................................... 958 AIR CONDITIONER UNIT ................................................................................................................................................................................................................................................. 959 DISASSEMBLY....................................................................................................................................................................................................................................................... 959 CHECKS BEFORE DISASSEMBLY..................................................................................................................................................................................................................................... 959 REMOVAL OF CONTROL PANELAND THERMOSTAT........................................................................................................................................................................................................................ 963 REMOVAL OF UNIT COVER......................................................................................................................................................................................................................................... 965 REMOVAL OF WATER VALVE........................................................................................................................................................................................................................................ 965 REMOVAL OF EXPANSION VALVE.................................................................................................................................................................................................................................... 967 REMOVAL OF EVAPORATOR......................................................................................................................................................................................................................................... 969 REMOVAL OF HEATER CORE........................................................................................................................................................................................................................................ 969 REMOVAL OF PRESSURE SWITCHES.................................................................................................................................................................................................................................. 969 BLOWER UNIT .......................................................................................................................................................................................................................................................... 970 DISASSEMBLY....................................................................................................................................................................................................................................................... 970 CHECKS BEFORE DISASSEMBLY..................................................................................................................................................................................................................................... 970 REMOVAL OF BLOWER RESISTOR.................................................................................................................................................................................................................................... 970 REMOVAL OF BLOWER MOTOR AND FAN............................................................................................................................................................................................................................... 971 CONDENSER ............................................................................................................................................................................................................................................................ 972 DISASSEMBLY OF.................................................................................................................................................................................................................................................... 972 CHECKS BEFORE DISASSEMBLY..................................................................................................................................................................................................................................... 972 REMOVAL OF CONDENSER, FAN MOTOR............................................................................................................................................................................................................................... 973 REMOVAL OF PRESSURE SWITCH.................................................................................................................................................................................................................................... 974 REMOVAL OF RESISTOR........................................................................................................................................................................................................................................... 974 97 GEAR PUMP SA SERIES.................................................................................................................................................................................................................................................... 975 GENERAL............................................................................................................................................................................................................................................................... 976 PRINCIPLE OF OPERATION............................................................................................................................................................................................................................................ 977 PRESSURE LOADED TYPE GEAR PUMP.................................................................................................................................................................................................................................... 980 FIXED SIDE PLATE TYPE GEAR PUMP................................................................................................................................................................................................................................... 982 SA SERIES............................................................................................................................................................................................................................................................. 983 STRUCTURE......................................................................................................................................................................................................................................................... 983 TESTING AND ADJUSTING............................................................................................................................................................................................................................................. 987 DISASSEMBLY....................................................................................................................................................................................................................................................... 990 ASSEMBLY ......................................................................................................................................................................................................................................................... 994 MAINTENANCE STANDARD.............................................................................................................................................................................................................................................. 999 99 METRIC CONVERSIONS.....................................................................................................................................................................................................................................................1001 METRIC CONVERSIONS....................................................................................................................................................................................................................................................1002
KOMATSU WHEEL LOADER WA600-1LC SHOP MANUAL CEBMW26030 – PDF DOWNLOAD:
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