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KOMATSU WA450-1 SHOP MANUAL SEBM04210108 – PDF DOWNLOAD
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KOMATSU WA450-1 SHOP MANUAL SEBM04210108 – PDF DOWNLOAD
Language : English
Pages : 1029
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA450-1 SHOP MANUAL SEBM04210108 – PDF DOWNLOAD
COVER...................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................................. 18 WEIGHT TABLE........................................................................................................................................................................... 19 TABLE OF OIL AND COOLANT QUANTITIES.................................................................................................................................................... 21 10 ENGINE.................................................................................................................................................................................. 22 11 STRUCTURE AND FUNCTION.............................................................................................................................................................. 22 ENGINE MOUNT....................................................................................................................................................................... 23 RADIATOR........................................................................................................................................................................... 24 FUEL TANK AND PIPING............................................................................................................................................................... 25 ENGINE CONTROL..................................................................................................................................................................... 26 12 TESTING AND ADJUSTING............................................................................................................................................................... 27 STANDARD VALUE TABLE............................................................................................................................................................... 28 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 30 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................... 31 MEASURING COMPRESSION PRESSURE..................................................................................................................................................... 32 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................................ 33 MEASURING BLOW-BY PRESSURE......................................................................................................................................................... 35 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................................................. 36 MEASURING EXHAUST GAS COLOR........................................................................................................................................................ 37 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATION ANGLE.................................................................................................................... 38 TESTING AND ADJUSTING FUEL CUT SOLENOID............................................................................................................................................ 42 13 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 43 STARTING MOTOR ASSEMBLY............................................................................................................................................................ 44 REMOVAL........................................................................................................................................................................ 44 INSTALLATION................................................................................................................................................................... 44 ALTERNATOR ASSEMBLY................................................................................................................................................................ 45 REMOVAL........................................................................................................................................................................ 45 INSTALLATION................................................................................................................................................................... 45 FUEL INJECTION PUMP ASSEMBLY....................................................................................................................................................... 46 REMOVAL........................................................................................................................................................................ 46 INSTALLATION................................................................................................................................................................... 46 WATER PUMP ASSEMBLY................................................................................................................................................................ 47 REMOVAL........................................................................................................................................................................ 47 INSTALLATION................................................................................................................................................................... 47 NOZZLE HOLDER ASSEMBLY............................................................................................................................................................. 48 REMOVAL........................................................................................................................................................................ 48 INSTALLATION................................................................................................................................................................... 49 TURBOCHARGER ASSEMBLY.............................................................................................................................................................. 50 REMOVAL........................................................................................................................................................................ 50 INSTALLATION................................................................................................................................................................... 50 CYLINDER HEAD ASSEMBLY............................................................................................................................................................. 51 REMOVAL........................................................................................................................................................................ 51 INSTALLATION................................................................................................................................................................... 57 RADIATOR ASSEMBLY.................................................................................................................................................................. 64 REMOVAL........................................................................................................................................................................ 64 INSTALLATION................................................................................................................................................................... 67 OIL COOLER ASSEMBLY................................................................................................................................................................ 69 REMOVAL........................................................................................................................................................................ 69 INSTALLATION................................................................................................................................................................... 69 ENGINE ASSEMBLY.................................................................................................................................................................... 70 REMOVAL........................................................................................................................................................................ 70 INSTALLATION................................................................................................................................................................... 76 FUEL TANK ASSEMBLY................................................................................................................................................................. 82 REMOVAL........................................................................................................................................................................ 82 INSTALLATION................................................................................................................................................................... 83 14 MAINTENANCE STANDARD................................................................................................................................................................ 84 ENGINE MOUNT....................................................................................................................................................................... 85 20 POWER TRAIN............................................................................................................................................................................. 86 21 STRUCTURE AND FUNCTION.............................................................................................................................................................. 86 GENERAL............................................................................................................................................................................ 87 ใปHYDRAULIC CIRCUIT FOR POWER TRAIN............................................................................................................................................. 89 ใปHYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN..................................................................................................................................... 90 TRANSMISSION MOUNT................................................................................................................................................................. 92 DAMPER............................................................................................................................................................................. 93 TORQUE CONVERTER AND TRANSMISSION PIPING........................................................................................................................................... 95 TORQUE CONVERTER CHARGING PUMP..................................................................................................................................................... 96 TORQUE CONVERTER................................................................................................................................................................... 97 TORQUE CONVERTER OIL FILTER........................................................................................................................................................ 100 TORQUE CONVERTER OIL COOLER........................................................................................................................................................ 101 TORQUE CONVERTER RELIEF VALVE...................................................................................................................................................... 102 TRANSMISSION....................................................................................................................................................................... 103 TRANSMISSION CONTROL VALVE......................................................................................................................................................... 111 UPPER VALVE.................................................................................................................................................................... 115 LOWER VALVE.................................................................................................................................................................... 116 TRANSMISSION SOLENOID VALVE.................................................................................................................................................... 119 EMERGENCY MANUAL SPOOL......................................................................................................................................................... 120 FORWARD 1ST.................................................................................................................................................................... 121 PRIORITY VALVE................................................................................................................................................................. 123 MODULATING VALVE AND QUICK RETURN VALVE........................................................................................................................................ 124 ACCUMULATOR VALVE.............................................................................................................................................................. 127 PILOT REDUCING VALVE........................................................................................................................................................... 129 TRANSMISSION PILOT FILTER.......................................................................................................................................................... 130 TRANSFER........................................................................................................................................................................... 131 DRIVE SHAFT........................................................................................................................................................................ 132 AXLE MOUNT......................................................................................................................................................................... 133 AXLE AND DIFFERENTIAL.............................................................................................................................................................. 137 FRONT AXLE..................................................................................................................................................................... 137 FRONT DIFFERENTIAL............................................................................................................................................................. 138 REAR AXLE...................................................................................................................................................................... 139 REAR DIFFERENTIAL.............................................................................................................................................................. 140 TORQUE PROPORTIONING DIFFERENTIAL.............................................................................................................................................. 142 FINAL DRIVE........................................................................................................................................................................ 143 TIRE AND WHEEL..................................................................................................................................................................... 145 22 TESTING AND ADJUSTING............................................................................................................................................................... 146 STANDARD VALUE TABLE............................................................................................................................................................... 147 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 148 MEASURING ENGINE STALL SPEED....................................................................................................................................................... 149 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION........................................................................................................................ 151 MEASURING SHIFT LEVER.............................................................................................................................................................. 153 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL..................................................................................................................................... 154 TIRE AND WHEEL..................................................................................................................................................................... 156 TROUBLESHOOTING.................................................................................................................................................................... 157 PRECAUTIONS WHEN TROUBLESHOOTING............................................................................................................................................... 158 METHOD OF READING TROUBLESHOOTING TABLE........................................................................................................................................ 160 PREVENTING RECURRENCE OF TROUBLE............................................................................................................................................... 162 JUDGEMENT ON POWER TRAIN....................................................................................................................................................... 163 TROUBLESHOOTING TABLE.......................................................................................................................................................... 166 1. MACHINE DOES NOT MOVE................................................................................................................................................... 166 2. MACHINE LACKS POWER OR SPEED............................................................................................................................................ 168 3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OF SHIFTING GEAR............................................................................................................... 169 4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH............................................................................................................................... 170 23 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 171 DAMPER............................................................................................................................................................................. 172 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999).............................................................................................................................. 172 REMOVAL AND INSTALLATION (SERIAL NO. 20001 AND UP)............................................................................................................................. 173 DISASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................................................... 174 ASSEMBLY (SERIAL NO. 10001-19999).............................................................................................................................................. 176 DISASSEMBLY (SERIAL NO. 20001 AND UP).......................................................................................................................................... 178 ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................................. 180 TORQUE CONVERTER CHARGING PUMP..................................................................................................................................................... 184 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999).............................................................................................................................. 184 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 185 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 186 TORQUE CONVERTER AND TRANSMISSION.................................................................................................................................................. 187 REMOVAL(SERIAL NO. 10001-19999)................................................................................................................................................ 187 INSTALLATION(SERIAL NO. 10001-19999)........................................................................................................................................... 195 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 205 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 213 TORQUE CONVERTER ASSEMBLY.......................................................................................................................................................... 222 DISASSEMBLY.................................................................................................................................................................... 222 ASSEMBLY....................................................................................................................................................................... 226 TRANSMISSION ASSEMBLY.............................................................................................................................................................. 232 DISASSEMBLY.................................................................................................................................................................... 232 ASSEMBLY....................................................................................................................................................................... 247 TRANSFER ASSEMBLY.................................................................................................................................................................. 262 DISASSEMBLY.................................................................................................................................................................... 262 ASSEMBLY....................................................................................................................................................................... 266 TRANSMISSION CONTROL VALVE......................................................................................................................................................... 273 REMOVAL........................................................................................................................................................................ 273 INSTALLATION................................................................................................................................................................... 276 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................... 279 FRONT DIFFERENTIAL................................................................................................................................................................. 283 REMOVAL........................................................................................................................................................................ 283 INSTALLATION................................................................................................................................................................... 287 REAR DIFFERENTIAL.................................................................................................................................................................. 291 REMOVAL........................................................................................................................................................................ 291 INSTALLATION................................................................................................................................................................... 295 DIFFERENTIAL....................................................................................................................................................................... 299 DISASSEMBLY.................................................................................................................................................................... 299 ASSEMBLY....................................................................................................................................................................... 302 FRONT AXLE......................................................................................................................................................................... 310 REMOVAL........................................................................................................................................................................ 310 INSTALLATION................................................................................................................................................................... 313 REAR AXLE.......................................................................................................................................................................... 316 REMOVAL........................................................................................................................................................................ 316 INSTALLATION................................................................................................................................................................... 321 DRIVE SHAFT........................................................................................................................................................................ 326 DISASSEMBLY.................................................................................................................................................................... 326 ASSEMBLY....................................................................................................................................................................... 328 FINAL DRIVE........................................................................................................................................................................ 330 DISASSEMBLY.................................................................................................................................................................... 330 ASSEMBLY....................................................................................................................................................................... 334 24 MAINTENANCE STANDARD................................................................................................................................................................ 339 TRANSMISSION MOUNT................................................................................................................................................................. 340 TORQUE CONVERTER CHARGING PUMP..................................................................................................................................................... 341 DAMPER............................................................................................................................................................................. 342 TORQUE CONVERTER................................................................................................................................................................... 345 TORQFLOW TRANSMISSION.............................................................................................................................................................. 347 1. TRANSMISSION................................................................................................................................................................ 347 2. TRANSMISSION CONTROL VALVE.................................................................................................................................................. 350 3. SOLENOID VALVE.............................................................................................................................................................. 358 TRANSFER........................................................................................................................................................................... 359 DIFFERENTIAL....................................................................................................................................................................... 361 FINAL DRIVE........................................................................................................................................................................ 365 DRIVE SHAFT........................................................................................................................................................................ 367 AXLE MOUNT......................................................................................................................................................................... 368 40 STEERING SYSTEM......................................................................................................................................................................... 370 41 STRUCTURE AND FUNCTION.............................................................................................................................................................. 370 GENERAL............................................................................................................................................................................ 371 HYDRAULIC CIRCUIT FOR STEERING..................................................................................................................................................... 373 STEERING VALVE..................................................................................................................................................................... 379 TWO-WAY RESTRICTOR VALVE........................................................................................................................................................... 400 ORBIT-ROLL VALVE................................................................................................................................................................... 401 STOP VALVE......................................................................................................................................................................... 405 STEERING PUMP...................................................................................................................................................................... 406 STEERING CYLINDER.................................................................................................................................................................. 407 STEERING COLUMN AND GEAR BOX....................................................................................................................................................... 408 STEERING LINKAGE................................................................................................................................................................... 409 STEERING COLUMN AND ORBIT-ROLL..................................................................................................................................................... 410 CENTER HINGE PIN................................................................................................................................................................... 411 42 TESTING AND ADJUSTING............................................................................................................................................................... 413 STANDARD VALUE TABLE............................................................................................................................................................... 414 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 414 MEASURING STEERING WHEEL PLAY...................................................................................................................................................... 415 MEASURING OPERATING FORCE OF STEERING WHEEL........................................................................................................................................ 416 OPERATING TIME OF STEERING WHEEL................................................................................................................................................... 417 TESTING STEERING LINKAGE........................................................................................................................................................... 418 ADJUSTING STEERING LINKAGE......................................................................................................................................................... 419 STEERING OIL PRESSURE.............................................................................................................................................................. 420 TROUBLESHOOTING.................................................................................................................................................................... 422 TROUBLESHOOTING TABLE (SERIAL NO. 10001-20000)................................................................................................................................. 423 1. STEERING WHEEL DOES NOT TURN............................................................................................................................................ 423 2. STEERING WHEEL IS SLUGGISH.............................................................................................................................................. 424 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.......................................................................................................... 425 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING.............................................................................................. 425 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT.............................................................................................................................. 425 TROUBLESHOOTING TABLE (SERIAL NO. 20001 AND UP)................................................................................................................................ 426 1. STEERING WHEEL DOES NOT TURN............................................................................................................................................ 426 2. STEERING WHEEL IS SLUGGISH.............................................................................................................................................. 427 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.......................................................................................................... 428 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING.............................................................................................. 428 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT.............................................................................................................................. 428 6. WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT, CHASSIS IS SUBJECTED TO LARGE SHOCK............................................................................... 428 43 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 429 STEERING GEAR...................................................................................................................................................................... 430 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 430 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 431 DISASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................................................... 432 ASSEMBLY (SERIAL NO. 10001-19999).............................................................................................................................................. 433 STEERING VALVE..................................................................................................................................................................... 436 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 436 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 438 DISASSEMBLY (SERIAL NO. 20001 AND UP).......................................................................................................................................... 441 ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................................. 444 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 449 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 451 DISASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................................................... 453 ASSEMBLY (SERIAL NO. 10001-19999).............................................................................................................................................. 455 STEERING DEMAND VALVE.............................................................................................................................................................. 457 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 457 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 459 DISASSEMBLY (SERIAL NO. 20001 AND UP).......................................................................................................................................... 462 ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................................. 466 STEERING PUMP...................................................................................................................................................................... 470 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 470 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 471 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 472 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 473 STEERING CYLINDER.................................................................................................................................................................. 474 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 474 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 475 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 476 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 477 DISASSEMBLY.................................................................................................................................................................... 478 ASSEMBLY....................................................................................................................................................................... 480 CENTER HINGE PIN................................................................................................................................................................... 483 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 483 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 492 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 503 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 512 44 MAINTENANCE STANDARD................................................................................................................................................................ 523 STEERING LINKAGE................................................................................................................................................................... 524 STEERING COLUMN AND GEAR BOX....................................................................................................................................................... 526 STEERING COLUMN AND ORBIT-ROLL..................................................................................................................................................... 527 STEERING VALVE..................................................................................................................................................................... 528 STEERING PUMP...................................................................................................................................................................... 531 STEERING CYLINDER MOUNT............................................................................................................................................................ 532 STEERING CYLINDER.................................................................................................................................................................. 534 CENTER HINGE PIN................................................................................................................................................................... 535 50 BRAKE AND AIR SYSTEM.................................................................................................................................................................... 537 51 STRUCTURE AND FUNCTION.............................................................................................................................................................. 537 GENERAL............................................................................................................................................................................ 538 BRAKE AND AIR PIPING............................................................................................................................................................... 539 BRAKE AND AIR CIRCUIT SYSTEM....................................................................................................................................................... 541 AIR TANK........................................................................................................................................................................... 543 SAFETY VALVE....................................................................................................................................................................... 545 BRAKE VALVE........................................................................................................................................................................ 546 BRAKE ACTUATED................................................................................................................................................................. 547 OPERATING IN BALANCE........................................................................................................................................................... 548 BRAKE RELEASED................................................................................................................................................................. 549 AIR GOVERNOR....................................................................................................................................................................... 550 TWO-WAY VALVE...................................................................................................................................................................... 552 BRAKE CHAMBER...................................................................................................................................................................... 553 SLACK ADJUSTER..................................................................................................................................................................... 555 BRAKE.............................................................................................................................................................................. 558 PARKING BRAKE...................................................................................................................................................................... 561 PARKING BRAKE SOLENOID VALVE....................................................................................................................................................... 563 SPRING CYLINDER.................................................................................................................................................................... 564 BRAKE CALIPER...................................................................................................................................................................... 565 52 TESTING AND ADJUSTING............................................................................................................................................................... 566 STANDARD VALUE TABLE............................................................................................................................................................... 567 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 568 MEASURING BRAKE PEDAL.............................................................................................................................................................. 569 MEASURING AIR...................................................................................................................................................................... 570 BRAKE PERFORMANCE.................................................................................................................................................................. 573 CHECKING BRAKE OIL PRESSURE........................................................................................................................................................ 574 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................... 575 AIR BLEEDING FROM BRAKE LINE....................................................................................................................................................... 577 PARKING BRAKE PERFORMANCE.......................................................................................................................................................... 578 CHECKING AND ADJUSTING PARKING BRAKE............................................................................................................................................... 579 TROUBLESHOOTING.................................................................................................................................................................... 581 TROUBLESHOOTING TABLE.......................................................................................................................................................... 582 1. AIR PRESSURE DOES NOT RISES AT ALL...................................................................................................................................... 582 2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE....................................................................................................................... 583 3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE.............................................................................................................................. 584 4. BRAKE DOES NOT RELEASE, OR DRAGS........................................................................................................................................ 585 5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS................................................................................................................................ 586 53 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 587 AIR GOVERNOR....................................................................................................................................................................... 588 DISASSEMBLY.................................................................................................................................................................... 588 ASSEMBLY....................................................................................................................................................................... 589 BRAKE VALVE........................................................................................................................................................................ 590 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 590 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 591 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 592 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 593 DISASSEMBLY.................................................................................................................................................................... 594 ASSEMBLY....................................................................................................................................................................... 596 BRAKE CHAMBER...................................................................................................................................................................... 598 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 598 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 599 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 600 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 602 DISASSEMBLY.................................................................................................................................................................... 604 ASSEMBLY....................................................................................................................................................................... 607 SLACK ADJUSTER..................................................................................................................................................................... 610 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999).............................................................................................................................. 610 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 611 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 613 DISASSEMBLY.................................................................................................................................................................... 615 ASSEMBLY....................................................................................................................................................................... 616 BRAKE ASSEMBLY..................................................................................................................................................................... 617 DISASSEMBLY.................................................................................................................................................................... 617 ASSEMBLY....................................................................................................................................................................... 624 DISASSEMBLY (SERIAL NO. 20001 AND UP).......................................................................................................................................... 632 ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................................. 638 SPRING CYLINDER.................................................................................................................................................................... 646 REMOVAL........................................................................................................................................................................ 646 INSTALLATION................................................................................................................................................................... 647 DISASSEMBLY.................................................................................................................................................................... 648 ASSEMBLY....................................................................................................................................................................... 650 PARKING BRAKE...................................................................................................................................................................... 652 REMOVAL........................................................................................................................................................................ 652 INSTALLATION................................................................................................................................................................... 654 PARKING BRAKE PAD.................................................................................................................................................................. 657 REMOVAL AND INSTALLATION....................................................................................................................................................... 657 54 MAINTENANCE STANDARD................................................................................................................................................................ 658 BRAKE VALVE........................................................................................................................................................................ 659 BRAKE CHAMBER...................................................................................................................................................................... 661 SLACK ADJUSTER..................................................................................................................................................................... 662 BRAKE.............................................................................................................................................................................. 663 PARKING BRAKE...................................................................................................................................................................... 667 SPRING CYLINDER.................................................................................................................................................................... 668 60 WORK EQUIPMENT SYSTEM................................................................................................................................................................... 669 61 STRUCTURE AND FUNCTION.............................................................................................................................................................. 669 GENERAL............................................................................................................................................................................ 670 HYDRAULIC PIPING................................................................................................................................................................... 671 HYDRAULIC CIRCUIT SYSTEM........................................................................................................................................................... 673 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................................................... 674 HYDRAULIC TANK..................................................................................................................................................................... 677 OIL FILTER BYPASS VALVE........................................................................................................................................................ 679 BREATHER....................................................................................................................................................................... 680 HYDRAULIC PUMPS.................................................................................................................................................................... 681 ใปHYDRAULIC PUMP................................................................................................................................................................ 681 ใปSWITCH AND POC PUMP........................................................................................................................................................... 682 ใปSWITCH AND PPC PUMP........................................................................................................................................................... 682 POC VALVE.......................................................................................................................................................................... 683 PPC VALVE.......................................................................................................................................................................... 685 MAIN CONTROL VALVE................................................................................................................................................................. 695 RELIEF VALVE................................................................................................................................................................... 701 SAFETY VALVE (WITH SUCTION VALVE).............................................................................................................................................. 702 SUCTION VALVE.................................................................................................................................................................. 703 FLOAT SELECTOR VALVE AND UNLOADED VALVE........................................................................................................................................ 704 ACCUMULATOR........................................................................................................................................................................ 712 HYDRAULIC CYLINDER................................................................................................................................................................. 713 BUCKET LINKAGE..................................................................................................................................................................... 715 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................ 717 WORK EQUIPMENT LEVER LINKAGE....................................................................................................................................................... 720 62 TESTING AND ADJUSTING............................................................................................................................................................... 722 STANDARD VALUE TABLE............................................................................................................................................................... 723 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................ 726 MEASURING DUMP AND LIFT CONTROL LEVERS............................................................................................................................................. 727 ADJUSTING DUMP AND LIFT CONTROL LEVERS............................................................................................................................................. 728 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT..................................................................................................................................... 730 MEASURING WORK EQUIPMENT........................................................................................................................................................... 733 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT........................................................................................................................................ 734 ADJUSTING BUCKET POSITIONER........................................................................................................................................................ 735 ADJUSTING BOOM KICK-OUT............................................................................................................................................................ 736 TROUBLESHOOTING.................................................................................................................................................................... 737 TROUBLESHOOTING TABLE.......................................................................................................................................................... 738 1. LIFT ARM DOES NOT RISE.................................................................................................................................................. 738 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER......................................................................................................... 739 3 LIFT ARM MOVEMENT BECOMES SLOW AFTER IF REACHES A CERTAIN HEIGHT......................................................................................................... 740 4. BUCKET CANNOT BE HELD DOWN WITH LIFT CYLINDER........................................................................................................................... 740 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT...................................................................................................................................... 740 6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK............................................................................................................................... 740 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"...................................................................................... 740 8. BUCKET DOES NOT TILT BACK............................................................................................................................................... 741 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER................................................................................................................. 742 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK.......................................................................................................................... 743 11. BUCKET CANNOT BE HELD DOWN BY THEN BUCKET CYLINDER..................................................................................................................... 743 12. BUCKET HAS LARGE HYDRAULIC DRIFT....................................................................................................................................... 743 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN "HOLD")................................................................................. 743 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"...................................................................................... 743 15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY........................................................................................................ 744 63 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 745 HYDRAULIC TANK..................................................................................................................................................................... 746 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 746 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 747 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 748 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 752 HYDRAULIC PUMP..................................................................................................................................................................... 755 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 755 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 756 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 757 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 758 HYDRAULIC FILTER................................................................................................................................................................... 759 REMOVAL AND INSTALLATION....................................................................................................................................................... 759 SWITCH, POC PUMP................................................................................................................................................................... 760 REMOVAL AND INSTALLATION (SERIAL NO. 10001-19999).............................................................................................................................. 760 SWITCH, PPC PUMP................................................................................................................................................................... 761 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 761 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 762 POC VALVE.......................................................................................................................................................................... 763 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 763 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 765 DISASSEMBLY AND ASSEMBLY (SERIAL NO. 10001-19999).............................................................................................................................. 767 PPC VALVE.......................................................................................................................................................................... 768 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 768 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 770 DISASSEMBLY AND ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................. 772 MAIN CONTROL VALVE................................................................................................................................................................. 773 REMOVAL (SERIAL NO. 10001-19999)............................................................................................................................................... 773 INSTALLATION (SERIAL NO. 10001-19999).......................................................................................................................................... 775 DISASSEMBLY (SERIAL NO. 10001-19999)........................................................................................................................................... 777 ASSEMBLY (SERIAL NO. 10001-19999).............................................................................................................................................. 779 REMOVAL (SERIAL NO. 20001 AND UP).............................................................................................................................................. 781 INSTALLATION (SERIAL NO. 20001 AND UP)......................................................................................................................................... 784 DISASSEMBLY (SERIAL NO. 20001 AND UP).......................................................................................................................................... 786 ASSEMBLY (SERIAL NO. 20001 AND UP)............................................................................................................................................. 788 DUMP CYLINDER...................................................................................................................................................................... 790 REMOVAL........................................................................................................................................................................ 790 INSTALLATION................................................................................................................................................................... 792 LIFT CYLINDER...................................................................................................................................................................... 794 REMOVAL........................................................................................................................................................................ 794 INSTALLATION................................................................................................................................................................... 795 LIFT AND DUMP CYLINDERS............................................................................................................................................................ 796 DISASSEMBLY.................................................................................................................................................................... 796 ASSEMBLY....................................................................................................................................................................... 798 WORK EQUIPMENT..................................................................................................................................................................... 801 REMOVAL........................................................................................................................................................................ 801 INSTALLATION................................................................................................................................................................... 804 COUNTERWEIGHT...................................................................................................................................................................... 807 REMOVAL AND INSTALLATION....................................................................................................................................................... 807 64 MAINTENANCE STANDARD................................................................................................................................................................ 808 MAIN CONTROL VALVE................................................................................................................................................................. 809 SWITCH AND POC (PPC) PUMP.......................................................................................................................................................... 817 HYDRAULIC PUMP..................................................................................................................................................................... 819 POC VALVE.......................................................................................................................................................................... 820 POC VALVE (RELIEF VALVE)........................................................................................................................................................... 821 PPC VALVE.......................................................................................................................................................................... 822 DUMP CYLINDER...................................................................................................................................................................... 824 LIFT CYLINDER...................................................................................................................................................................... 825 BUCKET LINKAGE..................................................................................................................................................................... 826 BUCKET POSITIONER AND BOOM KICK-OUT................................................................................................................................................ 828 BUCKET............................................................................................................................................................................. 829 80 ELECTRIC AND ELECTRONIC SYSTEM.......................................................................................................................................................... 830 81 STRUCTURE AND FUNCTION.............................................................................................................................................................. 830 ELECTRICAL WIRING DIAGRAM.......................................................................................................................................................... 831 ELECTRICAL WIRING DIAGRAM CIRCUIT.................................................................................................................................................. 832 ENGINE STARTING CIRCUIT............................................................................................................................................................ 839 ENGINE STOP CIRCUIT................................................................................................................................................................ 842 PREHEATING CIRCUIT................................................................................................................................................................. 845 PREHEATING AND AFTER-HEATING WITH HEATER SWITCH................................................................................................................................ 845 PREHEATING WITH STARTING SWITCH................................................................................................................................................ 846 AUTOMATIC PREHEATING........................................................................................................................................................... 847 COMBINATION SWITCH................................................................................................................................................................. 848 ELECTRICAL TRANSMISSION CONTROL.................................................................................................................................................... 849 TRANSMISSION CUT-OFF SWITCH.................................................................................................................................................... 851 TRANSMISSION CUT-OFF SELECTOR SWITCH........................................................................................................................................... 852 NEUTRALIZER RELAY.............................................................................................................................................................. 854 KICK-DOWN SWITCH............................................................................................................................................................... 856 KICK-DOWN ELECTRIC CIRCUIT..................................................................................................................................................... 857 ELECTRICAL PARKING BRAKE CONTROL................................................................................................................................................... 863 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)........................................................................................................................................ 875 INDICATION ON MONITOR PANEL.................................................................................................................................................... 879 CONTROLLER..................................................................................................................................................................... 881 SENSOR............................................................................................................................................................................. 882 WIRING HARNESS................................................................................................................................................................. 888 OPERATION OF PROXIMITY SWITCH.................................................................................................................................................. 890 82 TESTING AND ADJUSTING............................................................................................................................................................... 894 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM......................................................................................................................................... 895 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)..................................................................................................................................... 897 TROUBLESHOOTING.................................................................................................................................................................... 899 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................................. 900 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.............................................................................................................................. 901 CONNECTOR TERMINAL NUMBERS..................................................................................................................................................... 903 PRECAUTION WHEN HANDING CONNECTOR.............................................................................................................................................. 908 ELECTRICAL WIRING DIAGRAM...................................................................................................................................................... 910 ELECTRICAL CIRCUIT SYSTEM...................................................................................................................................................... 912 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO. 10001-20000)............................................................................................................. 922 E-1 ENGINE DOES NOT START.................................................................................................................................................. 923 E-1A ENGINE DOES NOT START................................................................................................................................................. 925 E-2 ENGINE DOES NOT STOP................................................................................................................................................... 927 E-3 ENGINE STOPS WHEN TRAVELING............................................................................................................................................ 929 E-4 PARKING BRAKE DOES NOT WORK............................................................................................................................................ 931 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING................................................................................................................................ 933 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON......................................................................................................... 935 E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.................................................................................................. 936 E-8 MACHINE DOES NOT TRAVEL FORWARD........................................................................................................................................ 937 E-9 MACHINE DOES NOT TRAVEL REVERSE........................................................................................................................................ 939 E-10 TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL).................................................................................................................. 941 E-11 MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON (MACHINE TRAVELS ONLY WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS OFF)....................... 943 E-12 TRANSMISSION CANNOT BE CUT-OFF........................................................................................................................................ 944 E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL............................................................................................................................... 945 E-14 PREHEATING DISPLAY DOES NOT GO OUT.................................................................................................................................... 947 E-15 PREHEATING DOES NOT WORK.............................................................................................................................................. 948 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.20001 AND UP)............................................................................................................. 949 POSITION OF CONNECTORS FOR TROUBLESHOOTING................................................................................................................................. 950 E-1 ENGINE DOES NOT START.................................................................................................................................................. 956 E-2 ENGINE DOES NOT STOP................................................................................................................................................... 960 E-3 ENGINE STOPS WHEN TRAVELING............................................................................................................................................ 960 E-4 PARKING BRAKE DOES NOT WORK............................................................................................................................................ 961 E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING................................................................................................................................ 962 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON......................................................................................................... 964 E-7 WHEN PARKING BRAKE IS APPLIED,SHIFT LEVER DOES NOT ENTER NEUTRAL....................................................................................................... 964 E-8 TRANSMISSION DOES NOT WORK NORMALLY.................................................................................................................................... 965 E-9 KICK-DOWN SWITCH DOES NOT WORK(NORMAL F1-F4 SWITCHES CORRECTLY)........................................................................................................ 985 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON(KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)....................................................... 988 E-11 KICK-DOWN OPERATION IS NOT CANCELED................................................................................................................................... 989 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2....................................................................................................................... 991 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.............................................................................................................. 991 E-14 PREHEAT DISPLAY STAYS ON.............................................................................................................................................. 993 E-15 PREHEATING DOES NOT STOP.............................................................................................................................................. 993 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO. 10001-11147, SERIAL NO.10001-11151 (D SPEC.)]....................................................... 994 TROUBLESHOOTING TABLE(ELECTRONIC VEHICLE MONITORING SYSTEM)................................................................................................................ 996 M-1 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),CHECK BEFORE STARTING ITEM FLASHES............................................................................. 997 a) BRAKE OIL LEVEL..................................................................................................................................................... 997 b) ENGINE OIL LEVEL.................................................................................................................................................... 998 c) COOLANT LEVEL....................................................................................................................................................... 999 M-2 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEM FLASHES................................................................................................1000 a) BATTERY CHARGE......................................................................................................................................................1000 b) FUEL LEVEL..........................................................................................................................................................1001 M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),EMERGENCY ITEMS FLASHES.............................................................................................1002 a) FAILURE IN BRAKE LINE...............................................................................................................................................1002 b) ENGINE OIL PRESSURE.................................................................................................................................................1003 c) COOLANT LEVEL.......................................................................................................................................................1004 d) DROP IN AIR PRESSURE................................................................................................................................................1005 e) COOLANT TEMPERATURE.................................................................................................................................................1006 f) TORQUE CONVERTER OIL TEMPERATURE....................................................................................................................................1007 M-4 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),PILOT ITEMS LIGHT UP ABNORMALLY, OR DOES NOT LIGHT UP..........................................................1008 a) PARKING BRAKE DISPLAY DOES NOT GO OUT...............................................................................................................................1008 b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP.............................................................................................................................1009 c) WORKING LAMP DISPLAY DOES NOT GO OUT................................................................................................................................1010 d) WORKING LAMP DISPLAY DOES NT LIGHT UP...............................................................................................................................1011 e) PREHEAT DISPLAY LIGHTS UP...........................................................................................................................................1012 f) PREHEAT DISPLAY DOES NOT LIGHT UP...................................................................................................................................1013 g) FAILURE IN MAIN STEERING DISPLAY LIGHT UP (IF EQUIPPED).............................................................................................................1014 h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)....................................................................................................1015 I) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED)...........................................................................................................1016 j) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)...................................................................................................1017 k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP..............................................................................................................................1018 l) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP......................................................................................................................1019 M-5 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY , OR DO NOT LIGHT UP..................................................................................................1020 a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP.................................................................................................................1020 b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP..................................................................................................................1020 c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.........................................................................................................1021 d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP..........................................................................................................1022 e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP..............................................................................................................................1023 f) HIGH BEAM PILOT LAMP DOES NOT WORK NORMALLY.........................................................................................................................1024 M-6 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.............................................................................................................................1025 M-7 SERVICEMETER DOES NOT WORK NORMALLY....................................................................................................................................1026 M-8 ABNORMALITY IN MONITOR PANEL...........................................................................................................................................1028 a) NONE OF MONITOR PANEL WORKS.........................................................................................................................................1028 b) PART OF MONITOR PANEL DOES NOT WORK.................................................................................................................................1030 c) EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE FLASHES, CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP.....................................................1031 d) EVEN WHEN ENGINE IS STOPPED, BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP......................................................................................1032 e) NO LAMPS ON MONITOR LIGHTS UP(IMMEDIATELY AFTER TURNING STARTING SWITCH TO "ON",ENGINE STOPPED).....................................................................1032 f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY..................................................................................1033 g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.........................................................................................................................1034 h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY...................................................................................1035 I) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..........................................................................................................................1036 M-9 ABNORMALITY IN PANEL LAMPS ON MONITOR..................................................................................................................................1037 a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED.......................................................................................1037 b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON............................................................................................................1039 c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP.........................................................................................................................1040 d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP..........................................................................................1041 e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP........................................................................................................................1042 M-10 ABNORMALITY IN ALARM BUZZER OR WARNING LAMP...........................................................................................................................1043 a) EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND.........................................................................................................1043 b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMPS DOES NOT FLASH..................................................................................1045 M-11 ABNORMALITY IN GAUGE..................................................................................................................................................1047 a) FUEL GAUGE..........................................................................................................................................................1047 b) AIR PRESSURE GAUGE..................................................................................................................................................1049 c) COOLANT TEMPERATURE GAUGE...........................................................................................................................................1051 d) TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................................................1053 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO. 11148 AND UP, SERIAL NO. 11152 AND UP (D SPEC.)]....................................................1055 POSITION OF CONNECTORS FOR TROUBLESHOOTING [SERIAL NO. 11148 AND 20000,SERIAL NO. 11152-20000(D SPEC.)]....................................................................1057 POSITION OF CONNECTORS FOR TROUBLESHOOTING(SERIAL NO.20001 AND UP).........................................................................................................1063 M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS...........................................................................1069 a) NONE OF MONITOR PANEL LIGHTS UP.....................................................................................................................................1069 b) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHTS UP......................................................................................................1069 c) NONE OF CAUTION ITEMS LIGHT UP......................................................................................................................................1069 d) SOME OTHER PARTS DO NOT LIGHT UP....................................................................................................................................1069 M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT.........................................................................1070 M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES. (LEVELS OF CHECK ITEMS ARE CORRECT)................................................1071 a) (ENGINE OIL LEVEL) FLASHES..........................................................................................................................................1071 b) (RADIATOR WATER LEVEL) FLASHES......................................................................................................................................1072 c) (BRAKE OIL LEVEL) FLASHES...........................................................................................................................................1072 M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY..............................................................................................1074 a) (PREHEAT) LIGHT UP..................................................................................................................................................1074 b) (TRANSMISSION CUT-OFF) LIGHTS UP....................................................................................................................................1074 c) (PARKING BRAKE) LIGHTS UP...........................................................................................................................................1075 d) (WORKING LAMP) LIGHTS UP............................................................................................................................................1075 M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES.....................................................................................1077 a) ENGINE OIL PRESSURE SYSTEM..........................................................................................................................................1077 b) ALTERNATOR SYSTEM...................................................................................................................................................1077 M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM FLASHES...................................................................................1078 a) ENGINE OIL PRESSURE SYSTEM..........................................................................................................................................1078 b) ALTERNATOR SYSTEM...................................................................................................................................................1078 M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE).............................................1080 a) (CHARGE LEVEL) FLASHES..............................................................................................................................................1080 b) (FUEL LEVEL) FLASHES................................................................................................................................................1080 c) (BRAKE LINE FAILURE) FLASHES........................................................................................................................................1080 d) (ENGINE OIL PRESSURE) FLASHES.......................................................................................................................................1080 e) (RADIATOR WATER LEVEL) FLASHES......................................................................................................................................1080 f) (AIR PRESSURE) FLASHES..............................................................................................................................................1081 g) (ENGINE WATER TEMPERATURE) FLASHES..................................................................................................................................1081 h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES..........................................................................................................................1081 M-8 SPEED SENSOR DISPLAY STAYS AT '0'......................................................................................................................................1083 M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY...................................................................................................................1084 a) IF HIGH BEAM DOES NOT LIGHT UP......................................................................................................................................1084 b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF.................................................................................................................1084 c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION....................................................................................1085 M-10 TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING..................................................................................1086 a) IF TURN SIGNAL LAMP DOES NOT FLASH..................................................................................................................................1086 b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING..............................................................................................................1086 M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND...................1087 M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS...................................................................................................1088 M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH....1089 M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP................................................................................................1089 M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT UP FOR 4 SEC. WHEN LAMP SWITCH IS ON, LAMPS DO NOT LIGHT UP.........................................1090 a) NONE OF PANEL LIGHTS UP.............................................................................................................................................1090 b) SOME OF PANEL LAMPS DO NOT LIGHT UP.................................................................................................................................1090 M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON..............................................................................1091 M-17 SERVICE METER DOES NOT WORK...........................................................................................................................................1092 M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED............................................................................................................................1092 M-19 ABNORMALITY IN AIR PRESSURE GAUGE.....................................................................................................................................1093 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1093 b) IF INDICATOR REMAINS AT MAXIMUM LEVEL...............................................................................................................................1093 M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.........................................................................................................................1094 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1094 b) IF INDICATOR REMAINS AT MAXIMUM LEVEL...............................................................................................................................1094 M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.................................................................................................................1095 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1095 b) IF INDICATOR REMAINS AT MAXIMUM LEVEL...............................................................................................................................1095 M-22 ABNORMALITY IN FUEL GAUGE.............................................................................................................................................1096 a) IF NOTHING IS DISPLAYED IN DISPLAY AREA.............................................................................................................................1096 b) IF INDICATOR REMAINS AT FULL........................................................................................................................................1096 83 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................1097 MACHINE MONITOR....................................................................................................................................................................1098 REMOVAL AND INSTALLATION.......................................................................................................................................................1098 90 OTHERS..................................................................................................................................................................................1099 91 STRUCTURE AND FUNCTION..............................................................................................................................................................1099 CAB................................................................................................................................................................................1100 AIR CONDITIONER (IF EQUIPPED)......................................................................................................................................................1101 PIPING.........................................................................................................................................................................1101 AIR CONDITIONER WIRING DIAGRAM.................................................................................................................................................1102 AIR CONDITIONER ELECTRIC CIRCUIT...............................................................................................................................................1102 AIR CONDITIONER UNIT...........................................................................................................................................................1103 COMPRESSOR.....................................................................................................................................................................1104 CONDENSER......................................................................................................................................................................1104 DRY RESERVOIR..................................................................................................................................................................1105 93 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................1106 CAB................................................................................................................................................................................1107 REMOVAL........................................................................................................................................................................1107 INSTALLATION...................................................................................................................................................................1108 AIR CONDITIONER UNIT (OPTION)......................................................................................................................................................1109 REMOVAL........................................................................................................................................................................1109 INSTALLATION...................................................................................................................................................................1111 CONDENSER FOR AIR CONDITIONER (OPTION).............................................................................................................................................1113 REMOVAL AND INSTALLATION.......................................................................................................................................................1113 DRY RESERVOIR (OPTION).............................................................................................................................................................1114 REMOVAL AND INSTALLATION.......................................................................................................................................................1114 COMPRESSOR FOR AIR CONDITIONER (OPTION)............................................................................................................................................1115 REMOVAL AND INSTALLATION.......................................................................................................................................................1115 97 GEAR PUMP...........................................................................................................................................................................1116 97 GENERAL.........................................................................................................................................................................1116 GENERAL........................................................................................................................................................................1117 PRINCIPLE OF OPERATION.........................................................................................................................................................1118 PRESSURE LOADED TYPE GEAR PUMP.................................................................................................................................................1121 FIXED SIDE PLATE TYPE GEAR PUMP................................................................................................................................................1123 97 SA SERIES.......................................................................................................................................................................1124 STRUCTURE......................................................................................................................................................................1125 TESTING AND ADJUSTING..........................................................................................................................................................1128 DISASSEMBLY....................................................................................................................................................................1131 ASSEMBLY.......................................................................................................................................................................1135 MAINTENANCE STANDARD...........................................................................................................................................................1140
DESCRIPTION:
KOMATSU WA450-1 SHOP MANUAL SEBM04210108 – PDF DOWNLOAD
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 chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as wall as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 29/12/24
