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KOMATSU WA600-1 SHOP MANUAL SEBM04260111 – PDF DOWNLOAD
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KOMATSU WA600-1 SHOP MANUAL SEBM04260111 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA600-1 SHOP MANUAL SEBM04260111 – PDF DOWNLOAD
Language : English
Pages : 1210
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA600-1 SHOP MANUAL SEBM04260111 – PDF DOWNLOAD
MAIN MENU.............................................................................................................................................. 0 CONTENTS............................................................................................................................................... 2 10 ENGINE.............................................................................................................................................. 27 12 TESTING AND ADJUSTING........................................................................................................................... 27 STANDARD VALUE TABLE .......................................................................................................................... 28 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................... 31 ADJUSTING VALVE CLEARANCE ..................................................................................................................... 32 MEASURING COMPRESSION PRESSURE ................................................................................................................ 33 TESTING AND ADJUSTING FUEL INJECTION TIMING ................................................................................................... 34 MEASURING BLOW-BY PRESSURE .................................................................................................................... 36 TESTING AND ADJUSTING ALTERNATOR DRIVE BELT TENSION .......................................................................................... 37 MEASURING EXHAUST GAS COLOR ................................................................................................................... 38 MEASURING ENGINE OIL PRESSURE AND TEMPERATURE ................................................................................................. 39 ADJUSTING FUEL CUT SOLENOID ................................................................................................................... 40 ADJUSTMENT OF ENGINE STOP MOTOR CABLE ......................................................................................................... 41 MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE ............................................................................. 42 MEASURING ACCELERATOR PEDAL ................................................................................................................... 44 13 DISASSEMBLY AND ASSEMBLY........................................................................................................................ 47 STARTING MOTOR................................................................................................................................. 48 REMOVAL ................................................................................................................................... 48 INSTALLATION ............................................................................................................................. 48 ALTERNATOR..................................................................................................................................... 49 REMOVAL ................................................................................................................................... 49 INSTALLATION .............................................................................................................................. 49 OIL COOLER..................................................................................................................................... 50 REMOVAL ................................................................................................................................... 50 INSTALLATION............................................................................................................................... 50 FUEL INJECTION PUMP............................................................................................................................ 51 REMOVAL ................................................................................................................................... 51 INSTALLATION .............................................................................................................................. 51 WATER PUMP..................................................................................................................................... 52 REMOVAL.................................................................................................................................... 52 INSTALLATION .............................................................................................................................. 52 NOZZLE HOLDER.................................................................................................................................. 53 REMOVAL ................................................................................................................................... 53 INSTALLATION .............................................................................................................................. 53 TURBOCHARGER................................................................................................................................... 54 REMOVAL.................................................................................................................................... 54 INSTALLATION .............................................................................................................................. 54 AIR COMPRESSOR................................................................................................................................. 55 ASSEMBLY .................................................................................................................................. 55 INSTALLATION .............................................................................................................................. 55 CYLINDER HEAD.................................................................................................................................. 56 REMOVAL ................................................................................................................................... 56 INSTALLATION .............................................................................................................................. 61 RADIATOR....................................................................................................................................... 67 REMOVAL.................................................................................................................................... 67 INSTALLATION .............................................................................................................................. 70 ENGINE......................................................................................................................................... 73 REMOVAL ................................................................................................................................... 73 INSTALLATION .............................................................................................................................. 81 FUEL TANK...................................................................................................................................... 89 REMOVAL ................................................................................................................................... 89 INSTALLATION .............................................................................................................................. 91 20 POWER TRAIN......................................................................................................................................... 93 21 STRUCTURE AND FUNCTION.......................................................................................................................... 93 GENERAL ....................................................................................................................................... 94 LOCATION OF COMPONENTS .................................................................................................................... 94 POWER TRAIN ............................................................................................................................... 95 HYDRAULIC CIRCUIT SCHEMATICS FOR POWER TRAIN .............................................................................................. 96 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ................................................................................................. 97 TRANSMISSION MOUNT ............................................................................................................................ 98 TORQUE CONVERTER AND TRANSMISSION PIPING ...................................................................................................... 99 TORQUE CONVERTER OIL COOLER ................................................................................................................... 100 TORQUE CONVERTER OIL FILTER ................................................................................................................... 101 LUBRICATION BYPASS VALVE ...................................................................................................................... 102 PILOT OIL FILTER .............................................................................................................................. 103 TORQUE CONVERTER .............................................................................................................................. 104 TORQUE CONVERTER REGULATOR VALVE .............................................................................................................. 106 TORQUE CONVERTER RELIEF VALVE ................................................................................................................. 108 TRANSMISSION...................................................................................................................................1210 TRANSMISSION CONTROL VALVE .................................................................................................................... 115 UPPER VALVE ............................................................................................................................... 116 LOWER VALVE ............................................................................................................................... 117 MAIN RELIEF VALVE ......................................................................................................................... 118 PRIORITY VALVE ............................................................................................................................ 119 MODULATING VALVE AND QUICK RETURN VALVE ................................................................................................... 120 REDUCING VALVE ............................................................................................................................ 122 ACCUMULATOR VALVE ......................................................................................................................... 123 PILOT REDUCING VALVE ...................................................................................................................... 125 TRANSMISSION SOLENOID VALVE ................................................................................................................... 126 EMERGENCY MANUAL SPOOL ........................................................................................................................ 128 TRANSFER ...................................................................................................................................... 129 DRIVE SHAFT ................................................................................................................................... 130 CENTER SUPPORT ................................................................................................................................ 131 AXLE MOUNT .................................................................................................................................... 132 AXLE AND DIFFERENTIAL ........................................................................................................................ 134 FINAL DRIVE ................................................................................................................................... 139 TIRE AND WHEEL................................................................................................................................. 140 22 TESTING AND ADJUSTING........................................................................................................................... 141 STANDARD VALUE TABLE .......................................................................................................................... 142 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................... 143 MEASURING ENGINE STALL SPEED .................................................................................................................. 144 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION .................................................................................. 146 MEASURING SPEED LEVER ......................................................................................................................... 148 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ................................................................................................ 149 TIRE AND WHEEL................................................................................................................................. 150 TROUBLESHOOTING................................................................................................................................ 151 PRECAUTIONS WHEN TROUBLESHOOTING .......................................................................................................... 152 METHOD OF READING TROUBLESHOOTING TABLE ................................................................................................... 154 PREVENTING RECURRENCE OF TROUBLE .......................................................................................................... 156 METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM .......................................................... 157 TROUBLESHOOTING TABLE ..................................................................................................................... 158 1. Machine does not move............................................................................................................... 158 2. Machine lacks power or speed ....................................................................................................... 160 3. Excessive timing lag when starting machine or shifting gear......................................................................... 161 4. Torque converter oil temperature too high .......................................................................................... 162 23 DISASSEMBLY AND ASSEMBLY........................................................................................................................ 163 HYDRAULIC PUMP................................................................................................................................. 164 REMOVAL.................................................................................................................................... 164 INSTALLATION............................................................................................................................... 166 TORQUE CONVERTER............................................................................................................................... 168 REMOVAL.................................................................................................................................... 168 INSTALLATION............................................................................................................................... 172 DISASSEMBLY................................................................................................................................ 178 ASSEMBLY................................................................................................................................... 184 TRANSMISSION................................................................................................................................... 190 REMOVAL.................................................................................................................................... 190 INSTALLATION............................................................................................................................... 198 DISASSEMBLY................................................................................................................................ 206 ASSEMBLY................................................................................................................................... 221 TRANSFER....................................................................................................................................... 237 DISASSEMBLY................................................................................................................................ 237 ASSEMBLY................................................................................................................................... 246 TRANSMISSION CONTROL VALVE..................................................................................................................... 257 REMOVAL.................................................................................................................................... 257 INSTALLATION............................................................................................................................... 258 DISASSEMBLY AND ASSEMBLY................................................................................................................... 260 FRONT DIFFERENTIAL............................................................................................................................. 264 REMOVAL.................................................................................................................................... 264 INSTALLATION............................................................................................................................... 266 REAR DIFFERENTIAL.............................................................................................................................. 270 REMOVAL.................................................................................................................................... 270 INSTALLATION............................................................................................................................... 273 DIFFERENTIAL GEAR.............................................................................................................................. 278 DISASSEMBLY................................................................................................................................ 278 ASSEMBLY................................................................................................................................... 282 FRONT AXLE..................................................................................................................................... 288 REMOVAL.................................................................................................................................... 288 INSTALLATION............................................................................................................................... 290 REAR AXLE...................................................................................................................................... 292 REMOVAL.................................................................................................................................... 292 INSTALLATION............................................................................................................................... 296 CENTER SUPPORT................................................................................................................................. 300 REMOVAL.................................................................................................................................... 300 INSTALLATION............................................................................................................................... 301 DISASSEMBLY................................................................................................................................ 302 ASSEMBLY................................................................................................................................... 304 DRIVE SHAFT.................................................................................................................................... 306 DISASSEMBLY................................................................................................................................ 306 ASSEMBLY................................................................................................................................... 308 FINAL DRIVE.................................................................................................................................... 310 DISASSEMBLY................................................................................................................................ 310 ASSEMBLY................................................................................................................................... 313 24 POWER TRAIN..................................................................................................................................... 317 ENGINE MOUNT .................................................................................................................................. 318 TRANSMISSION MOUNT ............................................................................................................................ 319 TORQUE CONVERTER .............................................................................................................................. 320 TORQUE CONVERTER REGULATOR VALVE .............................................................................................................. 321 TRANSMISSION .................................................................................................................................. 322 TRANSMISSION SOLENOID VALVE ................................................................................................................... 325 TRANSMISSION CONTROL VALVE .................................................................................................................... 326 Upper valve................................................................................................................................ 326 Lower valve................................................................................................................................ 328 TRANSFER ...................................................................................................................................... 330 DRIVE SHAFT ................................................................................................................................... 332 CENTER SUPPORT ................................................................................................................................ 333 AXLE MOUNT .................................................................................................................................... 334 DIFFERENTIAL................................................................................................................................... 336 FINAL DRIVE ................................................................................................................................... 340 40 STEERING SYSTEM..................................................................................................................................... 341 41 STRUCTURE AND FUNCTION.......................................................................................................................... 341 GENERAL ....................................................................................................................................... 342 STEERING COLUMN, GEAR BOX AND LINKAGE ......................................................................................................... 343 HYDRAULIC CIRCUIT FOR STEERING ................................................................................................................ 346 HYDRAULIC CIRCUIT SCHEMATICS .............................................................................................................. 346 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................. 347 STEERING CONTROL SYSTEM ....................................................................................................................... 348 STEERING VALVE ............................................................................................................................ 348 STEERING RELIEF VALVE ..................................................................................................................... 350 SAFETY VALVE (with suction valve) ......................................................................................................... 351 OPERATION OF DEMAND SPOOL ................................................................................................................. 352 OPERATIONS OF STEERING VALVE .............................................................................................................. 355 TWO-WAY RESTRICTOR VALVE ...................................................................................................................... 356 STEERING CYLINDER ............................................................................................................................. 357 CENTER HINGE PIN .............................................................................................................................. 358 EMERGENCY STEERING PIPING (If equipped) ....................................................................................................... 359 EMERGENCY STEERING PUMP (If equipped) ......................................................................................................... 360 DIVERTER VALVE (If equipped) .................................................................................................................. 361 STEERING DEMAND VALVE (MACHINE WITH JOYSTICK STEERING)......................................................................................... 365 STEERING UNIT (ORBIT-ROLL VALVE) (MACHINE WITH JOYSTICK STEERING).............................................................................. 376 42 TESTING AND ADJUSTING........................................................................................................................... 379 STANDARD VALUE TABLE .......................................................................................................................... 380 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................... 380 MEASURING PLAY OF STEERING WHEEL ............................................................................................................. 381 MEASURING OPERATING FORCE OF STEERING WHEEL ................................................................................................... 382 MEASURING OPERATING TIME OF STEERING WHEEL .................................................................................................... 383 TESTING AND ADJUSTING OF STEERING LINKAGE ..................................................................................................... 384 ADJUSTING STEERING LINKAGE..................................................................................................................... 385 MEASURING STEERING OIL PRESSURE ............................................................................................................... 390 ADJUSTING JOYSTICK STEERING ................................................................................................................... 393 TROUBLESHOOTING................................................................................................................................ 397 TROUBLESHOOTING TABLE ..................................................................................................................... 399 1. Steering wheel does not turn........................................................................................................ 399 2. Steering wheel is sluggish. ........................................................................................................ 400 3. Steering wheel moves unsteadily or is subjected to large shock. ................................................................... 401 4. Machine tends to turn naturally in one particular direction when traveling.......................................................... 401 5. Left and right turning radii are different.......................................................................................... 401 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYTEM (J MODE)............................................................................. 403 1. FUNCTION .......................................................................................................................... 405 2. TROUBLESHOOTING ................................................................................................................... 405 3. TABLE OF FAILURE CODES ............................................................................................................. 405 4. TABLE OF FAILURE MODES AND CAUSES................................................................................................... 406 J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM ..................................................................... 407 J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM ..................................................................... 408 J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY SYSTEM ..................................................................... 409 J-4 FAILURE CODE [19] ABNORMALITY IN CAUTION LAMP SYSTEM .............................................................................. 410 J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R SIGNAL SYSTEM ........................................................... 411 J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING SOLENOID .............................................................. 412 J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID ............................................................... 413 J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L.H. STEERING SOLENOID .............................................................. 414 J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID ............................................................... 415 J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM ............................................................. 416 J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM ........................................................ 417 J-12 FAlLURE CODE [37] ABNORMALITY IN JOYSTICK STEERING LEVE 3 POTENTIOMETER ......................................................... 418 J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS ................................................................. 419 J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE ............................................................................ 420 J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM ............................................................................ 421 J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM .................................................................................... 422 J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM .................................................................................... 423 J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM .................................................................................... 424 J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM ............................................................................... 425 J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM ............................................................................... 426 J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM ............................................................................... 427 43 DISASSEMBLY AND ASSEMBLY........................................................................................................................ 429 STEERING GEAR [Serial No.10001 - 10880 (Except D spec.); Serial No. 10001 and up (D spec.)].................................................... 430 REMOVAL.................................................................................................................................... 430 INSTALLATION............................................................................................................................... 432 STEERING GEAR [Serial No. 10881 and up (Except D. spec.)]...................................................................................... 434 REMOVAL ................................................................................................................................... 434 INSTALLATION .............................................................................................................................. 436 STEERING BOX GEAR.............................................................................................................................. 438 DISASSEMBLY ............................................................................................................................... 438 ASSEMBLY .................................................................................................................................. 439 STEERING VALVE................................................................................................................................. 441 REMOVAL.................................................................................................................................... 441 INSTALLATION .............................................................................................................................. 443 DISASSEMBLY AND ASSEMBLY .................................................................................................................. 446 STEERING CYLINDER.............................................................................................................................. 448 REMOVAL ................................................................................................................................... 448 INSTALLATION .............................................................................................................................. 450 DISASSEMBLY ............................................................................................................................... 453 ASSEMBLY .................................................................................................................................. 455 CENTER HINGE PIN [Serial No. 10880 (Except D. spec.); Serial No. 10001 and up (D spec.)]...................................................... 458 REMOVAL.................................................................................................................................... 458 INSTALLATION .............................................................................................................................. 466 CENTER HINGE PIN [Serial No. 10881 and up (Except D spec.)].................................................................................... 476 REMOVAL ................................................................................................................................... 476 INSTALLATION............................................................................................................................... 485 44 MAINTENANCE STANDARD............................................................................................................................ 495 STEERING COLUMN AND GEAR BOX .................................................................................................................. 496 CENTER HINGE PIN .............................................................................................................................. 500 STEERING VALVE ................................................................................................................................ 502 STEERING CYLINDER MOUNT ....................................................................................................................... 503 STEERING CYLINDER ............................................................................................................................. 504 DIVERTER VALVE ................................................................................................................................ 505 EMERGENCY STEERING PUMP ....................................................................................................................... 506 50 BRAKE AND AIR SYSTEM................................................................................................................................ 507 51 STRUCTURE AND FUNCTION.......................................................................................................................... 507 GENERAL ....................................................................................................................................... 508 BRAKE AND AIR CIRCUIT DIAGRAM.............................................................................................................. 510 AIR GOVERNOR................................................................................................................................... 512 AIR TANK ...................................................................................................................................... 514 SAFETY VALVE................................................................................................................................... 514 BRAKE VALVE ................................................................................................................................... 515 BRAKE ACTUATED............................................................................................................................. 516 OPERATING IN BALANCE....................................................................................................................... 517 BRAKE RELEASED............................................................................................................................. 518 TWO-WAY VALVE ................................................................................................................................. 519 RELAY VALVE ................................................................................................................................... 520 BRAKE CHAMBER ................................................................................................................................. 521 SLACK ADJUSTER ................................................................................................................................ 523 BRAKE ......................................................................................................................................... 526 PARKING BRAKE ................................................................................................................................. 528 BRAKE CALIPER ................................................................................................................................. 530 SPRING CYLINDER ............................................................................................................................... 531 PARKING BRAKE SOLENOID VALVE .................................................................................................................. 532 HYDRAULIC TANK PRESSURIZING VALVE ............................................................................................................. 533 52 TESTING AND ADJUSTING........................................................................................................................... 535 STANDARD VALUE TABLE .......................................................................................................................... 536 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................... 537 MEASURING BRAKE PEDAL ......................................................................................................................... 538 MEASURING AIR PRESSURE ........................................................................................................................ 539 TESTING BRAKE PERFORMANCE ..................................................................................................................... 542 CHECKING BRAKE PISTON LEAKAGE ................................................................................................................. 543 MEASURING WEAR OF BRAKE DISC.................................................................................................................. 544 AIR BLEEDING FROM BRAKE LINE .................................................................................................................. 545 TESTING PARKING BRAKE PERFORMANCE ............................................................................................................. 546 CHECKING AND ADJUSTING PARKING BRAKE .......................................................................................................... 547 TROUBLESHOOTING................................................................................................................................ 549 TROUBLESHOOTING TABLE ..................................................................................................................... 550 1. Air pressure does not rise at all. ................................................................................................. 550 2. Air pressure does not rise to the specified range. ................................................................................ 551 3. Brake is ineffective or not very effective. ........................................................................................ 552 4. Brake does not release, or drags. .................................................................................................. 553 5. Parking brake does not release, or drags. .......................................................................................... 554 53 DISASSEMBLY AND ASSEMBLY........................................................................................................................ 555 BRAKE VALVE [Serial No. 10001 - 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]..................................................... 556 REMOVAL.................................................................................................................................... 556 INSTALLATION............................................................................................................................... 558 BRAKE VALVE [Serial No.10881 and up (Except D spec.)........................................................................................... 560 REMOVAL.................................................................................................................................... 560 INSTALLATION............................................................................................................................... 562 BRAKE VALVE.................................................................................................................................... 564 DISASSEMBLY................................................................................................................................ 564 ASSEMBLY................................................................................................................................... 566 BRAKE CHAMBER.................................................................................................................................. 568 REMOVAL.................................................................................................................................... 568 INSTALLATION............................................................................................................................... 571 DISASSEMBLY................................................................................................................................ 574 ASSEMBLY................................................................................................................................... 577 SLACK ADJUSTER................................................................................................................................. 580 REMOVAL.................................................................................................................................... 580 INSTALLATION............................................................................................................................... 580 DISASSEMBLY................................................................................................................................ 581 ASSEMBLY................................................................................................................................... 582 BRAKE.......................................................................................................................................... 583 REMOVAL.................................................................................................................................... 583 INSTALLATION............................................................................................................................... 586 DISASSEMBLY................................................................................................................................ 589 ASSEMBLY................................................................................................................................... 592 SPRING CYLINDER................................................................................................................................ 595 REMOVAL.................................................................................................................................... 595 INSTALLATION............................................................................................................................... 596 DISASSEMBLY................................................................................................................................ 597 ASSEMBLY................................................................................................................................... 598 PARKING BRAKE.................................................................................................................................. 600 REMOVAL.................................................................................................................................... 600 INSTALLATION............................................................................................................................... 603 PARKING BRAKE PAD.............................................................................................................................. 606 REMOVAL.................................................................................................................................... 606 INSTALLATION............................................................................................................................... 606 54 MAINTENANCE STANDARD............................................................................................................................ 607 BRAKE VALVE ................................................................................................................................... 608 BRAKE CHAMBER ................................................................................................................................. 610 SLACK ADJUSTER ................................................................................................................................ 611 BRAKE ......................................................................................................................................... 612 PARKING BRAKE ................................................................................................................................. 614 SPRING CYLINDER ............................................................................................................................... 615 60 WORK EQUIPMENT SYSTEM............................................................................................................................... 617 61 STRUCTURE AND FUNCTION.......................................................................................................................... 617 GENERAL ....................................................................................................................................... 618 WORK EQUIPMENT LEVER LINKAGE .................................................................................................................. 620 HYDRAULIC CIRCUIT SYSTEM ...................................................................................................................... 622 HYDRAULIC CIRCUIT SCHEMATICS............................................................................................................... 622 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 623 HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING)................................................................................. 626 HYDRAULIC TANK ................................................................................................................................ 628 OIL FILTER BYPASS VALVE.................................................................................................................... 631 BREATHER................................................................................................................................... 631 HYDRAULIC PUMP ................................................................................................................................ 632 POC VALVE (Pilot Operated Control valve) ...................................................................................................... 634 PPC VALVE (Proportional Pressure Control Valve) ............................................................................................... 640 POC RELIEF VALVE .............................................................................................................................. 644 PPC RELIEF VALVE .............................................................................................................................. 644 MAIN CONTROL VALVE ............................................................................................................................ 646 RELIEF VALVE............................................................................................................................... 650 SAFETY VALVE (with suction valve).......................................................................................................... 651 SUCTION VALVE.............................................................................................................................. 652 FLOAT SELECTOR VALVE AND UNLOADER.......................................................................................................... 653 ACCUMULATOR ................................................................................................................................... 655 OPERATION OF HYDRAULIC CIRCUIT ................................................................................................................ 656 HYDRAULIC CYLINDER ............................................................................................................................ 660 BUCKET LINKAGE ................................................................................................................................ 662 BUCKET POSITIONER AND BOOM KICK-OUT ........................................................................................................... 663 62 TESTING AND ADJUSTING........................................................................................................................... 665 STANDARD VALUE TABLE .......................................................................................................................... 666 TOOL LIST FOR TESTING AND ADJUSTING ........................................................................................................... 669 MEASURING DUMP AND LIFT CONTROL LEVERS ........................................................................................................ 670 ADJUSTING DUMP AND LIFT CONTROL LEVERS ........................................................................................................ 671 MEASURING AND ADJUSTING POC RELIEF VALVE PRESSURE ............................................................................................. 674 MEASURING AND ADJUSTING PPC RELIEF VALVE PRESSURE ............................................................................................ 674 MEASURING AND ADJUSTING WORK EQUIPMENT RELIEF VALVE PRESSURE................................................................................... 677 MEASURING WORK EQUIPMENT....................................................................................................................... 679 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT ’ ................................................................................................. 680 ADJUSTING BUCKET POSITIONER ................................................................................................................... 681 ADJUSTING BOOM KICK-OUT ....................................................................................................................... 682 TROUBLESHOOTING................................................................................................................................ 683 TROUBLESHOOTING TABLE ..................................................................................................................... 684 1. Lift arm does not rise. ............................................................................................................ 684 2. Lift arm moves slowly or does not have sufficient lifting power. .................................................................. 685 3. Lift arm movement becomes slow after it reaches a certain height.................................................................... 686 4. Bucket cannot be held down with lift arm cylinder................................................................................... 686 5. Lift arm has large hydraulic drift.................................................................................................. 686 6. Lift arm movementis unsteady during work............................................................................................ 686 7. Lift arm lowers momentarily when control lever is shifted from "Hold" to "Raise".................................................... 686 8. Bucket does not tilt back........................................................................................................... 687 9. Bucket moves slowly or has insufficient tilt back power............................................................................. 688 10. Bucket movement becomes slow during tilt back...................................................................................... 689 11. Bucket cannot be held down by the bucket cylinder.................................................................................. 689 12. Bucket has large hydraulic drift. ................................................................................................. 689 13. Bucket moves unsteadily when machine travels under load. (Main control valve is in "Hold")......................................... 689 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".................................................. 689 15. Control levers of lift arm and dump move stiffly and sluggishly.................................................................... 690 63 DISASSEMBLY AND ASSEMBLY........................................................................................................................ 691 HYDRAULIC TANK [Serial No. 10001- 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]................................................... 694 REMOVAL.................................................................................................................................... 694 INSTALLATION............................................................................................................................... 696 HYDRAULIC TANK [Serial No. 10881 and up (Except D spec.)]...................................................................................... 698 REMOVAL.................................................................................................................................... 698 INSTALLATION............................................................................................................................... 700 HYDRAULIC FILTER [Serial No. 10001 - 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]................................................ 702 REMOVAL.................................................................................................................................... 702 INSTALLATION............................................................................................................................... 703 HYDRAULIC FILTER [Serial No. 10881 and up (Except D spec.)].................................................................................... 704 REMOVAL.................................................................................................................................... 704 INSTALLATION............................................................................................................................... 705 WORK EQUIPMENT, STEERING, POC (PPC) PUMP....................................................................................................... 706 REMOVAL.................................................................................................................................... 706 INSTALLATION............................................................................................................................... 708 POC VALVE [Serial No. 10001 - 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]....................................................... 710 REMOVAL.................................................................................................................................... 710 INSTALLATION............................................................................................................................... 712 DISASSEMBLY................................................................................................................................ 714 ASSEMBLY................................................................................................................................... 714 PPC VALVE [Serial No. 10881 and up (Except D spec.)]........................................................................................... 715 REMOVAL.................................................................................................................................... 715 INSTALLATION............................................................................................................................... 717 DISASSEMBLY................................................................................................................................ 719 ASSEMBLY................................................................................................................................... 719 MAIN CONTROL VALVE............................................................................................................................. 721 REMOVAL.................................................................................................................................... 721 INSTALLATION............................................................................................................................... 724 MAIN CONTROL VALVE [Serial No. 10001 10880 (Except D spec.); Serial No. 10001 and up (D spec.)]................................................ 728 DISASSEMBLY................................................................................................................................ 728 ASSEMBLY................................................................................................................................... 728 MAIN CONTROL VALVE [Serial No. 10881 and up (Except D spec.)].................................................................................. 730 DISASSEMBLY................................................................................................................................ 730 ASSEMBLY................................................................................................................................... 732 DUMP CYLINDER.................................................................................................................................. 734 REMOVAL.................................................................................................................................... 734 INSTALLATION............................................................................................................................... 738 LIFT CYLINDER.................................................................................................................................. 740 REMOVAL.................................................................................................................................... 740 INSTALLATION............................................................................................................................... 743 LIFT CYLINDER AND DUMP CYLINDER................................................................................................................ 746 DISASSEMBLY................................................................................................................................ 746 ASSEMBLY................................................................................................................................... 748 WORK EQUIPMENT................................................................................................................................. 750 REMOVAL.................................................................................................................................... 750 INSTALLATION............................................................................................................................... 756 COUNTERWEIGHT.................................................................................................................................. 763 REMOVAL.................................................................................................................................... 763 INSTALLATION............................................................................................................................... 765 64 MAINTENANCE STANDARD............................................................................................................................ 767 BUCKET LINKAGE ................................................................................................................................ 768 BUCKET ........................................................................................................................................ 770 BUCKET POSITIONER AND BOOM KICK-OUT ........................................................................................................... 771 HYDRAULIC PUMP ................................................................................................................................ 772 MAIN CONTROL VALVE ............................................................................................................................ 774 POC VALVE ..................................................................................................................................... 778 PPC VALVE ..................................................................................................................................... 780 DUMP CYLINDER ................................................................................................................................. 782 LIFT CYLINDER ................................................................................................................................. 783 80 ELECTRIC AND ELECTRONIC SYSTEM...................................................................................................................... 785 81 STRUCTURE AND FUNCTION.......................................................................................................................... 785 ELECTRICAL WIRING DIAGRAM CIRCUIT.............................................................................................................. 787 ENGINE STARTING CIRCUIT........................................................................................................................ 796 ENGINE STOP CIRCUIT............................................................................................................................ 798 ELECTRICAL TRANSMISSION CONTROL................................................................................................................ 800 COMBINATION SWITCH......................................................................................................................... 802 TRANSMISSION CUT-OFF SWITCH................................................................................................................ 803 TRANSMISSION CUT-OFF SELECTOR SWITCH....................................................................................................... 804 NEUTRALIZER RELAY.......................................................................................................................... 806 KICK-DOWN SWITCH........................................................................................................................... 808 KICK-DOWN ELECTRIC CIRCUIT................................................................................................................. 809 ELECTRICAL PARKING BRAKE CONTROL............................................................................................................... 815 PROXIMITY SWITCH............................................................................................................................... 827 AUTO PRIMING SYSTEM (APS)...................................................................................................................... 832 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).................................................................................................... 837 MONITOR PANEL.............................................................................................................................. 837 INDICATION ON MONITOR PANEL................................................................................................................ 841 WIRING HARNESS............................................................................................................................. 843 CONTROLLER................................................................................................................................. 845 SENSORS.................................................................................................................................... 846 82 TESTING AND ADJUSTING........................................................................................................................... 853 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM..................................................................................................... 854 ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR................................................................................................ 860 TROUBLESHOOTING................................................................................................................................ 863 CHECK BEFORE TROUBLESHOOTING............................................................................................................... 864 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.......................................................................................... 865 CONNECTOR TERMINAL NUMBERS................................................................................................................. 867 PRECAUTION WHEN HANDLING CONNECTOR......................................................................................................... 871 ELECTRICAL WIRING DIAGRAM AND LOCATION OF CONNECTORS....................................................................................... 873 ELECTRICAL CIRCUIT SYSTEM.................................................................................................................. 875 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM.................................................................................................. 889 CONNECTOR TYPES AND LOCATION OF COMPONENTS............................................................................................. 890 ENGINE STARTING AND STOP CIRCUIT....................................................................................................... 896 E-1. ENGINE DOES NOT START......................................................................................................... 896 E-2. ENGINE DOES NOT STOP.......................................................................................................... 902 E-3. ENGINE STOPS WHEN TRAVELING................................................................................................... 904 PARKING BRAKE CIRCUIT.................................................................................................................. 906 E-4a. PARKING BRAKE DOES NOT WORK. (PARKING BRAKE SWITCH ON)....................................................................... 906 E-4b. PARKING BRAKE DOES NOT WORK. (AIR PRESSURE LESS THAN 2.0 KG/CM2)............................................................. 906 E-5. PARKING BRAKE IS NOT RELEASED................................................................................................. 910 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON................................................................ 914 E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED......................................................... 917 TRANSMISSION CONTROL CIRCUIT [SERIAL NO. 10001 AND UP (D SPEC.) SERIAL NO. 10001-10880 (EXCEPT D SPEC.)]............................... 918 E-8. MACHINE DOES NOT TRAVEL FORWARD............................................................................................... 918 E-9. MACHINE DOES NOT TRAVEL REVERSE............................................................................................... 920 E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL)...................................................................... 922 E-11. MACHINE DOES NOT WHEN TRANSMISSION SELECTOR SWITCH ON........................................................................ 924 E-12. TRANSMISSION CANNOT BE CUT-OFF............................................................................................... 925 E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL...................................................................................... 926 TRANSMISSION CONTROL CIRCUIT [SERIAL NO. 10881 AND UP (EXCEPT D SPEC.)]................................................................ 929 E-8. TRANSMISSION DOES NOT WORK NORMALLY........................................................................................... 929 E-9. KICK-DOWN SWITCH DOES NOT WORK (1/2).......................................................................................... 950 E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON............................................................................. 953 E-11. KICK-DOWN OPERATION IS NOT CANCELED.......................................................................................... 954 E-12. KICK-DOWN WORKS MISTAKE WHEN TRAVELING IN F2................................................................................. 956 E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED..................................................................... 956 PREHEATING CIRCUIT..................................................................................................................... 959 E-14. PREHEATING IS NOT CARRIED OUT................................................................................................ 959 E-15. PREHEATING DISPLAY DOES NOT GO OUT........................................................................................... 966 E-15A. PREHEATING STAY ON.......................................................................................................... 967 E-16. AFTERHEATING DOES NOT DISPLAY................................................................................................ 970 E-17. AFTERHEATING DISPLAY DOES NOT GO OUT......................................................................................... 970 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM............................................................................. 972 Serial No. 10001-10494................................................................................................................. 972 M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ....... 976 a) BRAKE OIL LEVEL............................................................................................................. 976 b) ENGINE OIL.................................................................................................................. 977 c) COOLANT LEVEL............................................................................................................... 978 M-2. WHEN STARTING SWITCH IS TURNED ON (AT ENGINE RUNNING), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES........... 979 a) BATTERY CHARGE.............................................................................................................. 979 b) FUEL LEVEL.................................................................................................................. 980 c) AFTERHEATING LIGHTS UP...................................................................................................... 981 d) AFTERHEATING DOES NOT LIGHT UP.............................................................................................. 982 e) CLOGGING IN TRANSMISSION OIL FILTER FLASHES................................................................................. 983 M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASH ES.......... 984 a) FAILURE IN BRAKE LINE FLASHES............................................................................................... 984 b) ENGINE OIL PRESSURE FLASHES. ............................................................................................... 985 c) COOLANT LEVEL FLASHES....................................................................................................... 986 d) DROP IN AIR PRESSURE FLASHES................................................................................................ 987 e) COOLANT TEMPERATURE FLASHES................................................................................................. 988 f) TORQUE CONVERTER OIL TEMPERATURE FLASHES.................................................................................... 989 M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP ........ 990 a) PARKING BRAKE DISPLAY DOES NOT GO OUT....................................................................................... 990 b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP. ................................................................................... 991 c) WORKING LAMP DISPLAY DOES NOT GO OUT........................................................................................ 992 d) WORKING LAMP DISPLAY DOES NOT LIGHT UP...................................................................................... 993 e) PREHEATING LIGHTS UP. ...................................................................................................... 994 f) PREHEATING DOES NOT LIGHT UP. .............................................................................................. 995 g) FAILURE IN MAIN STEERING LIGHTS UP. (IF EQUIPPED)........................................................................... 996 h) FAILURE IN MAIN STEERING DOES NOT LIGHT UP. (IF EQUIPPED)................................................................... 997 i) TRANSMISSION CUT-OFF LIGHTS UP.............................................................................................. 998 j) TRANSMISSION CUT-OFF DOES NOT LIGHT UP...................................................................................... 999 M-5. TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT U-P.........................................................1000 a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP.........................................................................1000 b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS up..........................................................................1000 c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.................................................................1001 d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP..................................................................1002 e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP......................................................................................1003 f) HIGH BEAM PILOT LAMP DOES NOT GO OUT........................................................................................1004 M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY....................................................................................1005 M-7. SERVICE METER DOES NOT WORK NORMALLY..........................................................................................1006 M-8. ABNORMALITY IN MONITOR PANEL..................................................................................................1008 a) NONE OF MONITOR PANEL WORKS.................................................................................................1008 b) PART OF MONITOR PANEL DOES NOT WORK.........................................................................................1010 c) EVEN WHEN ENGINE IS STOPPED, ENGINE 0iL PRESSURE FLASHES, CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP.............1011 d) EVEN WHEN ENGINE STOPPED, BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP.................................................1012 e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARGING SWITCH TO "ON", ENGINE STOPPED.)..........................1012 f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY..........................................1013 g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.................................................................................1014 h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY...........................................1015 i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..................................................................................1016 M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR.........................................................................................1018 a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SIDE LAMP IN COMBINATION LAMP IS USED................................................1018 b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON....................................................................1020 c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP.................................................................................1021 d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP..................................................1022 e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP................................................................................1023 M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP..................................................................................1024 a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND................................................................1024 b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMPS DOES NOT FLASH..........................................1026 M-11. ABNORMALITY IN GAUGE.........................................................................................................1028 a) FUEL GAUGE..................................................................................................................1028 b) AIR PRESSURE GAUGE..........................................................................................................1030 c) COOLANT TEMPERATURE GAUGE...................................................................................................1032 d) TORQUE CONVERTER OIL TEMPERATURE GAUGE......................................................................................1034 Serial No. 10495-and up (D Spec.) & Serial No. 10495-10880 (except D spec.)............................................................1037 CONNECTOR TYPES AND LOCATION OF COMPONENTS.........................................................................................1039 M-1. BRAKE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED................................................................................1046 M-2. ENGINE OIL LEVEL FLASHES WHEN ENGINE IS STOPPED...............................................................................1046 M-3. RADIATOR WATER LEVEL FLASHES WHEN - ENGINE IS STOPPED.........................................................................1048 M-4. BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING.................................................................................1048 M-5. TRANSMISSION OIL FILTER CLOGGING WHEN ENGINE IS RUNNING.......................................................................1050 M-6. FUEL LEVEL FLASHES WHEN ENGINE................................................................................................1052 M-7. BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING.............................................................................1052 M-8. ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING............................................................................1054 M-9. RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS RUNNING...........................................................................1054 M-10. DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING..........................................................................1056 M-11. ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING......................................................................1056 M-12. TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING..............................................................1056 M-13. PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.....................................................................1058 a) If stays lighted up.........................................................................................................1058 b) If does not light up........................................................................................................1058 M-14. WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP......................................................................1060 a) If stays lighted up.........................................................................................................1060 b) If does not light up........................................................................................................1060 M-15. PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP...................................................................................1062 a) (Preheating) lights up......................................................................................................1062 b) (Preheating) does not light up..............................................................................................1062 M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP..........................................................................1064 a) Lights up...................................................................................................................1064 b) Does not light up...........................................................................................................1064 M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP.............................................................................1066 a) Turn signal (right) pilot display lights up.................................................................................1066 b) Turn signal (left) pilot display lights up..................................................................................1067 c) Turn signal (right) pilot display does not light up.........................................................................1068 d) Turn signal (left) pilot display does not light up..........................................................................1068 e) Hi beam pilot does not light up.............................................................................................1069 f) Hi beam pilot stays lighted up..............................................................................................1069 M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON..............................................................1071 M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...................................................................................1072 M-20. HOURMETER DOES NOT WORK NORMALLY.............................................................................................1073 M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS...........................................1074 a) None of monitor panel lights up.............................................................................................1074 b) Except for speedometer module, none of monitqr panel lights up..............................................................1074 c) None of CAUTION items light up..............................................................................................1075 d) Some other parts do not light up............................................................................................1075 M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT..........................................1075 M-23. (ENGINE OIL PRESSURE) FLASHES (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED................................................1076 a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated...............................................1076 b) (Battery charge) flashes, and warning lamp lights up........................................................................1076 M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP..................................................1078 a) Even when combination lamp is placed at SMALL, none of panel lighting lights up.............................................1078 b) Even when working lamp is switched ON, none of monitor panel lights up......................................................1079 c) Even when starting switch is turned ON, none of monitor panel lights up.....................................................1080 d) Part of panel does not light up.............................................................................................1080 M-25. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS ............1082 M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS..........................................................1082 M-27. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.....................1084 M-28. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP.......................................................1085 M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM...........................................................................................1086 a) If nothing is displayed in display area.....................................................................................1086 b) If indicator remains at FULL................................................................................................1086 M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM...................................................................................1088 a) If nothing is displayed in display area.....................................................................................1088 b) If indicator remains at maximum level.......................................................................................1088 M-31. ABNORMALITY IN (ENGINE WATER C TEMPERATURE GAUGE) SYSTEM.....................................................................1090 a) If nothing is displayed in display area.....................................................................................1090 b) If indicator remains at minimum level.......................................................................................1090 M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM...............................................................1092 a) If nothing is displayed in display area.....................................................................................1092 b) If indicator remains at minimum level.......................................................................................1092 Serial No. 10881 and up (except D spec.)...............................................................................................1095 CONNECTOR TYPES AND LOCATION OF COMPONENTS.........................................................................................1097 M-1. (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED..............................................................................1104 M-2. (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.............................................................................1104 M-3. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED.........................................................................1106 M-4. (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING...............................................................................1106 M-5. (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING.............................................................1108 M-6. (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING...................................................................................1110 M-7. (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING...........................................................................1110 M-8. (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING..........................................................................1112 M-9. (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING.........................................................................1112 M-10. (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING........................................................................1114 M-11. (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING....................................................................1114 M-12. (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING............................................................1114 M-13. (PARKING BRAKE) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP...................................................................1116 a) If stays lighted up.........................................................................................................1116 b) If does not light up........................................................................................................1116 M-14. (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP....................................................................1118 a) If stays lighted up.........................................................................................................1118 b) If does not light up........................................................................................................1118 M-15. (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP.................................................................................1120 a) (Preheating) lights up......................................................................................................1120 b) (Preheating) does not light up..............................................................................................1120 M-16. (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP..........................................................................1122 a) Lights up ..................................................................................................................1122 b) Does not light up...........................................................................................................1122 M-17. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP.............................................................................1124 a) Turn signal (right) pilot display lights up.................................................................................1124 b) Turn signal (left) pilot display lights up..................................................................................1125 c) Turn signal (right) pilot display does not light up.........................................................................1126 d) Turn signal (left) pilot display does not light up..........................................................................1126 e) Hi beam pilot does not light up.............................................................................................1127 f) Hi beam pilot stays lighted up..............................................................................................1127 M-18. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON..............................................................1129 M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY...................................................................................1130 M-20. HOURMETER DOES NOT WORK NORMALLY.............................................................................................1131 M-21. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS...........................................1132 a) None of monitor panel lights up.............................................................................................1132 b) Except for speedometer module, none of monitor panel lights up..............................................................1132 c) None of CAUTION items light up..............................................................................................1133 d) Some other parts do not light up............................................................................................1133 M-22. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT..........................................1133 M-23. (ENGINE OIL PRESSURE) FLASHES OR (BATTERY CHARGE) FLASHES WHEN ENGINE IS STOPPED.............................................1134 a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated...............................................1134 b) (Battery charge) flashes, and warning lamp lights up........................................................................1134 M-24. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP..................................................1136 a) Even when combination lamp is placed at SMALL, none of panel lighting lights up.............................................1136 b) Even when working lamp is switched ON, none of monitor panel lights up......................................................1137 c) Even when starting switch is turned ON, none of monitor panel lights up.....................................................1138 d) Part of panel does not light up.............................................................................................1138 M-25. WHEN STARTING SWITCH IS TURNED TO ON POSlTlON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS ............1140 M-26. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS..........................................................1140 M-27. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM.......1142 M-28 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP........................................................1143 M-29. ABNORMALITY IN (FUEL GAUGE) SYSTEM...........................................................................................1144 a) If nothing is displayed in display area.....................................................................................1144 b) If indicator remains at FULL................................................................................................1144 M-30. ABNORMALITY IN (AIR PRESSURE GAUGE) SYSTEM...................................................................................1146 a) If nothing is displayed in display area.....................................................................................1146 b) If indicator remains at maximum level.......................................................................................1146 M-31. ABNORMALITY IN (ENGINE WATER TEMPERATURE GAUGE) SYSTEM.......................................................................1148 a) If nothing is displayed in display area.....................................................................................1148 b) If indicator remains at minimum level.......................................................................................1148 M-32. ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) SYSTEM...............................................................1150 a) If nothing is displayed in display area.....................................................................................1150 b) If indicator remains at minimum level.......................................................................................1150 83 DISASSEMBLY AND ASSEMBLY........................................................................................................................1153 MACHINE MONITOR................................................................................................................................1154 REMOVAL....................................................................................................................................1154 INSTALLATION...............................................................................................................................1154 90 OTHERS..............................................................................................................................................1155 91 OTHERS..........................................................................................................................................1155 CAB............................................................................................................................................1156 AIR CONDITIONER................................................................................................................................1159 AIR CONDITIONER WIRING DIAGRAM.............................................................................................................1160 AIR CONDITIONER ELECTRIC CIRCUIT...........................................................................................................1161 AIR CONDITIONER UNIT.......................................................................................................................1162 COMPRESSOR.................................................................................................................................1164 CONDENSOR..................................................................................................................................1165 DRY RESERVOIR..............................................................................................................................1166 93 DISASSEMBLY AND ASSEMBLY........................................................................................................................1167 CAB............................................................................................................................................1168 REMOVAL....................................................................................................................................1168 INSTALLATION...............................................................................................................................1169 AIR CONDITIONER UNIT (For DAIKIN air conditioner)..............................................................................................1170 REMOVAL....................................................................................................................................1170 INSTALLATION...............................................................................................................................1172 AIR CONDITIONER UNIT (For DENS0 air conditioner)...............................................................................................1174 REMOVAL....................................................................................................................................1174 INSTALLATION...............................................................................................................................1176 AIR CONDITIONER CONDENSER......................................................................................................................1178 REMOVAL....................................................................................................................................1178 INSTALLATION...............................................................................................................................1178 DRY RESERVOIR..................................................................................................................................1179 REMOVAL....................................................................................................................................1179 INSTALLATION...............................................................................................................................1179 COMPRESSOR FOR AIR CONDITIONER (For DAI KIN air conditioner)...................................................................................1180 REMOVAL....................................................................................................................................1180 INSTALLATION...............................................................................................................................1180 COMPRESSOR FOR AIR CONDITIONER (For DENS0 air conditioner).....................................................................................1181 REMOVAL....................................................................................................................................1181 INSTALLATION...............................................................................................................................1182 97 GEAR PUMP.......................................................................................................................................1183 GENERAL........................................................................................................................................1184 PRINCIPLE OF OPERATION.........................................................................................................................1185 PRESSURE LOADED TYPE GEAR PUMP.................................................................................................................1188 FIXED SIDE PLATE TYPE GEAR PUMP................................................................................................................1190
DESCRIPTION:
KOMATSU WA600-1 SHOP MANUAL SEBM04260111 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 30/12/24
