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KOMATSU WA800-1,2 SHOP MANUAL SEBM04280113 – PDF DOWNLOAD
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KOMATSU WA800-1,2 SHOP MANUAL SEBM04280113 – PDF DOWNLOAD
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KOMATSU WA800-1,2 SHOP MANUAL SEBM04280113 – PDF DOWNLOAD
Language : English
Pages : 1448
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA800-1,2 SHOP MANUAL SEBM04280113 – PDF DOWNLOAD
MAIN MENU............................................................................................................................................... 0 CONTENTS................................................................................................................................................ 2 10 ENGINE............................................................................................................................................... 29 11 STRUCTURE AND FUNCTION........................................................................................................................... 29 RADIATOR AND COOLER ............................................................................................................................ 30 ENGINE SPEED CONTROL ........................................................................................................................... 32 SERVO CYLINDER ................................................................................................................................. 34 ENGINE LOW IDLING SELECT SYSTEM ................................................................................................................ 37 12 TESTING AND ADJUSTING............................................................................................................................ 39 STANDARD VALUE TABLE ........................................................................................................................... 40 ADJUSTING VALVE CLEARANCE ...................................................................................................................... 45 MEASURING COMPRESSION PRESSURE ................................................................................................................. 47 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................... 48 MEASURING ACCELERATOR PEDAL OPERATING FORCE .................................................................................................... 51 MEASURING ACCELERATOR PEDAL OPERATING ANGLE .................................................................................................... 55 13 DISASSEMBLY AND ASSEMBLY......................................................................................................................... 61 WA800-1......................................................................................................................................... 62 STARTING MOTOR.............................................................................................................................. 62 REMOVAL AND INSTALLATION ............................................................................................................... 62 ALTERNATOR.................................................................................................................................. 63 REMOVAL AND INSTALLATION................................................................................................................ 63 AIR COMPRESSOR.............................................................................................................................. 64 REMOVAL AND INSTALLATION................................................................................................................ 64 WATER PUMP.................................................................................................................................. 65 REMOVAL AND INSTALLATION................................................................................................................ 65 TURBOCHARGER................................................................................................................................ 66 REMOVAL AND INSTALLATION................................................................................................................ 66 NOZZLE HOLDER............................................................................................................................... 67 REMOVAL AND INSTALLATION ............................................................................................................... 67 FUEL INJECTION PUMP......................................................................................................................... 68 REMOVAL AND INSTALLATION................................................................................................................ 68 CYLINDER HEAD .............................................................................................................................. 70 REMOVAL................................................................................................................................. 70 INSTALLATION ........................................................................................................................... 74 RADIATOR ................................................................................................................................... 79 REMOVAL................................................................................................................................. 79 ISTALLATION............................................................................................................................. 82 ENGINE ..................................................................................................................................... 85 REMOVAL................................................................................................................................. 85 INSTALLATION ........................................................................................................................... 91 WA800-2......................................................................................................................................... 99 STARTING MOTOR............................................................................................................................. 99 REMOVAL AND INSTALLATION................................................................................................................ 99 ALTERNATOR.................................................................................................................................. 100 REMOVAL AND INSTALLATION................................................................................................................ 100 FUEL INJECTION PUMP FOR RIGHT BANK (WITHOUT GOVERNOR) ..................................................................................... 101 REMOVAL AND INSTALLATION................................................................................................................ 101 FUEL INJECTION PUMP FOR LEFT BANK (WITH GOVERNOR) ......................................................................................... 102 REMOVAL AND INSTALLATION ............................................................................................................... 102 WATER PUMP.................................................................................................................................. 103 REMOVAL AND INSTALLATION ............................................................................................................... 103 NOZZLE HOLDER .............................................................................................................................. 104 REMOVAL AND INSTALLATION................................................................................................................ 104 TURBOCHARGER................................................................................................................................ 105 REMOVAL AND INSTALLATION ............................................................................................................... 105 RIGHT AFTER-COOLER ......................................................................................................................... 106 REMOVAL AND INSTALLATION ............................................................................................................... 106 LEFT AFTER-COOLER ......................................................................................................................... 107 REMOVAL AND INSTALLATION ............................................................................................................... 107 CYLINDER HEAD............................................................................................................................... 108 REMOVAL................................................................................................................................. 108 INSTALLATION............................................................................................................................ 110 RADIATOR ................................................................................................................................... 113 REMOVAL................................................................................................................................. 113 INSTALLATION............................................................................................................................ 116 ENGINE OIL COOLER........................................................................................................................... 119 REMOVAL AND INSTALLATION................................................................................................................ 119 AIR COMPRESSOR............................................................................................................................. 120 REMOVAL AND INSTALLATION................................................................................................................ 120 ENGINE ..................................................................................................................................... 121 REMOVAL................................................................................................................................. 121 INSTALLATION............................................................................................................................ 127 14 MAINTENANCE STANDARD............................................................................................................................. 135 ENGINE MOUNT.................................................................................................................................... 136 20 POWER TRAIN.......................................................................................................................................... 137 21 STRUCTURE AND FUNCTION........................................................................................................................... 137 GENERAL ........................................................................................................................................ 138 HYDRAULIC CIRCUIT SCHEMATICS ................................................................................................................... 140 HYDRAULIC CIRCUIT DIAGRAM ...................................................................................................................... 141 TRANSMISSION MOUNT ............................................................................................................................. 142 TORQUE CONVERTER AND TRANSMISSION PIPING ..................................................................................................... 143 TORQUE CONVERTER OIL COOLER .................................................................................................................... 145 DAMPER ......................................................................................................................................... 146 TORQUE CONVERTER OIL FILTER .................................................................................................................... 150 PILOT OIL FILTER................................................................................................................................ 151 TORQUE CONVERTER ............................................................................................................................... 152 TRANSMISSION.................................................................................................................................... 158 TRANSFER........................................................................................................................................ 160 DRIVE SHAFT .................................................................................................................................... 179 AXLE MOUNT ..................................................................................................................................... 180 AXLE AND DIFFERENTIAL .......................................................................................................................... 182 CENTER SUPPORT ................................................................................................................................. 187 FINAL DRIVE .................................................................................................................................... 188 TIRE AND WHEEL ................................................................................................................................. 189 22 TESTING AND ADJUSTING............................................................................................................................ 191 STANDARD VALUE TABLE............................................................................................................................ 192 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................ 193 MEASURING SHIFT LEVER .......................................................................................................................... 194 MEASURING ENGINE STALL SPEED ................................................................................................................... 195 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION ................................................................................... 197 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ................................................................................................ 200 TIRE AND WHEEL ................................................................................................................................. 201 TROUBLESHOOTING................................................................................................................................. 203 CHECK BEFORE TROUBLESHOOTING................................................................................................................ 204 PRECAUTIONS WHEN TROUBLESHOOTING ........................................................................................................... 205 METHOD OF READING TROUBLESHOOTING TABLE .................................................................................................... 207 PREVENTING RECURRENCE OF TROUBLE ........................................................................................................... 209 JUDGMENT ON POWER TRAIN .................................................................................................................... 210 TROUBLESHOOTING TABLE ...................................................................................................................... 214 1. Machine does not move.................................................................................................................... 214 2. Machine lacks power or speed............................................................................................................. 216 3. Excessive time lag when starting machine or shifting gear................................................................................ 217 4. Torque converter oil temperature too high................................................................................................ 218 23 DISASSEMBLY AND ASSEMBLY......................................................................................................................... 219 WA800-1......................................................................................................................................... 222 DAMPER...................................................................................................................................... 222 REMOVAL................................................................................................................................. 222 INSTALLATION ........................................................................................................................... 225 DISASSEMBLY............................................................................................................................. 228 ASSEMBLY................................................................................................................................ 230 TORQUE CONVERTER CHARGING AND POC PUMP .................................................................................................... 233 REMOVAL................................................................................................................................. 233 INSTALLATION ........................................................................................................................... 235 TORQUE CONVERTER AND TRANSMISSION .......................................................................................................... 237 REMOVAL................................................................................................................................. 237 INSTALLATION ........................................................................................................................... 243 TORQUE CONVERTER ASSEMBLY .................................................................................................................. 250 DISASSEMBLY............................................................................................................................. 250 ASSEMBLY ............................................................................................................................... 254 TORQUE CONVERTER VALVE ASSEMBLY ........................................................................................................... 259 DISASSEMBLY AND ASSEMBLY................................................................................................................ 259 PTO ASSEMBLY ............................................................................................................................... 260 DISASSEMBLY............................................................................................................................. 260 ASSEMBLY ............................................................................................................................... 262 TRANSMISSION ASSEMBLY....................................................................................................................... 265 DISASSEMBLY............................................................................................................................. 265 ASSEMBLY................................................................................................................................ 280 TRANSFER ASSEMBLY .......................................................................................................................... 296 DISASSEMBLY............................................................................................................................. 296 ASSEMBLY................................................................................................................................ 304 TRANSMISSION VALVE ASSEMBLY................................................................................................................ 314 DISASSEMBLY AND ASSEMBLY................................................................................................................ 314 LOWER VALVE ASSEMBLY ....................................................................................................................... 316 DISASSEMBLY AND ASSEMBLY................................................................................................................ 316 RELIEF VALVE ASSEMBLY ...................................................................................................................... 317 DISASSEMBLY AND ASSEMBLY............................................................................................................... 317 CENTER SUPPORT ............................................................................................................................. 318 REMOVAL................................................................................................................................. 318 INSTALLATION............................................................................................................................ 319 DISASSEMBLY ............................................................................................................................ 321 ASSEMBLY ............................................................................................................................... 323 DRIVE SHAFT................................................................................................................................. 326 DISASSEMBLY............................................................................................................................. 326 ASSEMBLY................................................................................................................................ 328 FRONT AXLE ................................................................................................................................. 330 REMOVAL................................................................................................................................. 330 INSTALLATION ........................................................................................................................... 332 REAR AXLE .................................................................................................................................. 334 REMOVAL................................................................................................................................. 334 INSTALLATION ........................................................................................................................... 341 DIFFERENTIAL ............................................................................................................................... 347 REMOVAL................................................................................................................................. 347 INSTALLATION ........................................................................................................................... 349 DISASSEMBLY............................................................................................................................. 353 ASSEMBLY................................................................................................................................ 356 FINAL DRIVE................................................................................................................................. 362 DISASSEMBLY............................................................................................................................. 362 ASSEMBLY................................................................................................................................ 365 WA800-2......................................................................................................................................... 369 DAMPER...................................................................................................................................... 369 REMOVAL................................................................................................................................. 369 INSTALLATION............................................................................................................................ 372 DISASSEMBLY ............................................................................................................................ 375 ASSEMBLY................................................................................................................................ 377 TORQUE CONVERTER CHARGING AND PPC PUMP .................................................................................................... 382 REMOVAL................................................................................................................................. 382 INSTALLATION............................................................................................................................ 384 TORQUE CONVERTER AND TRANSMISSION .......................................................................................................... 386 REMOVAL................................................................................................................................. 386 INSTALLATION ........................................................................................................................... 392 TORQUE CONVERTER ASSEMBLY .................................................................................................................. 399 DISASSEMBLY............................................................................................................................. 399 ASSEMBLY................................................................................................................................ 403 TORQUE CONVERTER VALVE ASSEMBLY............................................................................................................. 408 DISASSEMBLY AND ASSEMBLY................................................................................................................ 408 PTO ASSEMBLY ............................................................................................................................... 409 DISASSEMBLY............................................................................................................................. 409 ASSEMBLY................................................................................................................................ 411 TRANSMISSION ASSEMBLY ...................................................................................................................... 414 DISASSEMBLY............................................................................................................................. 414 ASSEMBLY ............................................................................................................................... 429 TRANSFER ASSEMBLY .......................................................................................................................... 445 DISASSEMBLY............................................................................................................................. 445 ASSEMBLY................................................................................................................................ 453 TRANSMISSION VALVE ........................................................................................................................ 463 REMOVAL................................................................................................................................. 463 INSTALLATION ........................................................................................................................... 463 DISASSEMBLY AND ASSEMBLY ............................................................................................................... 464 LOWER VALVE ASSEMBLY ....................................................................................................................... 466 DISASSEMBLY AND ASSEMBLY................................................................................................................ 466 RELIEF VALVE ASSEMBLY ...................................................................................................................... 467 DISASSEMBLY AND ASSEMBLY............................................................................................................... 467 CENTER SUPPORT ............................................................................................................................. 468 REMOVAL................................................................................................................................. 468 INSTALLATION............................................................................................................................ 469 DISASSEMBLY ............................................................................................................................ 471 ASSEMBLY ............................................................................................................................... 473 DRIVE SHAFT ................................................................................................................................ 476 DISASSEMBLY............................................................................................................................. 476 ASSEMBLY................................................................................................................................ 478 FRONT AXLE ................................................................................................................................. 480 REMOVAL................................................................................................................................. 480 INSTALLATION ........................................................................................................................... 482 REAR AXLE .................................................................................................................................. 484 REMOVAL................................................................................................................................. 484 INSTALLATION............................................................................................................................ 491 DIFFERENTIAL ............................................................................................................................... 497 REMOVAL................................................................................................................................. 497 INSTALLATION............................................................................................................................ 499 DISASSEMBLY............................................................................................................................. 501 ASSEMBLY................................................................................................................................ 504 FINAL DRIVE................................................................................................................................. 510 DISASSEMBLY............................................................................................................................. 510 ASSEMBLY................................................................................................................................ 513 24 MAINTENANCE STANDARD............................................................................................................................. 517 TRANSMISSION MOUNT.............................................................................................................................. 518 DAMPER.......................................................................................................................................... 519 TORQUE CONVERTER................................................................................................................................ 522 TORQUE CONVERTER REGULATOR VALVE................................................................................................................ 524 TRANSMISSION.................................................................................................................................... 525 TRANSMISSION CONTROL VALVE...................................................................................................................... 528 TRANSFER........................................................................................................................................ 533 DRIVE SHAFT..................................................................................................................................... 534 CENTER SUPPORT.................................................................................................................................. 535 DIFFERENTIAL.................................................................................................................................... 536 TORQUE CONVERTER CHARGING PUMP AND POC (PPC) PUMP............................................................................................... 539 FINAL DRIVE..................................................................................................................................... 540 AXLE MOUNT...................................................................................................................................... 542 40 STEERING SYSTEM...................................................................................................................................... 545 41 STRUCTURE AND FUNCTION........................................................................................................................... 545 GENERAL......................................................................................................................................... 546 STEERING COLUMN, GEAR BOX AND LINKAGE .......................................................................................................... 548 HYDRAULIC CIRCUIT FOR STEERING ................................................................................................................. 550 STEERING CONTROL SYSTEM ........................................................................................................................ 552 TWO-WAY RESTRICTOR VALVE ....................................................................................................................... 561 STEERING CYLINDER .............................................................................................................................. 562 CENTER HINGE PIN ............................................................................................................................... 563 EMERGENCY STEERING SYSTEM ...................................................................................................................... 566 STEERING DEMAND VALVE (MACHINE WITH JOYSTICK STEERING).......................................................................................... 571 STEERING UNIT (ORBIT-ROLL VALVE) (MACHINE WITH JOYSTICK STEERING)............................................................................... 582 42 TESTING AND ADJUSTING............................................................................................................................ 585 STANDARD VALUE TABLE ........................................................................................................................... 586 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................ 586 MEASURING STEERING WHEEL PLAY .................................................................................................................. 587 MEASURING OPERATING FORCE OF STEERING WHEEL .................................................................................................... 589 MEASURING OPERATING TIME OF STEERING WHEEL ..................................................................................................... 590 TESTING AND ADJUSTING STEERING LINKAGE ......................................................................................................... 591 MEASURING STEERING OIL PRESSURE ................................................................................................................ 595 MEASURING EMERGENCY STEERING PRESSURE .......................................................................................................... 596 ADJUSTING JOYSTICK STEERING .................................................................................................................... 598 TROUBLESHOOTING................................................................................................................................. 601 TROUBLESHOOTING TABLE....................................................................................................................... 602 1. Steering wheel does not turn............................................................................................................. 602 2. Steering wheel is sluggish............................................................................................................... 603 3. Steering wheel moves unsteadily or is subjected to large shock........................................................................... 604 4. Machine tends to turn naturally in one particular direction when traveling............................................................... 604 5. Left and right turning radii are different............................................................................................... 604 TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE)............................................................................. 605 1. FUNCTION............................................................................................................................. 607 2. TROUBLESHOOTING...................................................................................................................... 607 3. TABLE OF FAILURE CODES ............................................................................................................ 607 4. TABLE OF FAILURE MODES AND CAUSES.................................................................................................... 608 J-1 FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY SYSTEM........................................................................ 609 J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY SYSTEM........................................................................ 610 J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY SYSTEM........................................................................ 611 J-4 FAILURE CODE [19] ABNORMALITY IN CAUTION LAMP SYSTEM................................................................................ 612 J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R SIGNAL SYSTEM.............................................................. 613 J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING SOLENOID.................................................................. 614 J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING SOLENOID.................................................................. 615 J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L.H. STEERING SOLENOID.................................................................. 616 J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING SOLENOID................................................................. 617 J-10 FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT RELAY SYSTEM................................................................ 618 J-11 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING NEUTRAL SIGNAL SYSTEM........................................................... 619 J-12 FAILURE CODE [37] ABNORMALITY IN JOYSTICK STEERING LEVER POTENTIOMETER............................................................. 620 J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING HARNESS.................................................................... 621 J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE.............................................................................. 622 J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM.............................................................................. 623 J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM...................................................................................... 624 J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM...................................................................................... 625 J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM...................................................................................... 626 J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM................................................................................. 627 J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM................................................................................. 628 J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM................................................................................. 629 43 DISASSEMBLY AND ASSEMBLY......................................................................................................................... 631 WA800-1......................................................................................................................................... 632 STEERING GEAR............................................................................................................................... 632 REMOVAL................................................................................................................................. 632 INSTALLATION............................................................................................................................ 633 DISASSEMBLY............................................................................................................................. 634 ASSEMBLY ............................................................................................................................... 635 STEERING PUMP .............................................................................................................................. 638 REMOVAL................................................................................................................................. 638 INSTALLATION ........................................................................................................................... 640 STEERING VALVE ............................................................................................................................. 642 REMOVAL................................................................................................................................. 642 INSTALLATION ........................................................................................................................... 643 STEERING VALVE ASSEMBLY .................................................................................................................... 644 DISASSEMBLY AND ASSEMBLY................................................................................................................ 644 STEERING CYLINDER .......................................................................................................................... 646 REMOVAL................................................................................................................................. 646 INSTALLATION............................................................................................................................ 647 EMERGENCY STEERING PUMP .................................................................................................................... 649 REMOVAL................................................................................................................................. 649 INSTALLATION ........................................................................................................................... 650 DIVERTER VALVE ............................................................................................................................. 651 REMOVAL................................................................................................................................. 651 INSTALLATION............................................................................................................................ 652 DISASSEMBLY AND ASSEMBLY................................................................................................................ 653 WA800-2......................................................................................................................................... 655 STEERING GEAR............................................................................................................................... 655 REMOVAL................................................................................................................................. 655 INSTALLATION ........................................................................................................................... 656 DISASSEMBLY ............................................................................................................................ 657 ASSEMBLY ............................................................................................................................... 658 STEERING PUMP .............................................................................................................................. 661 REMOVAL................................................................................................................................. 661 INSTALLATION............................................................................................................................ 663 STEERING VALVE ............................................................................................................................. 665 REMOVAL................................................................................................................................. 665 INSTALLATION............................................................................................................................ 666 STEERING VALVE ASSEMBLY..................................................................................................................... 668 DISASSEMBLY AND ASSEMBLY................................................................................................................ 668 STEERING CYLINDER .......................................................................................................................... 670 REMOVAL................................................................................................................................. 670 INSTALLATION ........................................................................................................................... 671 EMERGENCY STEERING PUMP .................................................................................................................... 673 REMOVAL................................................................................................................................. 673 INSTALLATION............................................................................................................................ 674 DIVERTER VALVE ............................................................................................................................. 675 REMOVAL................................................................................................................................. 675 INSTALLATION ........................................................................................................................... 676 DISASSEMBLY AND ASSEMBLY................................................................................................................ 677 44 MAINTENANCE STANDARD............................................................................................................................. 679 STEERING COLUMN AND GEAR BOX ................................................................................................................... 680 STEERING VALVE ................................................................................................................................. 684 STEERING CYLINDER MOUNT ........................................................................................................................ 685 CENTER HINGE PIN................................................................................................................................ 686 STEERING CYLINDER .............................................................................................................................. 690 EMERGENCY STEERING PUMP ........................................................................................................................ 691 DIVERTER VALVE.................................................................................................................................. 692 50 BRAKE AND AIR SYSTEM................................................................................................................................. 693 51 STRUCTURE AND FUNCTION........................................................................................................................... 693 BRAKE AND AIR PIPING ........................................................................................................................... 694 AIR GOVERNOR.................................................................................................................................... 699 AIR TANK ....................................................................................................................................... 701 BRAKE VALVE .................................................................................................................................... 704 TWO-WAY VALVE................................................................................................................................... 708 RELAY VALVE .................................................................................................................................... 709 BRAKE CHAMBER................................................................................................................................... 710 SLACK ADJUSTER ................................................................................................................................. 712 BRAKE .......................................................................................................................................... 715 PARKING BRAKE .................................................................................................................................. 717 BRAKE CALIPER................................................................................................................................... 719 SPRING CYLINDER ................................................................................................................................ 720 PARKING BRAKE SOLENOID VALVE ................................................................................................................... 721 52 TESTING AND ADJUSTING............................................................................................................................ 722 STANDARD VALUE TABLE ........................................................................................................................... 723 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................ 724 MEASURING BRAKE PEDAL .......................................................................................................................... 725 MEASURING AIR PRESSURE ......................................................................................................................... 726 TESTING BRAKE PERFORMANCE ...................................................................................................................... 728 CHECKING BRAKE PISTON LEAKAGE .................................................................................................................. 729 MEASURING WEAR OF BRAKE DISC ................................................................................................................... 730 AIR BLEEDING FROM BRAKE LINE ................................................................................................................... 731 TESTING PARKING BRAKE PERFORMANCE .............................................................................................................. 732 CHECKING AND ADJUSTING PARKING BRAKE ........................................................................................................... 733 TROUBLESHOOTING................................................................................................................................. 736 TROUBLESHOOTING TABLE ...................................................................................................................... 737 1. Air pressure does not rise at all........................................................................................................ 737 2. Air pressure does not rise to the special fied range..................................................................................... 738 3. Brake is ineffective or not very effective............................................................................................... 739 4. Brake does not release, or drags......................................................................................................... 740 5. Parking brake does not release, or drags................................................................................................. 741 53 DISASSEMBLY AND ASSEMBLY......................................................................................................................... 742 WA800-1......................................................................................................................................... 743 BRAKE VALVE................................................................................................................................. 743 REMOVAL................................................................................................................................. 743 INSTALLATION ........................................................................................................................... 745 DISASSEMBLY ............................................................................................................................ 747 ASSEMBLY................................................................................................................................ 749 BRAKE CHAMBER .............................................................................................................................. 751 REMOVAL................................................................................................................................. 751 INSTALLATION ........................................................................................................................... 752 DISASSEMBLY............................................................................................................................. 753 ASSEMBLY................................................................................................................................ 756 SLACK ADJUSTER.............................................................................................................................. 759 REMOVAL AND INSTALLATION................................................................................................................ 759 DISASSEMBLY............................................................................................................................. 760 ASSEMBLY................................................................................................................................ 761 BRAKE ASSEMBLY.............................................................................................................................. 762 REMOVAL................................................................................................................................. 762 INSTALLATION............................................................................................................................ 763 DISASSEMBLY............................................................................................................................. 764 ASSEMBLY................................................................................................................................ 766 SPRING CYLINDER ASSEMBLY.................................................................................................................... 769 REMOVAL................................................................................................................................. 769 INSTALLATION............................................................................................................................ 769 DISASSEMBLY............................................................................................................................. 770 ASSEMBLY................................................................................................................................ 771 PARKING BRAKE CALIPER....................................................................................................................... 772 REMOVAL................................................................................................................................. 772 INSTALLATION............................................................................................................................ 773 DISASSEMBLY............................................................................................................................. 774 ASSEMBLY................................................................................................................................ 774 PARKING BRAKE PAD........................................................................................................................... 775 REMOVAL................................................................................................................................. 775 INSTALLATION............................................................................................................................ 775 WA800-2......................................................................................................................................... 776 BRAKE VALVE................................................................................................................................. 776 REMOVAL................................................................................................................................. 776 INSTALLATION............................................................................................................................ 778 DISASSEMBLY............................................................................................................................. 780 ASSEMBLY................................................................................................................................ 782 BRAKE CHAMBER............................................................................................................................... 784 REMOVAL................................................................................................................................. 784 INSTALLATION............................................................................................................................ 785 DISASSEMBLY............................................................................................................................. 786 ASSEMBLY................................................................................................................................ 789 SLACK ADJUSTER.............................................................................................................................. 792 REMOVAL AND INSTALLATION................................................................................................................ 792 DISASSEMBLY............................................................................................................................. 793 ASSEMBLY................................................................................................................................ 794 BRAKE ASSEMBLY.............................................................................................................................. 795 REMOVAL................................................................................................................................. 795 INSTALLATION............................................................................................................................ 796 DISASSEMBLY............................................................................................................................. 797 ASSEMBLY................................................................................................................................ 799 SPRING CYLINDER ASSEMBLY.................................................................................................................... 802 REMOVAL................................................................................................................................. 802 INSTALLATION............................................................................................................................ 802 DISASSEMBLY............................................................................................................................. 803 ASSEMBLY................................................................................................................................ 804 PARKING BRAKE CALIPER....................................................................................................................... 805 REMOVAL................................................................................................................................. 805 INSTALLATION............................................................................................................................ 806 DISASSEMBLY............................................................................................................................. 807 ASSEMBLY................................................................................................................................ 807 PARKING BRAKE PAD........................................................................................................................... 808 REMOVAL................................................................................................................................. 808 INSTALLATION............................................................................................................................ 808 54 MAINTENANCE STANDARD............................................................................................................................. 810 BRAKE VALVE..................................................................................................................................... 811 BRAKE CHAMBER................................................................................................................................... 813 SLACK ADJUSTER.................................................................................................................................. 814 BRAKE........................................................................................................................................... 815 SPRING CYLINDER................................................................................................................................. 817 PARKING BRAKE................................................................................................................................... 818 60 WORK EQUIPMENT SYSTEM................................................................................................................................ 819 61 STRUCTURE AND FUNCTION........................................................................................................................... 819 HYDRAULIC PIPING................................................................................................................................ 820 HYDRAULIC CIRCUIT SCHEMATIC..................................................................................................................... 822 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................... 823 HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING)...................................................................................... 827 HYDRAULIC TANK.................................................................................................................................. 828 PISTON PUMP .................................................................................................................................... 830 WORK EQUIPMENT LEVER LINKAGE ................................................................................................................... 845 POC VALVE (Pilot Operated Control Valve) (For WA800-1) ......................................................................................... 847 PPC VALVE (Proportional Pressure Valve) (For WA800-2) .......................................................................................... 853 POC (PPC) RELIEF VALVE ......................................................................................................................... 857 MAIN CONTROL VALVE ............................................................................................................................. 859 ACCUMULATOR .................................................................................................................................... 868 OPERATION OF HYDRAULIC CIRCUIT ................................................................................................................. 869 HYDRAULIC CYLINDER ............................................................................................................................. 873 BUCKET LINKAGE ................................................................................................................................. 875 BUCKET POSITIONER AND BOOM KICK-OUT ............................................................................................................ 876 62 TESTING AND ADJUSTING............................................................................................................................ 878 STANDARD VALUE TABLE ........................................................................................................................... 879 TOOL LIST FOR TESTING AND ADJUSTING ............................................................................................................ 880 MEASURING DUMP AND LIFT CONTROL LEVERS ......................................................................................................... 881 ADJUSTING DUMP AND LIFT CONTROL LEVERS ......................................................................................................... 883 MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT ................................................................................................. 885 AIR BLEEDING FROM PISTON PUMP .................................................................................................................. 888 MEASURING WORK EQUIPMENT........................................................................................................................ 889 MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT .................................................................................................... 890 ADJUSTING BUCKET POSITIONER .................................................................................................................... 891 ADJUSTING BOOM KICK-OUT ........................................................................................................................ 892 TROUBLESHOOTING................................................................................................................................. 894 TROUBLESHOOTING TABLE ...................................................................................................................... 895 1. Lift arm does not rise............................................................................................................... 895 2. Lift arm moves slowly or does not have sufficient lifting power...................................................................... 896 3. Lift arm movement becomes slow after it reaches a certain height..................................................................... 897 4. Bucket cannot be held down with lift arm cylinder.................................................................................... 897 5. Lift arm has large hydraulic drift................................................................................................... 897 6. Lift arm movement is unsteady during work............................................................................................ 897 7. Lift arm lowers momentarily when control lever is shifted from "Hold" to "Raise"..................................................... 897 8. Bucket does not tilt back............................................................................................................ 898 9. Bucket moves slowly or has insufficient tilt back power.............................................................................. 899 10. Bucket movement becomes slow during tilt back....................................................................................... 900 11. Bucket cannot be held down by the bucket cylinder................................................................................... 900 12. Bucket has large hydraulic drift.................................................................................................... 900 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")............................................. 900 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"................................................... 900 15.Control levers of lift arm and dump move stiffly and sluggishly...................................................................... 901 63 DISASSEMBLY AND ASSEMBLY ........................................................................................................................ 902 WA800- 1........................................................................................................................................ 905 HYDRAULIC TANK AND FILTER CASE.............................................................................................................. 905 REMOVAL................................................................................................................................. 905 INSTALLATION ........................................................................................................................... 907 HYDRAULIC FILTER ........................................................................................................................... 909 REMOVAL................................................................................................................................. 909 INSTALLATION ........................................................................................................................... 910 HYDRAULIC PUMP ............................................................................................................................. 911 REMOVAL................................................................................................................................. 911 INSTALLATION ........................................................................................................................... 912 SWITCH PUMP ................................................................................................................................ 913 REMOVAL................................................................................................................................. 913 INSTALLATION ........................................................................................................................... 914 PISTON PUMP ................................................................................................................................ 915 DISASSEMBLY............................................................................................................................. 915 ASSEMBLY ............................................................................................................................... 920 POC VALVE ASSEMBLY ......................................................................................................................... 935 REMOVAL................................................................................................................................. 935 INSTALLATION ........................................................................................................................... 936 DISASSEMBLY AND ASSEMBLY ............................................................................................................... 937 MAIN CONTROL VALVE ......................................................................................................................... 939 REMOVAL................................................................................................................................. 939 INSTALLATION ........................................................................................................................... 941 DISASSEMBLY............................................................................................................................. 943 ASSEMBLY ............................................................................................................................... 945 DUMP CYLINDER .............................................................................................................................. 947 REMOVAL................................................................................................................................. 947 INSTALLATION............................................................................................................................ 949 LIFT CYLINDER .............................................................................................................................. 951 REMOVAL................................................................................................................................. 951 INSTALLATION............................................................................................................................ 953 STEERING, LIFT, DUMP CYLINDER .............................................................................................................. 955 DISASSEMBLY............................................................................................................................. 955 ASSEMBLY................................................................................................................................ 957 CENTER HINGE PIN ........................................................................................................................... 959 REMOVAL................................................................................................................................. 959 INSTALLATION ........................................................................................................................... 967 WORK EQUIPMENT ............................................................................................................................. 977 REMOVAL................................................................................................................................. 977 INSTALLATION............................................................................................................................ 983 WA800-2......................................................................................................................................... 990 HYDRAULIC TANK AND FILTER CASE.............................................................................................................. 990 REMOVAL................................................................................................................................. 990 INSTALLATION............................................................................................................................ 992 HYDRAULIC FILTER ........................................................................................................................... 994 REMOVAL................................................................................................................................. 994 INSTALLATION ........................................................................................................................... 995 HYDRAULIC PUMP ............................................................................................................................. 996 REMOVAL................................................................................................................................. 996 INSTALLATION ........................................................................................................................... 997 SWITCH PUMP ................................................................................................................................ 998 REMOVAL................................................................................................................................. 998 INSTALLATION ........................................................................................................................... 999 PISTON PUMP ................................................................................................................................1000 DISASSEMBLY.............................................................................................................................1000 ASSEMBLY................................................................................................................................1005 PPC VALVE ASSEMBLY..........................................................................................................................1020 REMOVAL.................................................................................................................................1020 INSTALLATION............................................................................................................................1021 DISASSEMBLY AND ASSEMBLY................................................................................................................1022 MAIN CONTROL VALVE..........................................................................................................................1023 REMOVAL.................................................................................................................................1023 INSTALLATION............................................................................................................................1025 DISASSEMBLY.............................................................................................................................1027 ASSEMBLY................................................................................................................................1029 DUMP CYLINDER...............................................................................................................................1031 REMOVAL.................................................................................................................................1031 INSTALLATION............................................................................................................................1033 LIFT CYLINDER...............................................................................................................................1035 REMOVAL.................................................................................................................................1035 INSTALLATION............................................................................................................................1037 STEERING, LIFT, DUMP CYLINDER...............................................................................................................1039 DISASSEMBLY.............................................................................................................................1039 ASSEMBLY................................................................................................................................1041 CENTER HINGE PIN............................................................................................................................1043 REMOVAL.................................................................................................................................1043 INSTALLATION............................................................................................................................1051 WORK EQUIPMENT..............................................................................................................................1061 REMOVAL.................................................................................................................................1061 INSTALLATION............................................................................................................................1067 64 MAINTENANCE STANDARD.............................................................................................................................1074 BUCKET LINKAGE..................................................................................................................................1075 BUCKET POSITIONER AND BOOM KICK-OUT ............................................................................................................1077 MAIN CONTROL VALVE .............................................................................................................................1079 POC VALVE (PILOT OPERATED CONTROL VALVE) .......................................................................................................1081 CONTROL PUMP ...................................................................................................................................1083 LIFT CYLINDER ..................................................................................................................................1084 DUMP CYLINDER...................................................................................................................................1085 80 ELECTRIC AND ELECTRONIC SYSTEM.......................................................................................................................1086 81 STRUCTURE AND FUNCTION...........................................................................................................................1086 ELECTRIC AND ELECTRONIC SYSTEM .................................................................................................................1087 ELECTRIC CIRCUIT DIAGRAM .......................................................................................................................1088 ELECTRIC CIRCUIT DIAGRAM (MACHINE WITH JOYSTICK STEERING).......................................................................................1092 ENGINE STARTING CIRCUIT ........................................................................................................................1093 ENGINE STOP CIRCUIT ............................................................................................................................1094 COMBINATION SWITCH .............................................................................................................................1095 ELECTRICAL TRANSMISSION CONTROL ................................................................................................................1096 KICK-DOWN SWITCH................................................................................................................................1104 ELECTRICAL PARKING BRAKE CONTROL................................................................................................................1112 PROXIMITY SWITCH................................................................................................................................1127 AUTO PRIMING SYSTEM (APS).......................................................................................................................1132 TRANSMISSION CLUTCH OVERRUN CONTROLLER..........................................................................................................1141 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).....................................................................................................1143 SENSORS.........................................................................................................................................1151 82 TESTING AND ADJUSTING............................................................................................................................1158 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM......................................................................................................1159 ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)..................................................................................................1162 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR...................................................................................................1164 TROUBLESHOOTING.................................................................................................................................1166 ELECTRICAL CIRCUIT SYSTEM...................................................................................................................1167 ELECTRICAL WIRING DIAGRAM...................................................................................................................1178 CONNECTOR TERMINAL NUMBERS..................................................................................................................1180 PRECAUTION WHEN HANDLING CONNECTOR..........................................................................................................1185 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...........................................................................................1187 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM...................................................................................................1190 WA800-1.................................................................................................................................1190 E-1. ENGINE DOES NOT START..........................................................................................................1191 E-2. ENGINE DOES NOT STOP...........................................................................................................1195 E-3. ENGINE STOPS WHEN TRAVELING....................................................................................................1196 E-4. a) PARKING BRAKE DOES NOT WORK (PARKING BRAKE SWITCH ON).......................................................................1197 b) PARKING BRAKE DOES NOT WORK (AIR PRESSURE LESS THAN 2.0kg/cm2)...............................................................1197 E-5. PARKING BRAKE IS NOT RELEASED..................................................................................................1199 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON.................................................................1201 E-7. TRANSMISSION IN NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED..........................................................1202 E-8. MACHINE DOES NOT TRAVEL FORWARD................................................................................................1203 E-9. MACHINE DOES NOT TRAVEL REVERSE................................................................................................1205 E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).......................................................................1207 E-11. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON. (MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF ..........1209 E-12. TRANSMISSION CANNOT BE CUT-OFF (WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON AND DEPRESS LEFT BRAKE PEDAL).................1210 E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL.......................................................................................1211 E-14. PREHEATING DOES NOT DISPLAY...................................................................................................1213 a) PREHEATING DOES NOT DISPLAY WHEN TURN PREHEATING SWITCH ON...................................................................1213 b) PREHEATING DISPLAYS WHEN TURN PREHEATING SWITCH TURN ON, BUT DOES NOT DISPLAY WHEN TURN PREHEATING SWITCH AUTO...............1213 E-15. PREHEATING DISPLAY DOES NOT GO OUT (PREHEATING DISPLAY DOES NOT GO OUT AFTER TURNED PREHEATING SWITCH ON ABOUT 80 SECONDS.....1215 E-16. AFTERHEATING DOES NOT DISPLAY.................................................................................................1216 E-17. AFTERHEATING DISPLAY DOES NOT GO OUT (AFTERHEATING DISPLAY DOES NOT GO OUT AFTER COOLANT TEMPERATURE BECAME ABOVE 20 DEGRE....1216 WA800-2.................................................................................................................................1218 CONNECTOR TYPE AND POSITION OF DEVICE...............................................................................................1219 E-1. ENGINE DOES NOT START..........................................................................................................1226 a) Inspection of starting circuit...............................................................................................1226 b) inspection of battery - battery relay - starting switch......................................................................1226 c) Inspection of starting switch - engine stop motor............................................................................1227 E-2. ENGINE DOES NOT STOP...........................................................................................................1229 E-3. ENGINE STOPS WHEN TRAVELING....................................................................................................1229 E-4. PARKING BRAKE DOES NOT WORK....................................................................................................1230 a) If parking brake does not work when parking brake switch is ON (applied).....................................................1230 b) If parking brake does not work then air pressure has dropped. (does not work as emergency brake).............................1230 E-5. PARKING BRAKE IS NOT RELEASED..................................................................................................1231 E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....................................................................1233 E-7. WHEN PARKING BRAKE IS APPLIED, TRANSMISSION DOES NOT ENTER NEUTRAL (PARKING BRAKE IS WORKING NORMALLY).........................1233 E-8. TRANSMISSION DOES NOT WORK NORMALLY............................................................................................1234 a) Problem in parking brake, transmission cut-off switch, neutral relay circuit.................................................1235 b) Defective continuity in FORWARD solenoid circuit.............................................................................1237 c) Defective continuity in REVERSE solenoid circuit.............................................................................1239 d) Contact in F-R circuit (l/2).................................................................................................1241 e) Problem in speed solenoid circuit (l/2)......................................................................................1245 f) Contact in speed circuit (l/3)...............................................................................................1249 E-9. KICK-DOWN SWITCH DOES NOT WORK (1/2) (NORMAL F1 - F3 SWITCHES CORRECTLY).......................................................1255 E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON. (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION).............1258 E-11. KICK-DOWN OPERATION IS NOT CANCELED...........................................................................................1259 E-12. KICK-DOWN WORKS MISTAKE WHEN TRAVELING IN F2..................................................................................1261 E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED......................................................................1261 E-14. PREHEATING IS NOT CARRIED OUT.................................................................................................1263 a) Preheating is not carried out automatically..................................................................................1264 b) Preheating is not carried out normally or automatically......................................................................1265 E-15. PREHEATING STAYS ON...........................................................................................................1268 a) Automatic preheating is not canceled.........................................................................................1268 b) Preheating continues even when heater switch is turned OFF...................................................................1269 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM..............................................................................1271 WA800-1.................................................................................................................................1271 M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE STARTING ITEM....1275 a) BRAKE OIL LEVEL..............................................................................................................1275 b) ENGINE OIL LEVEL.............................................................................................................1276 c) COOLANT LEVEL................................................................................................................1277 M-2. WHEN STARTING SWITCH IS TURNED ON (AT ENGINE RUNNING), AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM FLASHES............1278 a) BATTERY CHARGE...............................................................................................................1278 b) FUEL LEVEL...................................................................................................................1279 c) AFTERHEATING.................................................................................................................1280 d) AFTERHEATING.................................................................................................................1281 e) CLOGGING IN TRANSMISSION OIL FILTER..........................................................................................1282 M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS FLASHES...........1283 a) FAILURE IN BRAKE LINE........................................................................................................1283 b) ENGINE OIL PRESSURE..........................................................................................................1284 c) COOLANT LEVEL................................................................................................................1285 d) DROP IN AIR PRESSURE.........................................................................................................1286 e) COOLANT TEMPERATURE..........................................................................................................1287 f) TORQUE CONVERTER OIL TEMPERATURE.............................................................................................1288 M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP.........1289 a) DOES NOT GO OUT. ............................................................................................................1289 b) DOES NOT LIGHT UP............................................................................................................1290 c) DOES NOT GO OUT..............................................................................................................1291 d) DOES NOT LIGHT UP. ..........................................................................................................1292 e) PREHEATING LIGHTS UP.........................................................................................................1293 f) PREHEATING DOES NOT LIGHT UP. ...............................................................................................1294 g) FAILURE IN MAIN STEERING LIGHTS UP. (IF EQUIPPED) ...........................................................................1295 h) FAILURE IN MAIN STEERING DOES NOT LIGHT UP. (IF EQUIPPED) ...................................................................1296 i) TRANSMISSION CUT-OFF LIGHTS UP. .............................................................................................1297 j) TRANMISSION CUT-OFF DOES NOT LIGHT UP. ......................................................................................1298 M-5. TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT LIGHT UP..........................................................1299 a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP. ........................................................................1299 b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP. ........................................................................1299 c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP. ................................................................1300 d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP. ................................................................1300 e) HIGH BEAM PILOT LAMP DOES ...................................................................................................1301 f) HIGH BEAM PILOT LAMP DOES NOT GO OUT. .......................................................................................1302 M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.....................................................................................1303 M-7. SERVICE METER DOES NOT WORK NORMALLY...........................................................................................1304 M-8. ABNORMALITY IN MONITOR PANEL...................................................................................................1305 a) NONE OF MONITOR PANEL WORKS. ................................................................................................1305 b) PART OF MONITOR PANEL DOES NOT WORK. ........................................................................................1307 c) EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE FLASHES, CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP. ..........1308 d) EVEN WHEN ENGINE STOPPED, BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP..................................................1309 e) NO LAMPS ON MONITOR LIGHTS UP IMMEDIATELY AFTER TURNING STARTING SWITCH TO "ON", ENGINE STOPPED..............................1309 f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY. ........................................1310 g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY. ................................................................................1311 h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY. .........................................1312 i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY. .................................................................................1312 M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR..........................................................................................1313 a) PANEL LAMPS LIGHT UP EVEN WHEN ONLY SIDE LAMP IN NO COMBINATION LAMP IS USED. ...............................................1313 b) NO PANEL LAMPS, LIGHT UP EVEN WORKING LAMP IS SWITCHED ON. .................................................................1315 c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP. ................................................................................1316 d) PANEL LAMPS OF CHECKS, CAUTION 1 AND 2, SPEEDOMETER MODULE DO NOT LIGHT UP. ................................................1317 e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP.................................................................................1318 M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP...................................................................................1319 a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND. ..............................................................1319 b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMPS DOES NOT FLASH. ........................................1320 M-11. ABNORMALITY IN GAUGE..........................................................................................................1321 a) FUEL GUAGE...................................................................................................................1321 b) PRESSURE GAUGE ..............................................................................................................1323 c) COOLANT TEMPERATURE GAUGE....................................................................................................1325 d) TORQUE CONVERTER OIL TEMPERATURE GAUGE ......................................................................................1327 WA800-2.................................................................................................................................1329 CONNECTORTYPE AND POSITION OF DEVICE................................................................................................1331 M-1. BRAKE OIL LEVEL FLASHES WHEN ENGINE............................................................................................1341 M-2. ENGINE OIL LEVEL FLASHES WHEN ENGINE...........................................................................................1341 M-3. RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS STOPPED. ..........................................................................1343 M-4. BATTERY CHARGE FLASHES WHEN ENGINE IS RUNNING..................................................................................1343 M-5. TRANSMISSION OIL FILTER CLOGGING FLASHES WHEN ENGINE IS RUNNING. ..............................................................1345 M-6. FUEL LEVEL FLASHES WHEN ENGINE IS RUNNING......................................................................................1347 M-7. BRAKE LINE FAILURE FLASHES WHEN ENGINE IS RUNNING. ............................................................................1347 M-8. ENGINE OIL PRESSURE FLASHES WHEN ENGINE IS RUNNING. ...........................................................................1349 M-9. RADIATOR WATER LEVEL FLASHES WHEN ENGINE IS RUNNING............................................................................1349 M-10. DROP IN AIR PRESSURE FLASHES WHEN ENGINE IS RUNNING. ........................................................................1351 M-11. ENGINE WATER TEMPERATURE FLASHES WHEN ENGINE IS RUNNING. .....................................................................1351 M-12. TORQUE CONVERTER OIL TEMPERATURE FLASHES WHEN ENGINE IS RUNNING. .............................................................1351 M-13. PARKING BRAKE LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP......................................................................1353 a) If parking brake stays lighted up ...........................................................................................1353 b) If parking brake does not light up ..........................................................................................1353 M-14. WORKING LAMP LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP. .....................................................................1355 a) If working lamp stays lighted up.............................................................................................1355 b) If working lamp does not light up............................................................................................1355 M-15. PREHEATING LIGHTS UP, OR DOES NOT LIGHT UP. .................................................................................1357 a) Preheating lights up ........................................................................................................1357 b) Preheating does not light up ................................................................................................1357 M-16. MAIN STEERING FAILURE LIGHTS UP, OR DOES NOT LIGHT UP. .......................................................................1359 a) Main steering failure lights up..............................................................................................1359 b) Main steering failure does not light up......................................................................................1359 M-17. TRANSMISSION CUT-OFF LIGHTS UP, DOES NOT LIGHT UP. ...........................................................................1361 a) Transmission cut-off lights up...............................................................................................1361 b) Transmission cut-off does not light up......................................................................................1361 M-18. TURN SIGNAL HI BEAM LIGHT UP, OR DO NOT LIGHT UP. ...........................................................................1363 a) Turn signal (right) pilot display lights up..................................................................................1363 b) Turn signal (left) pilot display lights up...................................................................................1364 c) Turn signal (right) pilot display does not light UP..........................................................................1365 d) Turn signal (left) pilot display does not light UP...........................................................................1365 e) Hi beam pilot does not light up..............................................................................................1366 f) Hi beam pilot stays lighted up...............................................................................................1366 M-19. TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON. ............................................................1368 M-20. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY. ..................................................................................1370 M-21. HOURMETER DOES NOT WORK NORMALLY. ............................................................................................1372 M-22. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, .............................................................1374 a) None of monitor panel lights up..............................................................................................1374 b) Except for speedometer module, none of monitor panel lights up...............................................................1374 c) None of CAUTION items light up...............................................................................................1375 d) Some other parts do not light up.............................................................................................1375 M-23. WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS UP, BUT DOES NOT GO OUT..........................................1375 M-24. ENGINE OIL PRESSURE FLASHES OR BATTERY CHARGE FLASHES WHEN ENGINE IS STOPPED..................................................1376 a) Engine oil pressure flashes, and alarm buzzer and warning lamp are actuated..................................................1376 b) Battery charge flashes, and warning lamp lights up...........................................................................1376 M-25. NONE OF MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PART DOES NOT LIGHT UP. ................................................1378 a) Even when combination lamp is placed at SMALL, none of panel lighting lights up..............................................1378 b) Even when working lamp is switched ON, none of monitor panel lights up.......................................................1379 c) Even when starting switch is turned ON, none of monitor panel lights up......................................................1381 d) Part of panel does not light up..............................................................................................1381 M-26. WHEN STARTING SWITCH IS TURNED TO ON POSITION ENGINE STOPPED, BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING.....1383 M-27. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS. ........................................................1383 M-28. WHEN STARTING SWITCH IS TURNED TO ON POSITION ENGINE STOPPED, WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS F.....1385 M-29. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP. .....................................................1386 M-30. ABNORMALITY IN FUEL GUAGE.....................................................................................................1387 a) If nothing is displayed in display area......................................................................................1387 b) If indicator remains at FULL.................................................................................................1387 M-31. ABNORMALITY IN AIR PRESSURE GAUGE.............................................................................................1389 a) If nothing is displayed in display area......................................................................................1389 b) If indicator remains at maximum level........................................................................................1389 M-32. ENGINE WATER ABNORMALITY IN TEMPERATURE GAUGE.................................................................................1391 a) If nothing is displayed in display area .....................................................................................1391 b) If indicator remains at minimum level........................................................................................1391 M-33. TORQUE CONVERTER OIL ABNORMALITY IN TEMPERATURE GAUGE ........................................................................1393 a) If nothing is displayed in display area......................................................................................1393 b) If indicator remains at minimum level........................................................................................1393 83 DISASSEMBLY AND ASSEMBLY.........................................................................................................................1396 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).....................................................................................................1397 REMOVAL AND INSTALLATION....................................................................................................................1397 90 OTHERS...............................................................................................................................................1400 91 STRUCTURE AND FUNCTION...........................................................................................................................1400 CAB.............................................................................................................................................1401 93 DISASSEMBLY AND ASSEMBLY.........................................................................................................................1402 WA800-1.........................................................................................................................................1403 AIR CONDITIONER UNIT........................................................................................................................1403 REMOVAL.................................................................................................................................1403 INSTALLATION............................................................................................................................1406 AIR CONDITIONER CONDENSER...................................................................................................................1409 REMOVAL AND INSTALLATION................................................................................................................1409 RECEIVER (LIQUID TANK)......................................................................................................................1410 REMOVAL AND INSTALLATION................................................................................................................1410 COMPRESSOR FOR AIR CONDITIONER..............................................................................................................1411 REMOVAL AND INSTALLATION................................................................................................................1411 COUNTERWEIGHT...............................................................................................................................1413 REMOVAL.................................................................................................................................1413 INSTALLATION............................................................................................................................1415 FUEL TANK...................................................................................................................................1417 REMOVAL.................................................................................................................................1417 INSTALLATION............................................................................................................................1418 CAB.........................................................................................................................................1419 REMOVAL ................................................................................................................................1419 INSTALLATION............................................................................................................................1420 WA800-2.........................................................................................................................................1422 AIR CONDITIONER UNIT........................................................................................................................1422 REMOVAL.................................................................................................................................1422 INSTALLATION............................................................................................................................1425 AIR CONDITIONER CONDENSER...................................................................................................................1428 REMOVAL AND INSTALLATION................................................................................................................1428 RECEIVER (LIQUID TANK)......................................................................................................................1429 REMOVAL AND INSTALLATION................................................................................................................1429 COMPRESSOR FOR AIR CONDITIONER..............................................................................................................1430 REMOVAL AND INSTALLATION................................................................................................................1430 COUNTERWEIGHT...............................................................................................................................1431 REMOVAL.................................................................................................................................1431 INSTALLATION............................................................................................................................1432 FUEL TANK...................................................................................................................................1433 REMOVAL.................................................................................................................................1433 INSTALLATION............................................................................................................................1434 CAB.........................................................................................................................................1435 REMOVAL.................................................................................................................................1435 INSTALLATION............................................................................................................................1436 97 GEAR PUMP SA SERIES..............................................................................................................................1438 DISASSEMBLY.....................................................................................................................................1439 ASSEMBLY........................................................................................................................................1443
DESCRIPTION:
KOMATSU WA800-1,2 SHOP MANUAL SEBM04280113 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as 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
