Komatsu Wheel Loader WA600-1L Shop Manual
FILE DETAILS:
Komatsu Wheel Loader WA600-1L Shop Manual
Brands: Komatsu Dresser
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA600-1L
Serial Number: A10391 and up
Book Code: CEBMW26010
Language: English
Pages: 1023
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Wheel Loader WA600-1L Shop Manual
1 GENERAL :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
TABLE OF CONTENTS:
Komatsu Wheel Loader WA600-1L Shop Manual
MAIN MENU....................................................................................................................................... 0 CONTENTS........................................................................................................................................ 5 10 ENGINE....................................................................................................................................... 19 12 TESTING AND ADJUSTING ................................................................................................................... 19 STANDARD VALUE TABLE ................................................................................................................... 20 TOOL LIST .............................................................................................................................. 21 VALVE CLEARANCE ........................................................................................................................ 22 COMPRESSION PRESSURE ................................................................................................................... 24 FUEL INJECTION ......................................................................................................................... 25 TESTING TIMING...................................................................................................................... 25 ADJUSTING TIMING BY DELIVERY CHECK.................................................................................................. 26 BLOW-BY PRESSURE ....................................................................................................................... 27 ALTERNATOR FAN BELT .................................................................................................................... 28 EXHAUST GAS COLOR ...................................................................................................................... 29 ENGINE OIL PRESSURE..................................................................................................................... 31 ENGINE OIL TEMPERATURE ................................................................................................................. 32 ENGINE STOP MOTOR CABLE ................................................................................................................ 33 ACCELERATOR PEDAL ...................................................................................................................... 34 OPERATING FORCE..................................................................................................................... 34 ENGINE.............................................................................................................................. 35 13 DISASSEMBLY AND ASSEMBLY ................................................................................................................ 37 STARTING MOTOR ......................................................................................................................... 39 UPPER ASSEMBLY...................................................................................................................... 39 REMOVAL......................................................................................................................... 39 INSTALLATION.................................................................................................................... 39 LOWER ASSEMBLY...................................................................................................................... 39 REMOVAL......................................................................................................................... 39 INSTALLATION.................................................................................................................... 39 ALTERNATOR ............................................................................................................................. 40 REMOVAL............................................................................................................................. 40 INSTALLATION........................................................................................................................ 40 OIL COOLER ............................................................................................................................. 41 REMOVAL............................................................................................................................. 41 INSTALLATION........................................................................................................................ 41 FUEL INJECTION PUMP .................................................................................................................... 42 REMOVAL............................................................................................................................. 42 INSTALLATION........................................................................................................................ 42 WATER PUMP ............................................................................................................................. 43 REMOVAL............................................................................................................................. 43 INSTALLATION........................................................................................................................ 43 NOZZLE HOLDER .......................................................................................................................... 44 REMOVAL............................................................................................................................. 44 INSTALLATION........................................................................................................................ 44 TURBOCHARGER ........................................................................................................................... 45 REMOVAL............................................................................................................................. 45 INSTALLATION........................................................................................................................ 45 AIR COMPRESSOR ......................................................................................................................... 46 REMOVAL............................................................................................................................. 46 INSTALLATION........................................................................................................................ 46 CYLINDER HEAD .......................................................................................................................... 47 REMOVAL............................................................................................................................. 47 INSTALLATION........................................................................................................................ 53 RADIATOR ............................................................................................................................... 59 REMOVAL............................................................................................................................. 59 INSTALLATION........................................................................................................................ 62 ENGINE ................................................................................................................................. 65 REMOVAL............................................................................................................................. 65 INSTALLATION........................................................................................................................ 72 FUEL TANK .............................................................................................................................. 80 REMOVAL............................................................................................................................. 80 INSTALLATION........................................................................................................................ 82 14 MAINTENANCE STANDARD .................................................................................................................... 85 ENGINE MOUNT ........................................................................................................................... 86 20 POWER TRAIN.................................................................................................................................. 87 21 STRUCTURE AND FUNCTION .................................................................................................................. 87 GENERAL ................................................................................................................................ 89 POWER TRAIN ........................................................................................................................ 90 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................................................... 92 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN .......................................................................................... 93 TORQUE CONVERTER AND TRANSMISSION PIPING ............................................................................................... 94 TORQUE CONVERTER OIL COOLER ............................................................................................................ 95 TORQUE CONVERTER ....................................................................................................................... 96 TORQUE CONVERTER RELIEF VALVE ......................................................................................................... 99 TORQUE CONVERTER REGULATOR VALVE ....................................................................................................... 100 TORQUE CONVERTER OIL FILTER ............................................................................................................ 102 LUBRICATION BY-PASS VALVE .............................................................................................................. 103 TRANSMISSION MOUNT ..................................................................................................................... 104 TRANSMISSION ........................................................................................................................... 105 TRANSMISSION foldout # 1 ........................................................................................................... 106 FORWARD 1st......................................................................................................................... 108 Power pass...................................................................................................................... 108 Hydraulic circuit schematics.................................................................................................... 110 TRANSMISSION CONTROL VALVE ............................................................................................................. 112 UPPER VALVE ........................................................................................................................ 113 LOWER VALVE ........................................................................................................................ 114 MAIN RELIEF VALVE .................................................................................................................. 115 PRIORITY VALVE ..................................................................................................................... 116 MODULATING VALVE AND QUICK RETURN VALVE ............................................................................................ 117 REDUCING VALVE ..................................................................................................................... 120 ACCUMULATOR VALVE .................................................................................................................. 121 PILOT REDUCING VALVE ............................................................................................................... 123 TRANSMISSION SOLENOID VALVE ............................................................................................................ 124 EMERGENCY MANUAL SPOOL ................................................................................................................. 126 TRANSMISSION PILOT OIL FILTER .......................................................................................................... 127 TRANSFER ............................................................................................................................... 128 DRIVE SHAFT ............................................................................................................................ 129 CENTER SUPPORT ......................................................................................................................... 130 AXLE MOUNT ............................................................................................................................. 132 AXLES .................................................................................................................................. 134 FRONT............................................................................................................................... 134 REAR................................................................................................................................ 135 DIFFERENTIAL ........................................................................................................................... 136 FRONT .............................................................................................................................. 136 REAR ............................................................................................................................... 137 TORQUE PROPORTIONING DIFFERENTIAL .................................................................................................. 139 FINAL DRIVE ............................................................................................................................ 140 TIRE AND WHEEL ......................................................................................................................... 141 22 TESTING AND ADJUSTING ................................................................................................................... 143 STANDARD VALUE TABLE ................................................................................................................... 144 TOOL LIST .............................................................................................................................. 145 ENGINE STALL SPEED ..................................................................................................................... 146 1. Measuring torque converter stall................................................................................................. 146 2. Measuring hydraulic stall. engine and run at high .............................................................................. 147 3. Measuring full stall. ........................................................................................................... 147 TORQUE CONVERTER AND TRANSMISSION ...................................................................................................... 148 SHIFT LEVER ............................................................................................................................ 150 EMERGENCY MANUAL SPOOL ................................................................................................................. 152 TIRE AND WHEEL ......................................................................................................................... 154 TROUBLESHOOTING......................................................................................................................... 155 PRECAUTIONS WHEN TROUBLESHOOTING ................................................................................................... 156 METHOD OF READING TROUBLESHOOTING TABLES .......................................................................................... 158 PREVENTING RECURRENCE OF TROUBLE ................................................................................................... 160 JUDGEMENT ON POWER TRAIN ........................................................................................................... 161 TROUBLESHOOTING TABLE............................................................................................................... 164 Machine does not move. ......................................................................................................... 164 Machine lacks power or speed. .................................................................................................. 166 Excessive time lag when starting machine or shifting gear. .................................................................... 167 Torque converter oil temperature too high. ..................................................................................... 168 23 DISASSEMBLY AND ASSEMBLY................................................................................................................. 169 HYDRAULIC PUMP ......................................................................................................................... 171 Transmission lubricating + Torque converter charging + Switch pump ................................................................. 171 REMOVAL ............................................................................................................................ 171 INSTALLATION ....................................................................................................................... 173 TORQUE CONVERTER ....................................................................................................................... 175 REMOVAL ............................................................................................................................ 175 INSTALLATION........................................................................................................................ 179 DISASSEMBLY ........................................................................................................................ 184 ASSEMBLY ........................................................................................................................... 190 TRANSMISSION ........................................................................................................................... 196 REMOVAL ............................................................................................................................ 196 INSTALLATION ....................................................................................................................... 202 DISASSEMBLY ........................................................................................................................ 209 ASSEMBLY ........................................................................................................................... 224 TRANSFER ASSEMBLY ...................................................................................................................... 240 DISASSEMBLY ........................................................................................................................ 240 ASSEMBLY ........................................................................................................................... 249 TRANSMISSION CONTROL VALVE ............................................................................................................. 260 REMOVAL ............................................................................................................................ 260 INSTALLATION ....................................................................................................................... 261 DISASSEMBLY AND ASSEMBLY OF SPEED VALVE ASSEMBLY ................................................................................... 262 DISASSEMBLY OF SPEED VALVE ASSEMBLY............................................................................................. 263 ASSEMBLY OF SPEED VALVE ASSEMBLY................................................................................................ 263 DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE ASSEMBLY .............................................................................. 264 DISASSEMBLY OF MODULATING VALVE ASSEMBLY........................................................................................ 265 ASSEMBLY OF MODULATING VALVE ASSEMBLY........................................................................................... 265 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY....................................................................................... 265 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY.......................................................................................... 265 FRONT DIFFERENTIAL ..................................................................................................................... 266 REMOVAL ............................................................................................................................ 266 INSTALLATION ....................................................................................................................... 268 REAR DIFFERENTIAL ...................................................................................................................... 271 REMOVAL ............................................................................................................................ 271 INSTALLATION........................................................................................................................ 274 DIFFERENTIAL GEAR ASSEMBLY ............................................................................................................. 278 DISASSEMBLY ........................................................................................................................ 278 FINE DISASSEMBLY OF PINION ASSEMBLY............................................................................................. 280 FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY ........................................................................... 281 ASSEMBLY ........................................................................................................................... 282 FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY................................................................................ 282 FINE ASSEMBLY OF PINION ASSEMBLY................................................................................................ 283 ASSEMBLY OF DIFFERENTIAL ASSEMBLY............................................................................................... 284 FRONT AXLE ............................................................................................................................. 289 REMOVAL ............................................................................................................................ 289 INSTALLATION ....................................................................................................................... 291 REAR AXLE .............................................................................................................................. 293 REMOVAL ............................................................................................................................ 293 INSTALLATION ....................................................................................................................... 297 CENTER SUPPORT ......................................................................................................................... 301 REMOVAL ............................................................................................................................ 301 INSTALLATION ....................................................................................................................... 302 DISASSEMBLY ........................................................................................................................ 304 ASSEMBLY ........................................................................................................................... 306 DRIVE SHAFT ............................................................................................................................ 309 DISASSEMBLY ........................................................................................................................ 309 ASSEMBLY ........................................................................................................................... 311 FINAL DRIVE ASSEMBLY ................................................................................................................... 313 DISASSEMBLY ........................................................................................................................ 313 ASSEMBLY ........................................................................................................................... 316 24 MAINTENANCE STANDARD .................................................................................................................... 319 TRANSMISSION MOUNT ..................................................................................................................... 320 TORQUE CONVERTER ....................................................................................................................... 321 TORQUE CONVERTER REGULATOR VALVE ....................................................................................................... 322 TRANSMISSION ........................................................................................................................... 324 TRANSMISSION SOLENOID VALVE ............................................................................................................ 327 TRANSMISSION CONTROL VALVE ............................................................................................................. 328 UPPER VALVE......................................................................................................................... 328 LOWER VALVE ........................................................................................................................ 330 TRANSFER ............................................................................................................................... 332 DRIVE SHAFT ............................................................................................................................ 334 CENTER SUPPORT ......................................................................................................................... 336 AXLE MOUNT ............................................................................................................................. 338 DIFFERENTIAL............................................................................................................................ 340 FINAL DRIVE ............................................................................................................................ 344 40 STEERING SYSTEM.............................................................................................................................. 347 41 STRUCTURE AND FUNCTION .................................................................................................................. 347 GENERAL ................................................................................................................................ 348 STEERING COLUMN, GEAR BOX, AND LINKAGE ................................................................................................ 350 HYDRAULIC CIRCUIT FOR STEERING ......................................................................................................... 352 HYDRAULIC CIRCUIT SCHEMATIC......................................................................................................... 352 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................... 353 STEERING CONTROL SYSTEM ................................................................................................................ 354 STEERING VALVE...................................................................................................................... 354 STEERING RELIEF VALVE............................................................................................................... 356 SAFETY VALVE (WITH SUCTION VALVE)................................................................................................... 357 OPERATION OF DEMAND SPOOL........................................................................................................... 359 OPERATION OF THE STEERING VALVE..................................................................................................... 362 TWO-WAY RESTRICTOR VALVE ............................................................................................................... 363 STEERING CYLINDER ...................................................................................................................... 364 CENTER HlNGE PIN........................................................................................................................ 365 GROUND DRIVEN STEERING (IF EQUIPPED) ................................................................................................... 366 GROUND DRIVEN STEERING PIPING....................................................................................................... 366 GROUND DRIVEN STEERING PUMP......................................................................................................... 367 DIVERTER VALVE...................................................................................................................... 368 OPERATION........................................................................................................................... 369 42 TESTING AND ADJUSTING ................................................................................................................... 371 STANDARD VALUE TABLE ................................................................................................................... 372 TOOL LIST .............................................................................................................................. 372 STEERING WHEEL ......................................................................................................................... 373 PLAY................................................................................................................................ 373 OPERATING FORCE..................................................................................................................... 374 OPERATING TIME...................................................................................................................... 375 STEERING OIL PRESSURE .................................................................................................................. 376 STEERING LINKAGE ....................................................................................................................... 378 TROUBLESHOOTING TABLES.................................................................................................................. 381 1. Steering wheel does not turn..................................................................................................... 382 2. Steering wheel is sluggish....................................................................................................... 383 3. Steering wheel moves unsteadily or is subject to large shock..................................................................... 384 4. Machine tends to turn naturally in one particular direction while traveling...................................................... 384 5. Left and right turning radii are different....................................................................................... 384 43 DISASSEMBLY AND ASSEMBLY ................................................................................................................ 385 STEERING GEAR .......................................................................................................................... 387 REMOVAL............................................................................................................................. 387 INSTALLATION........................................................................................................................ 389 STEERING GEAR BOX ...................................................................................................................... 390 DISASSEMBLY......................................................................................................................... 390 ASSEMBLY............................................................................................................................ 391 STEERING VALVE ......................................................................................................................... 393 REMOVAL............................................................................................................................. 393 INSTALLATION........................................................................................................................ 395 DISASSEMBLY AND ASSEMBLY............................................................................................................ 398 STEERING CYLINDER ...................................................................................................................... 400 REMOVAL............................................................................................................................. 400 INSTALLATION........................................................................................................................ 402 DISASSEMBLY......................................................................................................................... 404 ASSEMBLY............................................................................................................................ 406 CENTER HINGE PIN ....................................................................................................................... 409 REMOVAL............................................................................................................................. 409 INSTALLATION........................................................................................................................ 418 44 MAINTENANCE STANDARD .................................................................................................................... 429 STEERING COLUMN AND GEAR BOX ........................................................................................................... 430 STEERING VALVE ......................................................................................................................... 432 STEERING CYLINDER MOUNT ................................................................................................................ 433 STEERING CYLINDER ...................................................................................................................... 434 CENTER HINGE PIN ....................................................................................................................... 436 GROUND DRIVEN STEERING PUMP ............................................................................................................ 439 DIVERTER VALVE ......................................................................................................................... 440 50 BRAKE AND AIR SYSTEM......................................................................................................................... 441 51 STRUCTURE AND FUNCTION .................................................................................................................. 441 GENERAL ................................................................................................................................ 442 AIR SYSTEM ......................................................................................................................... 442 BRAKE CIRCUIT ...................................................................................................................... 442 BRAKE AND AIR PIPING ................................................................................................................... 443 AIR CIRCUIT SYSTEM ..................................................................................................................... 444 AIR GOVERNOR ........................................................................................................................... 445 AIR TANK ............................................................................................................................... 447 WET TANK............................................................................................................................ 447 DRY TANK........................................................................................................................... 447 SAFETY VALVE ........................................................................................................................... 447 BRAKE VALVE ............................................................................................................................ 448 BRAKE ACTUATED ..................................................................................................................... 449 OPERATING IN BALANCE ............................................................................................................... 450 BRAKE RELEASED ..................................................................................................................... 451 TWO-WAY VALVE .......................................................................................................................... 452 RELAY VALVE ............................................................................................................................ 453 BRAKE CHAMBER .......................................................................................................................... 454 SLACK ADJUSTER ......................................................................................................................... 456 BRAKE .................................................................................................................................. 459 PARKING BRAKE........................................................................................................................... 461 BRAKE CALIPER .......................................................................................................................... 463 PARKING BRAKE SOLENOID VALVE ........................................................................................................... 464 SPRING CYLINDER ........................................................................................................................ 465 HYDRAULIC TANK PRESSURIZING VALVE ...................................................................................................... 466 52 TESTING AND ADJUSTING ................................................................................................................... 467 STANDARD VALUE TABLE ................................................................................................................... 469 TOOL LIST .............................................................................................................................. 470 MEASURING BRAKE PEDAL .................................................................................................................. 471 MEASURING AIR PRESSURE ................................................................................................................. 472 BRAKE PERFORMANCE ...................................................................................................................... 474 CHECKING BRAKE OIL PRESSURE ............................................................................................................ 475 MEASURING WEAR OF BRAKE DISC .......................................................................................................... 476 AIR BLEEDING FROM BRAKE LINE ........................................................................................................... 477 PARKING BRAKE PERFORMANCE .............................................................................................................. 478 CHECKING AND ADJUSTING PARKING BRAKE .................................................................................................. 479 TROUBLESHOOTING......................................................................................................................... 481 TROUBLESHOOTING TABLE .............................................................................................................. 482 1. Air pressure does not rise at all............................................................................................ 482 2. Air pressure does not rise to the specified range............................................................................ 483 3. Brake is ineffective or not very effective................................................................................... 484 4. Brake does not release, or drags............................................................................................. 485 5. Parking brake does not release, or drags..................................................................................... 486 53 DISASSEMBLY AND ASSEMBLY ................................................................................................................ 487 BRAKE VALVE ............................................................................................................................ 489 REMOVAL............................................................................................................................. 489 INSTALLATION........................................................................................................................ 491 DISASSEMBLY......................................................................................................................... 493 ASSEMBLY............................................................................................................................ 495 BRAKE CHAMBER .......................................................................................................................... 497 REMOVAL............................................................................................................................. 497 INSTALLATION........................................................................................................................ 500 DISASSEMBLY......................................................................................................................... 503 ASSEMBLY............................................................................................................................ 506 SLACK ADJUSTER ......................................................................................................................... 509 REMOVAL............................................................................................................................. 509 INSTALLATION........................................................................................................................ 509 DISASSEMBLY......................................................................................................................... 510 ASSEMBLY............................................................................................................................ 511 BRAKE ASSEMBLY ......................................................................................................................... 512 REMOVAL............................................................................................................................. 512 INSTALLATION........................................................................................................................ 515 DISASSEMBLY......................................................................................................................... 518 ASSEMBLY............................................................................................................................ 521 SPRING CYLINDER ........................................................................................................................ 524 REMOVAL............................................................................................................................. 524 INSTALLATION........................................................................................................................ 525 DISASSEMBLY......................................................................................................................... 526 ASSEMBLY............................................................................................................................ 527 PARKING BRAKE .......................................................................................................................... 528 REMOVAL............................................................................................................................. 528 INSTALLATION........................................................................................................................ 531 PARKING BRAKE PAD ...................................................................................................................... 534 REMOVAL............................................................................................................................. 534 INSTALLATION........................................................................................................................ 534 54 MAINTENANCE STANDARD .................................................................................................................... 535 BRAKE VALVE ............................................................................................................................ 536 BRAKE CHAMBER .......................................................................................................................... 538 SLACK ADJUSTER ......................................................................................................................... 539 BRAKE .................................................................................................................................. 540 PARKING BRAKE .......................................................................................................................... 542 SPRING CYLINDER ........................................................................................................................ 544 60 WORK EQUIPMENT SYSTEM........................................................................................................................ 547 61 STRUCTURE AND FUNCTION .................................................................................................................. 547 GENERAL ................................................................................................................................ 550 HYDRAULIC PIPING ....................................................................................................................... 551 HYDRAULIC CIRCUIT....................................................................................................................... 552 SCHEMATICS ......................................................................................................................... 552 DIAGRAM............................................................................................................................. 554 HYDRAULIC TANK ......................................................................................................................... 556 OIL FILTER BYPASS VALVE............................................................................................................. 558 BREATHER............................................................................................................................ 559 HYDRAULIC PUMPS ........................................................................................................................ 560 HYDRAULIC PUMP + STEERING PUMP + PPC PUMP........................................................................................... 560 TRANSMISSION LUBRICATION + TORQUE CONVERTER CHARGING + SWITCH PUMP.................................................................. 561 PROPORTIONAL PRESSURE CONTROL VALVE (PPC VALVE) ........................................................................................ 562 FUNCTION OF PPC VALVE .............................................................................................................. 564 PPC RELIEF VALVE ................................................................................................................... 566 MAIN CONTROL VALVE ..................................................................................................................... 567 RELIEF VALVE........................................................................................................................ 570 SAFETY VALVE........................................................................................................................ 571 SUCTION VALVE....................................................................................................................... 572 FLOAT SELECTOR VALVE AND UNLOADER VALVE ............................................................................................ 573 ACCUMULATOR ............................................................................................................................ 577 HYDRAULIC CIRCUIT OPERATION ............................................................................................................ 578 LIFT AND DUMP SPOOLS AT “HOLD”...................................................................................................... 578 LIFT SPOOL AT “RAISE”............................................................................................................... 580 LIFT SPOOL AT “FLOAT’............................................................................................................... 582 DUMP SPOOL AT “TILT BACK”........................................................................................................... 584 HYDRAULIC CYLINDER ..................................................................................................................... 586 LIFT CYLINDER....................................................................................................................... 586 DUMP CYLINDER....................................................................................................................... 587 BUCKET LINKAGE ......................................................................................................................... 588 BUCKET POSITIONER AND BOOM KICK-OUT .................................................................................................... 590 WORK EQUIPMENT LEVER LINKAGE ........................................................................................................... 592 62 TESTING AND ADJUSTING ................................................................................................................... 593 STANDARD VALUE TABLE ................................................................................................................... 595 TOOL LIST .............................................................................................................................. 596 DUMP AND LIFT CONTROL LEVERS............................................................................................................ 597 MEASURING........................................................................................................................... 597 ADJUSTING .......................................................................................................................... 598 HYDRAULIC CIRCUIT FLUSHING ............................................................................................................. 600 PPC RELIEF VALVE ....................................................................................................................... 603 MEASURING PRESSURE.................................................................................................................. 603 ADJUSTING .......................................................................................................................... 605 WORK EQUIPMENT.......................................................................................................................... 606 RELIEF VALVE........................................................................................................................ 606 MEASURING TIME...................................................................................................................... 608 HYDRAULIC DRIFT..................................................................................................................... 609 BUCKET POSITIONER ...................................................................................................................... 610 BOOM KICK-OUT .......................................................................................................................... 611 TROUBLESHOOTING ........................................................................................................................ 613 TROUBLESHOOTING TABLE .............................................................................................................. 614 1. Lift arm does not rise....................................................................................................... 614 2. Lift arm moves slowly or does not have sufficient lifting power.............................................................. 615 3. Lift arm movement becomes slow after it reaches a certain height............................................................. 616 4. Bucket cannot be held down with lift arm cylinder............................................................................ 616 5. Lift arm has large hydraulic drift........................................................................................... 616 6. Lift arm movement is unsteady during work.................................................................................... 616 7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”........................................... 616 8. Bucket does not tilt back.................................................................................................... 617 9. Bucket moves slowly or has insufficient tilt back power...................................................................... 618 10. Bucket movement becomes slow during tilt back............................................................................... 619 11. Bucket cannot be held down by the bucket cylinder........................................................................... 619 12. Bucket has large hydraulic drift............................................................................................ 619 13. Bucket moves unsteadily when machine travels under load..................................................................... 619 14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”........................................... 619 15. Control levers of lift arm and dump move stiffly and sluggishly............................................................. 620 63 DISASSEMBLY AND ASSEMBLY ................................................................................................................ 621 HYDRAULIC TANK ......................................................................................................................... 623 REMOVAL............................................................................................................................. 623 INSTALLATION........................................................................................................................ 625 HYDRAULIC FILTER ....................................................................................................................... 627 REMOVAL............................................................................................................................. 627 INSTALLATION........................................................................................................................ 628 HYDRAULIC PUMP ......................................................................................................................... 629 WORK EQUIPMENT, STEERING, PPC PUMP ................................................................................................. 629 REMOVAL......................................................................................................................... 629 INSTALLATION.................................................................................................................... 631 PPC VALVE ASSEMBLY ..................................................................................................................... 633 REMOVAL............................................................................................................................. 633 INSTALLATION........................................................................................................................ 635 DISASSEMBLY......................................................................................................................... 637 ASSEMBLY............................................................................................................................ 637 MAIN CONTROL VALVE ..................................................................................................................... 638 REMOVAL............................................................................................................................. 638 INSTALLATION........................................................................................................................ 641 DISASSEMBLY......................................................................................................................... 644 ASSEMBLY............................................................................................................................ 646 DUMP CYLINDER .......................................................................................................................... 648 REMOVAL............................................................................................................................. 648 INSTALLATION........................................................................................................................ 651 LIFT CYLINDER .......................................................................................................................... 653 REMOVAL............................................................................................................................. 653 INSTALLATION........................................................................................................................ 656 LIFT AND DUMP CYLINDERS ................................................................................................................ 659 DISASSEMBLY......................................................................................................................... 659 ASSEMBLY............................................................................................................................ 661 WORK EQUIPMENT ......................................................................................................................... 663 REMOVAL............................................................................................................................. 663 INSTALLATION........................................................................................................................ 669 COUNTERWEIGHT .......................................................................................................................... 675 REMOVAL............................................................................................................................. 675 INSTALLATION........................................................................................................................ 677 64 MAINTENANCE STANDARD .................................................................................................................... 679 MAIN CONTROL VALVE ..................................................................................................................... 680 HYDRAULIC PUMP ......................................................................................................................... 682 SAR250 (HYDRAULIC) + SAR125 (STEERING) + SAR20 (PPC) PUMP........................................................................... 682 SAR125 (TRANSMISSION LUBRICATION) + SARlOO (TORQUE CONVERTER CHARGING) + SARI00 (SWITCH PUMP)....................................... 684 PPC VALVE .............................................................................................................................. 686 DUMP CYLINDER .......................................................................................................................... 688 LIFT CYLINDER .......................................................................................................................... 690 BUCKET LINKAGE ......................................................................................................................... 692 BUCKET POSITIONER AND BOOM KICK-OUT .................................................................................................... 694 BUCKET ................................................................................................................................. 695 80 ELECTRIC AND ELECTRONIC SYSTEM............................................................................................................... 697 81 STRUCTURE AND FUNCTION .................................................................................................................. 697 ELECTRICAL WIRING DIAGRAM .............................................................................................................. 699 ENGINE STARTING CIRCUIT ................................................................................................................ 701 ENGINE STOP CIRCUIT .................................................................................................................... 702 COMBINATION SWITCH ................................................................................................................. 704 TRANSMISSION CUT-OFF SWITCH ........................................................................................................ 705 TRANSMISSION CUT-OFF SELECTOR SWITCH ............................................................................................... 706 NEUTRALIZER RELAY .................................................................................................................. 707 KICK-DOWN SWITCH.................................................................................................................... 708 KICK-DOWN ELECTRIC CIRCUIT ......................................................................................................... 709 ELECTRICAL PARKING BRAKE CONTROL ....................................................................................................... 715 PARKING BRAKE VALVE................................................................................................................. 717 PARKING SAFETY RELAY ............................................................................................................... 717 NEUTRALIZER RELAY................................................................................................................... 717 EMERGENCY BRAKE SWITCH.............................................................................................................. 717 CONDITIONS ......................................................................................................................... 718 1. STARTING SWITCH OFF.......................................................................................................... 718 2. STARTING SWITCH ON........................................................................................................... 719 2-1. When parking brake switch is turned ON before starting switch is turned ON............................................. 719 2-2. Parking brake switch turned OFF (released) before starting switch is turned ON......................................... 720 3. PARKING BRAKE SWITCH TURNED OFF (Re- leased) AFTER STARTING SWITCH IS TURNED ON.............................................. 721 4. PARKING BRAKE SWITCH ON (operated)........................................................................................... 722 5. WHEN AIR PRESSURE DROPS. (Emergency brake actuated).......................................................................... 723 PROXIMITY SWITCH ....................................................................................................................... 724 OPERATION........................................................................................................................... 725 Lift arm RAISE.................................................................................................................. 725 Kick-out........................................................................................................................ 727 BUCKET “TILT’....................................................................................................................... 728 Hold............................................................................................................................ 728 Tilt............................................................................................................................ 729 Positioned...................................................................................................................... 730 AUTO PRIMING SYSTEM (APS)............................................................................................................... 731 OPERATION........................................................................................................................... 734 1. Preheat monitor lamp on vehicle monitor ON................................................................................... 734 2. After-heating monitor on vehicle monitor ON.................................................................................. 735 APS CONTROLLER...................................................................................................................... 736 RESISTOR............................................................................................................................ 737 BIMETAL TIMER....................................................................................................................... 737 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)............................................................................................. 738 INDICATION ON MONITOR PANEL......................................................................................................... 740 MONITOR WIRING HARNESS.............................................................................................................. 742 SENSORS................................................................................................................................. 743 ENGINE OIL LEVEL SENSOR............................................................................................................. 743 BRAKE OIL LEVEL SENSOR.............................................................................................................. 744 COOLANT LEVEL SENSOR................................................................................................................ 744 FUEL GAUGE SENSOR................................................................................................................... 745 ENGINE OIL PRESSURE SENSOR.......................................................................................................... 746 PARKING BRAKE SENSOR................................................................................................................ 746 AIR PRESSURE SENSOR................................................................................................................. 747 COOLANT TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE SENSOR........................................................................ 747 ROTATIONAL SPEED SENSOR............................................................................................................. 748 BRAKE LINE FAILURE SENSOR........................................................................................................... 748 TRANSMISSION OIL FILTER CLOGGING SENSOR............................................................................................. 749 GROUND DRIVEN STEERING OPERATION SENSOR............................................................................................. 749 82 TESTING AND ADJUSTING ................................................................................................................... 750 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ............................................................................................. 754 MACHINE MONITOR (SPEEDOMETER MODULE) ................................................................................................... 757 TROUBLESHOOTING......................................................................................................................... 758 CHECKS BEFORE TROUBLESHOOTING ...................................................................................................... 759 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART .................................................................................. 760 CONNECTOR TERMINAL NUMBERS ......................................................................................................... 762 PRECAUTION WHEN HANDLING CONNECTOR ................................................................................................. 766 ELECTRICAL WIRING DIAGRAM .......................................................................................................... 768 ELECTRICAL CONNECTOR (CN) DIAGRAM .................................................................................................. 768 SENSOR LOCATION DIAGRAM ............................................................................................................ 768 ELECTRICAL CIRCUIT SYSTEM .......................................................................................................... 769 ENGINE STARTING CIRCUIT SYSTEM.................................................................................................. 769 ENGINE STOP CIRCUIT SYSTEM...................................................................................................... 770 TRANSMISSION CONTROL, PARKING CIRCUIT SYSTEM ................................................................................... 771 PARKING BRAKE SYSTEM ........................................................................................................... 772 PREHEATING SYSTEM............................................................................................................... 773 ELECTRICAL SYSTEM .............................................................................................................. 774 VEHICLE MONITOR SYSTEM.......................................................................................................... 775 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM............................................................................................... 776 POSITION OF CONNECTORS FOR TROUBLESHOOTING ........................................................................................ 777 E-1 ENGINE DOES NOT START........................................................................................................... 785 E-2 ENGINE DOES NOT STOP........................................................................................................... 789 E-3 ENGINE STOPS WHEN TRAVELING.................................................................................................... 790 E-4 PARKING BRAKE DOES NOT WORK. (PARKING BRAKE SWITCH ON)......................................................................... 791 E-5 PARKING BRAKE IS NOT RELEASED.................................................................................................. 793 E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................... 795 E-7 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.......................................................... 796 E-8 TRANSMISSION DOES NOT WORK NORMALLY............................................................................................ 797 E-9 KICK-DOWN SWITCH DOES NOT WORK (1/2)........................................................................................... 819 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.............................................................................. 822 E-11 KICK-DOWN OPERATION IS NOT CANCELED........................................................................................... 823 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2............................................................................... 825 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED...................................................................... 825 E-14 PREHEATING IS NOT CARRIED OUT................................................................................................. 827 E-15 PREHEATING REMAINS ON......................................................................................................... 829 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM.......................................................................... 834 POSITION OF CONNECTORS FOR TROUBLESHOOTING ......................................................................................... 835 M-1 (BRAKE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED............................................................................... 843 M-2 (ENGINE OIL LEVEL) FLASHES WHEN ENGINE IS STOPPED.............................................................................. 843 M-3 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS STOPPED.......................................................................... 845 M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING................................................................................ 845 M-5 (TRANSMISSION OIL FILTER CLOGGING) FLASHES WHEN ENGINE IS RUNNING.............................................................. 847 M-6 (FUEL LEVEL) FLASHES WHEN ENGINE IS RUNNING.................................................................................... 848 M-7 (BRAKE LINE FAILURE) FLASHES WHEN ENGINE IS RUNNING............................................................................ 849 M-8 (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS RUNNING........................................................................... 850 M-9 (RADIATOR WATER LEVEL) FLASHES WHEN ENGINE IS RUNNING.......................................................................... 851 M-10 (DROP IN AIR PRESSURE) FLASHES WHEN ENGINE IS RUNNING......................................................................... 853 M-11 (ENGINE WATER TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING..................................................................... 853 M-12 (TORQUE CONVERTER OIL TEMPERATURE) FLASHES WHEN ENGINE IS RUNNING............................................................. 853 M-13 (PARKING BRAKE) LIGHTS UP ABNORMALLY OR DOES NOT LIGHT UP..................................................................... 855 M-14 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP..................................................................... 857 M-15 (PREHEATING) LIGHTS UP, OR DOES NOT LIGHT UP.................................................................................. 859 M-16 (TRANSMISSION CUT-OFF) LIGHTS UP, DOES NOT LIGHT UP........................................................................... 861 M-17 TURN SIGNAL HI BEAM LIGHTS UP, OR DOES NOT LIGHT UP........................................................................... 863 M-18 TURN SIGNAL DOES NOT FLASH EVEN WHEN HAZARD SWITCH IS TURNED ON............................................................... 868 M-19 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.................................................................................... 869 M-20 HOURMETER DISPLAY DOES NOT WORK NORMALLY...................................................................................... 871 M-21 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT WORK, OR ONLY PART WORKS............................................ 873 M-22 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LIGHTS LIGHT UP, BUT DO NOT GO OUT....................................... 875 M-23 (BATTERY CHARGE) FLASHES OR (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE IS STOPPED.............................................. 877 M-24 NONE OF THE MACHINE MONITOR PANEL LIGHTING LIGHTS UP, OR PARTS OF IT DOES NOT LIGHT UP........................................ 879 M-25 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE BUZZER DOES NOT SOUND FOR 1 SEC. WITH THE .... 883 M-26 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE ALARM BUZZER SOUNDS................................................... 883 M-27 WHEN THE STARTING SWITCH IS TURNED TO THE ON POSITION (ENGINE STOPPED), AND THE WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC, .... 885 M-28 NO ABNORMALITY IS SHOWN ON THE MONITOR DISPLAY, BUT THE WARNING LAMP LIGHTS UP................................................ 886 M-29 ABNORMALITY IN THE FUEL GAUGE SYSTEM.......................................................................................... 887 M-30 ABNORMALITY IN THE AIR PRESSURE GAUGE SYSTEM.................................................................................. 889 M-31 ABNORMALITY IN THE ENGINE WATER TEMPERATURE GAUGE SYSTEM...................................................................... 891 M-32 ABNORMALITY IN THE TORQUE CONVERTER OIL TEMPERATURE GAUGE SYSTEM.............................................................. 893 83 DISASSEMBLY AND ASSEMBLY ................................................................................................................ 896 MACHINE MONITOR......................................................................................................................... 897 REMOVAL............................................................................................................................. 897 INSTALLATION........................................................................................................................ 897 90 OTHERS....................................................................................................................................... 898 91 AIR CONDITIONER STRUCTURE AND FUNCTION................................................................................................... 898 GENERAL ................................................................................................................................ 900 BASIC INFORMATION ON AIR CONDITIONERS............................................................................................... 900 UNITS RELATED TO REFRIGERATION.................................................................................................. 900 Heat........................................................................................................................ 900 Temperature................................................................................................................. 900 Pressure.................................................................................................................... 901 Humidity.................................................................................................................... 902 PRINCIPLE OF COOLING............................................................................................................ 903 1. Why do coolers cool?..................................................................................................... 903 2. Refrigerator using evaporation latent heat............................................................................... 903 3. Refrigeration method (Vapor compression)................................................................................. 903 4. Refrigerating cycle...................................................................................................... 904 5. Heating cycle............................................................................................................ 906 REFRIGERANTS.................................................................................................................... 907 SAFETY PRECAUTIONS.......................................................................................................... 907 REFRIGERATOR OIL (LUBE OIL)..................................................................................................... 908 SPECIFICATIONS.................................................................................................................. 909 PIPING DIAGRAM ......................................................................................................................... 910 ELECTRIC WIRING DIAGRAM ................................................................................................................ 911 COMPRESSOR (CRANK TYPE) ................................................................................................................ 912 MAGNETIC CLUTCH......................................................................................................................... 915 CONDENSER .............................................................................................................................. 916 RECEIVER W/SIGHT GLASS (LIQUID TANK) .................................................................................................. 918 AIR CONDITIONER UNIT ................................................................................................................... 920 EXPANSION VALVE..................................................................................................................... 921 EVAPORATOR.......................................................................................................................... 923 THERMOSTAT.......................................................................................................................... 923 PRESSURE SWITCH..................................................................................................................... 924 HEATER.............................................................................................................................. 926 BLOWER UNIT......................................................................................................................... 926 PIPING.............................................................................................................................. 927 AIR CONTROL SYSTEM.................................................................................................................. 928 CONTROL PANEL .......................................................................................................................... 929 BLOWER SWITCH....................................................................................................................... 929 AIR CONDITIONER SWITCH.............................................................................................................. 929 TEMPERATURE CONTROL LEVER........................................................................................................... 929 AIR SOURCE SELECTOR LEVER........................................................................................................... 929 92 AIR CONDITIONER TESTING AND ADJUSTING ................................................................................................... 930 SERVICE TOOLS .......................................................................................................................... 932 GAUGE MANIFOLD...................................................................................................................... 932 GAS LEAK DETECTOR................................................................................................................... 935 HALIDE TORCH LEAK DETECTOR...................................................................................................... 935 ELECTRIC LEAK TESTER............................................................................................................ 937 VALVE FOR SERVICE CANS.............................................................................................................. 938 MAINTENANCE PROCEDURE .................................................................................................................. 939 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...................................................................................... 939 PROHIBITED WORK................................................................................................................. 939 OTHER PRECAUTIONS............................................................................................................... 939 BLEEDING AIR FROM REFRIGERATION CIRCUIT............................................................................................. 941 PURPOSE......................................................................................................................... 941 CONNECTING GAUGE MANIFOLD....................................................................................................... 941 EVACUATION...................................................................................................................... 942 AIR-TIGHTNESS CHECK............................................................................................................. 942 GAS-LEAK CHECK.................................................................................................................. 942 EVACUATION (REPEATING).......................................................................................................... 943 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIDGERANT................................................................................ 944 CHARGING FROM THE HIGH-PRESSURE SIDE............................................................................................ 944 CHARGING FROM THE LOW PRESSURE SIDE............................................................................................. 945 WHEN THE AMBIENT TEMPERATURE IS LOW............................................................................................. 946 WHEN THE AMBIENT TEMPERATURE IS HIGH............................................................................................ 946 REPLACING SERVICE CANS.............................................................................................................. 947 CHECKING THE AMOUNT OF REFRIGERANT.................................................................................................. 947 REMOVAL OF GAUGE MANIFOLD........................................................................................................... 949 DISCHARGING THE REFRIGERANT......................................................................................................... 949 DAILY CHECKS........................................................................................................................ 950 CHECK REFRIGERANT LEVEL......................................................................................................... 950 CLEANING THE CONDENSER.......................................................................................................... 950 CHECKING THE V-BELT............................................................................................................. 950 CHECKING OIL LEVEL.................................................................................................................. 951 PROCEDURE FOR CHECKING.......................................................................................................... 951 PROCEDURE FOR CHECKING OIL LEVEL................................................................................................ 951 ADDING AND REMOVING OIL......................................................................................................... 952 ADDING OIL BY EVACUATION........................................................................................................ 952 TROUBLESHOOTING ........................................................................................................................ 953 VISUAL AND ACOUSTICAL CHECKS........................................................................................................ 953 DEFECTIVE COOLING................................................................................................................... 954 TROUBLESHOOTING TABLES.............................................................................................................. 955 DEFECTIVE HEATING................................................................................................................... 957 TROUBLESHOOTING USING GAUGE MANIFOLD................................................................................................ 958 PREPARATIONS BEFORE MEASURING................................................................................................... 958 INSUFFICIENT REFRIGERANT........................................................................................................ 958 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER...................................................................... 959 AIR INSIDE REFRIGERATION SYSTEM................................................................................................. 959 MOISTURE IN REFRIGERATING SYSTEM................................................................................................ 960 REFRIGERANT DOES NOT CIRCULATE.................................................................................................. 961 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE............................................... 962 DEFECTIVE COMPRESSION BY COMPRESSOR............................................................................................. 962 93 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY ................................................................................................ 964 SPECIAL TOOLS .......................................................................................................................... 965 MAGNETIC CLUTCH ........................................................................................................................ 966 DISASSEMBLY OF...................................................................................................................... 966 CHECKS BEFORE DISASSEMBLY....................................................................................................... 967 REMOVAL OF ROTOR AND STATOR..................................................................................................... 967 REMOVAL OF CENTER PIECE FROM ROTOR.............................................................................................. 968 REMOVAL OF BEARING FROM ROTOR................................................................................................... 969 ASSEMBLY OF......................................................................................................................... 970 ASSEMBLY OF BEARING TO ROTOR.................................................................................................... 970 ASSEMBLY OF CENTER PIECE TO ROTOR............................................................................................... 970 ASSEMBLY OF STATOR AND ROTOR TO COMPRESSOR...................................................................................... 971 AIR CONDITIONER UNIT ................................................................................................................... 972 DISASSEMBLY OF...................................................................................................................... 972 CHECKS BEFORE DISASSEMBLY....................................................................................................... 972 REMOVAL OF CONTROL PANELAND THERMOSTAT.......................................................................................... 976 REMOVAL OF UNIT COVER........................................................................................................... 978 REMOVAL OF WATER VALVE.......................................................................................................... 978 REMOVAL OF EXPANSION VALVE...................................................................................................... 980 REMOVAL OF EVAPORATOR........................................................................................................... 982 REMOVAL OF HEATER CORE.......................................................................................................... 982 REMOVAL OF PRESSURE SWITCHES.................................................................................................... 982 BLOWER UNIT ............................................................................................................................ 983 DISASSEMBLY......................................................................................................................... 983 CHECKS BEFORE DISASSEMBLY....................................................................................................... 983 REMOVAL OF BLOWER RESISTOR...................................................................................................... 983 REMOVAL OF BLOWER MOTOR AND FAN................................................................................................. 984 CONDENSER .............................................................................................................................. 985 DISASSEMBLY......................................................................................................................... 985 CHECKS BEFORE DISASSEMBLY....................................................................................................... 985 REMOVAL OF CONDENSER, FAN MOTOR................................................................................................. 986 REMOVAL OF PRESSURE SWITCH...................................................................................................... 987 REMOVAL OF RESISTOR............................................................................................................. 987 97 GEAR PUMP SA SERIES ..................................................................................................................... 988 GENERAL................................................................................................................................. 989 PRINCIPLE OF OPERATION ............................................................................................................. 990 PRESSURE LOADED TYPE GEAR PUMP ..................................................................................................... 993 FIXED SIDE PLATE TYPE GEAR PUMP .................................................................................................... 995 SA SERIES .............................................................................................................................. 996 STRUCTURE .......................................................................................................................... 996 TESTING AND ADJUSTING ..............................................................................................................1000 DISASSEMBLY.........................................................................................................................1003 ASSEMBLY ...........................................................................................................................1007 MAINTENANCE STANDARD................................................................................................................1012 99 METRIC CONVERSION TABLE..................................................................................................................1014
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