Komatsu Wheel Loader WA450 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA450, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA450 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 6,823 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM000201 - Wheel Loader WA450-3 Operation & Maintenance Manual.pdf
CEAM003800 - Wheel Loader WA450-3 avance plus Operation & Maintenance Manual.pdf
CEAM018203 - Wheel Loader WA450-6 Operation & Maintenance Manual.pdf
CEBDW21020 - Wheel Loader WA450-2 Shop Manual.pdf
CEBM000401 - Wheel Loader WA450-3 Shop Manual.pdf
CEBM003602 - Wheel Loader WA450-3 avance plus Shop Manual.pdf
CEBMW21020 - Wheel Loader WA450-2 Shop Manual.pdf
SEAM042KD200 - Wheel Loader WA450-2 Operation & Maintenance Manual.pdf
SEAM020900 - Wheel Loader WA450-3 Operation & Maintenance Manual.pdf
SEBM015501 - Wheel Loader WA450-3 Shop Manual.pdf
SEBMA4210108 - Wheel Loader WA450-1 Shop Manual.pdf
TEN00125-04 - Wheel Loader WA450-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM000201 - Wheel Loader WA450-3 Operation & Maintenance Manual.....2
1. FORWARD.....5
2. SAFETY INFORMATION.....6
3. INTRODUCTION.....7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....8
5. CONTENTS.....9
SAFETY.....13
6. GENERAL PRECAUTIONS.....14
7. PRECAUTIONS DURING OPERATION.....19
7.1 BEFORE STARTING ENGINE.....19
7.2 OPERATING MACHINE.....21
7.3 TRANSPORTATION.....26
7.4 BATTERY.....27
7.5 TOWING.....28
8. PRECAUTIONS FOR MAINTENANCE.....29
8.1 BEFORE CARRYING OUT MAINTENANCE.....29
8.2 DURING MAINTENANCE.....31
8.3 TIRES.....36
9. POSITION FOR ATTACHING SAFETY LABELS.....38
OPERATION.....42
10. GENERAL VIEW.....43
10.1 GENERAL VIEW OF MACHINE.....43
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....44
11. EXPLANATION OF COMPONENTS.....45
11.1 MACHINE MONITOR.....45
11.2 SWITCHES.....55
11.3 CONTROL LEVERS AND PEDALS.....61
11.4 STEERING COLUMN TILT LEVER.....65
11.5 CAP WITH LOCK.....66
11.6 SAFETY BAR.....67
11.7 TOWING PIN.....67
11.8 GREASE PUMP.....68
11.9 BACK UP ALARM.....68
11.10 FUSE.....69
11.11 SLOW-BLOW FUSE.....70
12. OPERATION.....71
12.1 CHECKS BEFORE STARTING.....71
12.2 STARTING ENGINE.....84
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....85
12.4 MOVING MACHINE OFF.....86
12.5 CHANGING GEAR SPEED.....88
12.6 CHANGING DIRECTION.....88
12.7 TURNING.....89
12.8 STOPPING MACHINE.....90
12.9 OPERATION OF WORK EQUIPMENT.....91
12.10 WORK POSSIBLE USING WHEEL LOADER.....92
12.11 PRECAUTIONS FOR OPERATION.....97
12.12 ADJUSTING WORK EQUIPMENT POSTURE.....99
12.13 PARKING MACHINE.....101
12.14 CHECKS AFTER COMPLETION OF OPERATION.....102
12.15 STOPPING ENGINE.....102
12.16 CHECK AFTER STOPPING ENGINE.....103
12.17 LOCKING.....103
12.18 HANDLING THE TIRES.....104
13. TRANSPORTATION.....106
13.1 LOADING, UNLOADING WORK.....106
13.2 PRECAUTIONS FOR LOADING.....107
13.3 PRECAUTIONS FOR TRANSPORTATION.....107
14. COLD WEATHER OPERATION.....108
14.1 PRECAUTIONS FOR LOW TEMPERATURE.....108
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....110
14.3 AFTER COLD WEATHER.....110
15. LONG-TERM STORAGE.....111
15.1 BEFORE STORAGE.....111
15.2 DURING STORAGE.....111
15.3 AFTER STORAGE.....111
16. TROUBLESHOOTING.....112
16.1 WHEN MACHINE RUNS OUT OF FUEL.....112
16.2 TOWING THE MACHINE.....113
16.3 IF BATTERY IS DISCHARGED.....118
16.4 OTHER TROUBLE.....122
MAINTENANCE.....128
17. GUIDES TO MAINTENANCE.....129
18. OUTLINES OF SERVICE.....132
18.1 OUTLINE OF OIL, FUEL, COOLANT.....132
18.2 OUTLINE OF ELECTRIC SYSTEM.....135
19. WEAR PARTS LIST.....136
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....137
20.1 ENGINE OIL SPECIFICATIONS.....139
20.2 DIESEL FUEL SPECIFICATIONS.....140
20.3 COOLANT SPECIFICATIONS.....141
21. STANDARD TORQUE REQUIREMENTS FOR BOLTS AND NUTS.....147
21.1 INTRODUCTION OF NECESSARY TOOLS.....147
21.2 TORQUE LIST.....148
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....149
23. MAINTENANCE SCHEDULE CHART.....153
23.1 MAINTENANCE SCHEDULE CHART.....153
24. SERVICE PROCEDURE.....157
24.1 INITIAL 250 HOURS SERVICE.....157
24.2 WHEN REQUIRED.....158
24.3 CHECKS BEFORE STARTING.....167
24.4 EVERY 50 HOURS SERVICE.....168
24.5 EVERY 100 HOURS SERVICE.....169
24.6 EVERY 250 HOURS SERVICE.....171
24.7 EVERY 500 HOURS SERVICE.....179
24.8 EVERY 1000 HOURS SERVICE.....181
24.9 EVERY 1500 HOURS SERVICE.....184
24.10 EVERY 2000 HOURS SERVICE.....185
24.11 EVERY 6000 HOURS SERVICE.....194
SPECIFICATIONS.....195
25. SPECIFICATIONS.....196
OPTIONAL ATTACHMENTS.....198
26. OPTIONAL PARTS AND ATTACHMENTS.....199
27. SELECTING BUCKETS AND TIRES.....200
28. HEATER AND AIR CONDITIONING (IF EQUIPPED).....201
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....201
28.2 COOL BOX COMPARTMENT.....202
29. HANDLING E.C.S.S. (ELECTRONIC CONTROL SUSPENSION SYSTEM).....203
29.1 STRUCTURE AND FUNCTION OF E.C.S.S.....203
29.2 METHOD OF OPERATING E.C.S.S.....204
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH.....204
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....205
30. HANDLING AUTO-GREASING SYSTEM.....206
30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM.....206
30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.....214
30.3 TROUBLE SHOOTING.....215
30.4 SPECIFICATIONS.....215
31. OPTION DISPLAY.....216
CEAM003800 - Wheel Loader WA450-3 avance plus Operation & Maintenance Manual.....218
COVER.....218
INTRODUCTION.....221
1. FOREWARD.....222
2. SAFETY INFORMATION.....223
3. INTRODUCTION.....224
3.1 INTENDED USE.....224
3.2 FEATURES.....224
3.3 BREAKING IN A NEW MACHINE.....224
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....225
4.1 MACHINE SERIAL NO. PLATE POSITION.....225
4.1.1 POSITION OF PLATE (A).....225
4.1.2 POSITION OF STAMP(B).....225
4.2 ENGINE SERIAL NO. PLATE POSITION.....225
4.3 TABLE TO ENTER SERIAL NO. DISTRIBUTOR.....225
5. TABLE OF CONTENTS.....227
SAFETY.....234
6. GENERAL PRECAUTIONS.....235
7. PRECAUTIONS DURING OPERATION.....241
7.1 BEFORE STARTING ENGINE.....241
7.2 OPERATING MACHINE.....242
7.3 TRANSPORTATION.....251
7.4 BATTERY.....252
7.5 TOWING.....254
8. PRECAUTIONS FOR MAINTENANCE.....255
8.1 BEFORE CARRYING OUT MAINTENANCE.....255
8.2 DURING MAINTENANCE.....260
8.3 TIRES.....265
OPERATION.....274
10. GENERAL VIEW.....275
10.1 GENERAL VIEW OF MACHINE.....275
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....276
11. COMPONENT EXPLANATION.....277
11.1 MACHINE MONITOR.....277
11.1.1 WARNING DISPLAYS.....279
11.1.2 METER DISPLAY PORTION.....283
11.2 SWITCHES.....288
11.3 CONTROL LEVERS, PEDALS.....296
11.4 STEERING COLUMN TILT LEVER.....301
11.5 CAP WITH LOCK.....302
11.5.1 METHOD OF OPENING AND CLOSING THE CAP WITH LOCK.....302
11.6 SAFETY BAR.....303
11.7 TOWING PIN.....303
11.8 GREASE PUMP.....304
11.9 BACKUP ALARM.....304
11.10 FUSE.....305
11.10.1 FUSE CAPACITY AND CIRCUIT NAME.....305
11.11 SLOW-BLOW FUSE.....306
11.12 MANUAL STORAGE PLACE.....307
11.13 ELECTRIC POWER (with ROPS CAB).....307
12. OPERATION.....308
12.1 CHECKS BEFORE STARTING.....308
12.1.1 WALK AROUND CHECK.....308
12.1.2 CHECK BEFORE STARTING.....312
12.1.3 ADJUSTMENT BEFORE OPERTION.....318
12.1.4 OPERATIONS AND CHECKS AFTER STARTING THE ENGINE.....321
12.2 STARTING THE ENGINE.....323
12.2.1 COLD WEATHER STARTING.....324
12.3 OPERATIONS AND CHECKS AFTER STARTING THE ENGINE.....325
12.4 MOVING THE MACHINE.....327
12.5 CHANGING GEAR SPEED.....329
12.6 CHANGING DIRECTION.....330
12.7 TURNING.....331
12.8 STOPPING THE MACHINE.....332
12.9 WORK EQUIPMENT OPERATION.....333
12.9.1 STANDRD WORK EQUIPMENT CONTROLS.....333
12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS.....334
12.10 WORK POSSIBLE USING A WHEEL LOADER.....336
12.10.1 DIGGING OPERATIONS.....336
12.10.2 LEVELING OPERATION.....339
12.10.3 PUSHING OPERATION.....339
12.10.4 LOAD AND CARRY OPERATIONS.....339
12.10.5 LOADING OPERATIONS.....340
12.11 PRECAUTION FOR OPERATION.....340
12.11.1 PERMISSIBLE WATER DEPTH.....340
12.11.2 IF WHEEL BRAKES DO NOT WORK.....341
12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....341
12.11.4 PRECAUTIONS WHEN DRIVING THE MACHINE.....342
12.12 ADJUSTING THE WORK EQUIPMENT POSTURE.....343
12.12.1 ADJUSTING THE BOOM KICKOUT.....343
12.12.2 ADJUSTING THE BUCKET POSITIONER.....344
12.12.3 BUCKET LEVEL INDICATOR.....344
12.13 PARKING THE MACHINE.....345
12.14 CHECKS AFTER COMPLETION OF OPERATION.....346
12.15 STOPPING THE ENGINE.....346
12.16 CHECK AFTER STOPPING THE ENGINE.....347
12.17 LOCKING.....347
12.18 HANDLING THE TIRES.....348
12.18.1 PRECAUTIONS WHEN HANDLING TIRES.....348
12.18.2 TIRE PRESSURE.....348
13. TRANSPORTATION.....350
13.1 LOADING, UNLOADING WORK.....350
13.2 LOADING PRECAUTIONS.....351
13.3 LIFTING THE MACHINE.....351
13.3.1 POSITION FOR STICKING THE LIFTING POSITION MARK.....352
13.3.2 WEIGHT TABLE.....352
13.3.3 LIFTING PROCEDURE.....353
13.4 TRANSPORTATION PRECUATIONS.....354
14. COLD WEATHER OPERATION.....355
14.1 LOW TEMPERATURE PRECAUTIONS.....355
14.1.1 FUEL AND LUBRICANTS.....355
14.1.2 COOLANT.....355
14.1.3 BATTERY.....355
14.2 PRECAUTIONS AFTER WORK COMPLETION.....356
14.3 AFTER COLD WEATHER.....356
15. LONG-TERM STORAGE.....356
15.1 BEFORE STORAGE.....356
15.2 DURING STORAGE.....356
15.3 AFTER STORAGE.....356
16. TROUBLESHOOTING.....357
16.1 WHEN THE MACHINE RUNS OUT OF FUEL.....357
16.2 TOWING THE MACHINE.....357
16.2.1 WHEN ENGINE CAN BE USED.....358
16.2.2 WHEN ENGINE CANNOT BE USED.....358
16.2.3 RELEASING THE PARKING BRAKE.....359
16.2.4 EMERGENCY TRAVEL OPERATION.....361
16.3 IF BATTERY IS DISCHARGED.....362
16.3.1 BATTERY INSTALLATION AND REMOVAL.....362
16.3.2 PRECAUTION FOR CHARGING THE BATTERY.....363
16.3.3 STARTING THE ENGINE WITH BOOSTER CABLE.....364
16.4 OTHER TROUBLE.....366
16.4.1 ELECTRICAL SYSTEM.....366
16.4.2 CHASSIS.....367
16.4.3 ENGINE.....370
MAINTENANCE.....372
17. GUIDES TO MAINTENANCE.....373
18. OUTLINES OF SERVICE.....375
18.1 OUTLINE OF OIL, FUEL, COOLANT.....375
18.1.1 OIL.....375
18.1.2 FUEL.....376
18.1.3 COOLANT.....376
18.1.4 GREASE.....376
18.1.5 STORING OIL AND FUEL.....377
18.1.6 FILTERS.....377
18.2 FUEL INJECTION PUMP.....377
18.3 OUTLINE OF ELECTRIC SYSTEM.....377
18.4 OUTLINE OF HYDRAULIC SYSTEM.....378
19. WEAR PARTS LIST.....379
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....380
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....380
20.2 ENGINE OIL SPECIFICATIONS.....381
20.2.1 NORMAL OPERATION.....381
20.2.2 ARCTIC OPERATION.....381
20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.....382
20.4 DRIVE AXLE OIL SPECIFICATIONS.....382
20.5 DIESEL FUEL SPECIFICATIONS.....382
20.6 COOLANT SPECIFICATIONS.....383
20.6.1 GENERAL.....383
20.6.2 WATER.....383
20.6.3 ANTIFREEZE.....383
20.6.4 SUPPLEMENTAL COOLANT ADDITIVES.....384
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....388
21.1 INTRODUCTION OF NECESSARY TOOLS.....388
21.2 TORQUE LIST.....389
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....390
23. MAINTENANCE SCHEDULE CHART.....394
23.1 SCHEDULED MAINTENANCE CHART.....394
24. INITIAL 250 HOURS SERVICE.....397
24.1 INITIAL 250 HOURS SERVICE.....397
24.2 WHEN REQUIRED.....397
24.2.1 CHECK, CLEAN, AND REPLACE AIR CLEANER ELEMENT.....397
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.....400
24.2.3 CHECK AXLE OIL LEVEL, AD OIL.....401
24.2.4 CLEAN THE AXLE CASE BREATHER.....402
24.2.5 CLEAN THE RADIATOR FINS.....402
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.....403
24.2.7 REPLACE BUCKET TEETH.....404
24.2.8 CHECK AIR CONDITIONER.....405
24.2.9 CLEAN THE AIR CONDITIONER CONDENSER.....406
24.2.10 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE.....406
24.2.11 REPLACE THE SLOW-BLOW FUSE.....406
24.2.12 DRAIN WATER FROM WATER SEPARATOR (if equipped).....407
24.2.13 SELECTION AND INPECTION OF TIRES.....407
24.3 CHECKS BEFORE STARTING.....409
24.4 EVERY 50 HOURS SERVICE.....409
24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK.....409
24.5 EVERY 100 HOURS SERVICE.....409
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....409
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.....410
24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES).....411
24.6 EVERY 250 HOURS SERVICE.....411
24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....411
24.6.2 CHECK TENSION OF FAN BELT, ALTERNATOR BELT, ADJUST.....413
24.6.3 CHECK FOR LOOSE WHEEL HUB NUT, TIGHTEN.....414
24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.....414
24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....415
24.6.6 CHECK BATTERY ELECTROLYTE LEVEL.....416
24.6.7 LUBRICATING.....417
24.7 EVERY 500 HOURS.....418
24.7.1 REPLACE THE FUEL FILTER CARTRIDGE.....418
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.....419
24.7.3 LUBRICATE CENTER DRIVE SHAFT SPLINE.....420
24.8 EVERY 1000.....421
24.8.1 CHANGE OIL INTRANSMISSION, CLEAN STRAINER.....421
24.8.2 CLEAN TRANSMISSION CASE BREATHER.....422
24.8.3 LUBRICATE.....423
24.8.4 CHECK TIGHTENING PARTS OF TURBOCHARGER.....425
24.8.5 CHECK PLAY OF TURBOCHARGER ROTOR.....425
24.8.6 REPLACE CORROSION RESISTOR CARTRIDGE.....425
24.9 EVERY 2000 HOURS SERVICE.....426
24.9.1 CHANGE OIN IN HYDRAULIC TANK.....426
24.9.2 REPLACE THE HYDRAULIC TANK BREATHER ELEMENT.....428
24.9.3 CHANGE AXLE OIL.....429
24.9.4 CHECK BRAKE DISC WEAR.....430
24.9.5 CHECK ALTERNATOR, STARTING MOTOR.....430
24.9.6 CHECK ENGINE VALVE CLEARANCE, ADJUST.....430
24.9.7 CHECK VIBRATION DAMPER.....430
24.9.8 REPLACE THE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.....430
24.9.9 CLEAN AND CHECK TURBOCHARGER.....430
24.9.10 CLEAN PPC CIRCUIT STRAINER.....430
24.9.11 CHECK ACCUMULATOR GAS PRESSURE.....430
24.10 EVERY 4000 HOURS SERVICE.....431
24.10.1 CHECK WATER PUMP.....431
SPECIFICATIONS.....432
25. SPECIFICATIONS.....433
25.1 GENERAL.....433
OPTIONS, ATTACHMENTS.....435
26. OPTIONAL PARTS AND ATTACHMENTS.....436
27. SELECTING BUCKETS AND TIRES.....437
28. AIR CONDITIONING.....438
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....438
28.1.1 FAN SWITCH.....438
28.1.2 AIR CONDITIONER SWITCH.....438
28.1.3 MODE SELECTOR SWITCHES.....439
28.1.4 FRESH/RECIRC.SELECTOR SWITCH.....439
28.1.5 TEMPERATURE CONTROL SWITCH.....439
28.2 METHOD OF OPERATION.....440
28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY.....440
28.3 COOL BOX.....440
29. HANDLING ECSS.....441
29.1 STRUCTURE AND FUNCTION OF ECSS.....441
29.2 METHOD OF OPERATING ECSS.....442
29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH.....442
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....443
29.5 DISCONNECTING THE ECSS PIPING.....444
30. OPTION DISPLAY.....445
30.1 EMERGENCY STEERING PILOT LAMP.....445
30.2 RADIO.....446
30.2.1 OPERATION.....446
30.2.2 SETTING THE CLOCK.....448
30.2.3 REMOTE CONTROL UNIT.....449
30.2.4 BATTERY REPLACEMENT.....449
30.2.5 PRECAUTIONS WHEN USING.....449
31. LOAD METER.....450
31.1 GENERAL LOCATIONS.....450
31.2 ADJUSTING LOAD MEASUREMENTS POINTS.....452
31.3 CALIBRATION (ADJUSTING 0 POINT).....453
31.3.1 CHECK BEFORE ADJUSTING.....453
31.3.2 ADJUSTING.....454
31.3.3 CHECKING CALIBRATION.....454
31.4 MEASURING.....455
31.4.1 MEASURING SUBTOTAL.....455
31.4.2 MEASURING REMAIN.....455
31.5 SETTING TARGET AMOUNT IN REMAIN MODE.....457
31.6 PRINTING DATA.....458
31.6.1 PRINTING SUBTOTAL .....458
31.6.2 PRINTING TOTAL.....458
31.7 DELETING DATA FROM STORAGE DEVICE.....459
31.8 SETTING TIME ON CLOCK.....460
31.9 REPLACING PRINTER PAPER.....461
31.10 TROUBLESHOOTING FUNCTION.....463
31.11 SPARE PARTS.....463
CEAM018203 - Wheel Loader WA450-6 Operation & Maintenance Manual.....467
CEAM018203.....467
INTRODUCTION.....469
FOREWORD.....470
SAFETY INFORMATION.....471
APPROVED AND NON-APPROVED USES.....472
Approved Functions.....472
Non-Approved Functions.....472
VISIBILITY STANDARD.....473
Visibility in Immediate Area.....473
12-M Radius Visibility.....473
PRODUCT IDENTIFICATION.....474
Machine.....474
Service Meter Location.....475
Directions of Machine.....475
Machine Serial Number/Product Identification Number (PIN).....476
Engine Serial Number, EPA Regulations.....476
SERIAL NUMBERS AND DEALER INFORMATION.....477
Model: WA450-6.....477
TABLE OF CONTENTS.....479
SAFETY.....491
SAFETY AND WARNING DECALS.....492
Location of the Safety Labels.....492
Safety Labels.....493
GENERAL SAFETY RULES AND PRECAUTIONS.....500
General Safety Rules.....500
Safety at Job Site.....501
Safety Features.....501
Clothing and Protective Equipment.....501
Keep Machine Clean.....502
Fire and Explosion Prevention.....502
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid.....502
Fire Caused by Accumulation of Flammable Material.....503
Fire Caused by Electrical Wiring.....503
Fire Caused by Piping.....503
Explosion Caused by Lighting Equipment.....503
Action if Fire Occurs.....504
Fire Extinguisher and First Aid Kit.....504
Mounting and Dismounting.....505
Inside Operators Compartment.....506
Emergency Escape from Operators Cab.....506
Precautions When Standing Up from Operators Seat.....507
Leaving Operators Compartment.....508
Parking the Machine.....509
Precautions When Using ROPS.....510
Unauthorized Modification.....510
Precautions for Attachments and Options.....510
Precautions When Cleaning Cab Glass.....511
Asbestos Hazard Alert.....512
Crush or Pinch-Point Dangers.....512
Precautions for Ventilation Exhaust Gas.....512
PRECAUTIONS BEFORE STARTING OPERATIONS.....513
Pre-Operational Checks.....513
Ensure Good Visibility.....513
Signs and Signals.....513
Precaution for Warning Tag.....514
Checks Before Starting Engine, Adjustments.....514
Precautions When Starting.....515
Precautions in Cold Areas.....515
Precautions for Job Site.....515
Work Site Hazards.....515
Working on Loose or Unstable Ground.....516
Prohibited Operations.....516
Avoiding Dangerous Situations.....517
Working Near High Voltage Cables.....519
RULES FOR ROAD TRAVEL.....520
Travel Precautions.....520
Traveling on Slopes.....521
Using the Brakes.....522
Traveling in Reverse.....522
Operating on Snow or Frozen Surfaces.....523
PRECAUTIONS DURING INSPECTION AND MAINTENANCE.....524
Warning Tags.....524
Systems Equipped with ECSS.....524
Equipment Storage.....524
Working Under the Machine.....525
Using Drop Lamps.....525
Using Proper Tools.....525
Keeping the Machine Clean.....526
Precautions When Welding.....526
Precautions When Using Hammer.....526
Noise.....526
Stopping Engine During Inspection and Maintenance.....527
Running the Machine During Maintenance.....529
Rules for Refueling the Machine.....530
Cooling System Precautions.....530
Battery Information.....530
Precautions.....530
Hazards.....531
Using Booster Cables.....532
Starting the Machine with Booster Cables.....532
High-Pressure Precautions.....533
Precautions for High-Pressure Oil.....533
Safe Handling of High-Pressure Hoses.....533
Precautions for High-Pressure Fuel.....533
High-Temperature Precautions.....534
High-Temperature Areas.....534
High-Temperature Coolant.....534
High-Temperature Oil.....534
High Voltage.....534
Accumulator and Gas Spring.....535
Inflating Tires.....535
Using Compressed Air.....535
Disposal of Waste Materials.....536
Critical Parts.....536
Maintenance of Air Conditioner.....536
OPERATION.....537
GENERAL VIEW.....538
General View of Machine.....538
General View of Controls and Gauges.....539
Machine Monitor.....540
Switch Panel.....542
EXPLANATION OF COMPONENTS.....543
Machine Monitor.....543
Types of Warnings.....544
Emergency Stop.....544
Caution.....544
Mistaken Operation.....544
Inspection and Maintenance.....544
Central Warning Lamp.....544
Character Display Portion.....545
Service Meter.....546
Action Code Display.....546
Failure Code Display.....547
Filter, Oil Replacement Time Display.....548
Emergency Stop Items.....551
Brake Oil Pressure Caution Lamp.....552
Engine Oil Pressure Caution Lamp.....552
Battery Charge Circuit Caution Lamp.....553
Steering Oil Pressure Caution Lamp (if equipped).....553
Caution Items.....554
Brake Oil Temperature Caution Lamp.....555
Torque Converter Oil Temperature Caution Lamp.....555
Engine Coolant Temperature Caution Lamp.....556
Hydraulic Oil Temperature Caution Lamp.....556
Fuel Level Caution Lamp.....556
Inspection and Maintenance Items.....557
Radiator Coolant Level Caution Lamp.....557
Engine Oil Level Caution Lamp.....558
Battery Electrolyte Level Caution Lamp (if equipped).....558
Maintenance Caution Lamp.....558
Air Cleaner Clogging Caution Lamp.....559
Water Separator Caution Lamp.....559
Transmission Oil Filter Clogging Caution Lamp.....559
Pilot Display Portion.....560
Parking Brake Pilot Lamp.....561
Cooling Fan Reverse Rotation Pilot Lamp.....561
Emergency Steering Pilot Lamp (if equipped).....561
Power Mode Pilot Lamp (P Mode).....562
Preheating Pilot Lamp.....562
Semi-Auto Digging Pilot Lamp.....562
Auto-Greasing Pilot Lamp (if equipped).....562
Joystick Pilot Lamp (if equipped).....562
Directional Selector Pilot Lamp.....562
Economy Operation Display Lamp.....563
Shift Indicator.....563
Auto-Shift Pilot Lamp.....563
Torque Converter Lockup Pilot Light (if equipped).....563
Shift Hold Pilot Lamp.....564
Shift Lever Position Pilot Lamp.....564
Turn Signal Pilot Lamp.....564
Head Lamp High-Beam Pilot Lamp.....564
Meter Display Portion.....565
Torque Converter Oil Temperature Gauge.....565
Engine Coolant Temperature Gauge.....566
Hydraulic Temperature Gauge.....566
Fuel Gauge.....566
Speedometer.....567
Meter Display Pilot Lamp.....567
OTHER FUNCTIONS OF MACHINE MONITOR.....568
Overall Menu.....568
Displaying Odometer.....569
Resetting Filter, Oil Replacement Time.....569
Entering Telephone Number.....571
Selecting Language.....572
Adjusting Monitor Brightness.....574
Switching Travel Speed/Engine Speed Display.....576
Switching Travel Speed/Engine Speed Display/Non-Display.....577
SWITCHES AND CONTROLS.....578
General View.....578
Starting Switch.....580
Power Mode Selector Switch.....580
Transmission Shift Mode Selector Switch.....581
Transmission Cutoff Switch.....581
Transmission Cutoff Set Switch.....582
Lamp Switch.....582
Turn Signal Lever.....582
Dimmer Switch.....583
Horn Button.....583
Hazard Lamp Switch.....583
Parking Brake Switch.....584
Front Working Lamp Switch.....584
Rear Working Lamp Switch.....585
Machine Monitor Mode Selector Switch 1.....585
Machine Monitor Mode Selector Switch 2.....585
Kickdown Switch.....586
Hold Switch.....587
Front Wiper Switch.....587
Rear Wiper Switch.....588
Cigarette Lighter.....588
Room Lamp Switch.....588
Rear Heated Wire Glass Switch.....588
ECSS Switch.....589
Emergency Steering Switch (if equipped).....589
Cooling Fan Auto-Reverse Rotation Switch.....590
Torque Converter Lockup Switch (if equipped).....593
CONTROL LEVERS, PEDALS.....594
General View.....594
Gearshift Lever.....595
Directional Lever.....596
Gearshift Lever Stopper.....597
Work Equipment Lock Lever.....597
Bucket Control Lever.....598
Lift Arm Control Lever.....598
Brake Pedals.....599
Accelerator Pedal.....599
SECURITY LOCKS AND SAFETY FEATURES.....600
Steering Tilt Lock Lever.....600
Frame Lock Bar.....600
Cap with Lock.....601
Fuel Tank Filler Port Cap.....601
Backup Alarm.....601
MACHINE FEATURES.....602
Towing Pin.....602
Grease Pump.....602
Cab Door.....603
Emergency Escape Right Door.....603
Left Cab Door, Door Open Lock.....605
Left Cab Door, Knob.....606
Left Cab Door, Handle.....606
Left Cab Sliding Window (Lock Release Knob).....606
Cab Wiper.....607
Dust Indicator.....607
ELECTRICAL.....608
Power Outlet.....608
Fuses.....608
Fuse Capacity and Name of Circuit.....609
Slow-Blow Fuse.....610
WORK OPERATIONS.....611
Walk-Around Check.....611
Precautions Before Starting Work Operations.....611
Check Before Starting Engine.....615
Check Machine Monitor.....615
Check Coolant Level, Add Coolant.....616
Check Oil Level in Engine Oil Pan, Add Oil.....617
Check Water Separator.....618
Check Air Cleaner.....619
Check Fuel Level, Add Fuel.....620
Check Electric Wiring.....621
Adjustments.....623
Adjusting Seat.....623
Removing or Installing Headrest.....625
Adjusting Seat Belt.....626
Adjusting Lever Stand.....627
Adjusting Mirrors.....628
Final Checks Before Starting Engine.....629
Starting Engine.....631
Normal Starting.....631
Starting in Cold Weather.....633
Automatic Warming-Up Operation.....634
Operations and Checks After Starting Engine.....635
Checks After Starting Engine.....635
Breaking in the Machine.....636
Normal Operation.....636
Stopping Engine.....638
Check After Stopping Engine.....638
Moving the Machine (Directional, Speed), Stopping the Machine.....639
Moving the Machine.....639
Changing Gear Speed.....642
Changing Direction.....643
Stopping the Machine.....645
Transmission Cutoff Function.....646
Turning.....648
Emergency Steering (if equipped).....649
Emergency Steering Self-Check Function.....650
Operation of Work Equipment.....651
Work Equipment Lock Lever.....651
Lift Arm.....651
Bucket.....652
Work Possible Using Wheel Loader.....653
Digging Operations.....653
Loading Piled Soil or Blasted Rock.....653
Digging and Loading on Level Ground.....655
Leveling Operations.....656
Pushing Operations.....656
Load-and-Carry Operations.....656
Loading Operations.....657
Cross-Drive Loading.....657
V-Shape Loading.....657
Preparations for Loading, Gathering Rocks.....658
Approaching Facing.....658
Digging.....659
Traveling in Reverse After Excavation.....661
Approaching Dump Truck.....662
Loading Dump Truck.....663
Reversing Away From Dump Truck.....664
Precautions During Work Operations.....665
Piling Up Loads.....665
Handling Blasted Rock.....665
Loosened Boulders.....669
Pit Excavation.....669
Cutting Face Operations.....669
Switching Between Forward and Reverse.....669
Turning When Tires Are Stationary.....670
Wheel Brake Does Not Work.....670
Permissible Water Depth.....670
Lower the Center of Gravity when Turning.....670
Driving Up or Down Slopes.....670
Driving the Machine.....671
Braking Function.....672
Adjusting Work Equipment.....673
Adjusting Boom Kickout.....673
Adjusting Bucket Positioner.....674
Bucket Level Indicator.....675
Measuring Dump Angle.....676
Measuring Bucket Dump Angle.....676
Measuring Coupler Dump Angle.....679
Parking the Machine.....682
Checks After Completion of Operation.....684
Before Stopping Engine.....684
After Stopping Engine.....684
Locking the Machine.....685
HANDLING TIRES.....687
Precautions When Handling Tires.....687
Tire Pressure.....688
Precautions for Using Load-and-Carry Method.....689
TRANSPORTATION.....690
Transportation Procedure.....690
Loading and Unloading Trailers.....691
Loading Machine.....691
Securing Machine.....692
Unloading Machine.....694
LIFTING MACHINE.....695
Lifting Position.....695
Lifting Procedure.....696
COLD WEATHER OPERATION.....697
Precautions for Low Temperature.....697
Fuel and Lubricants.....697
Coolant.....697
Battery.....698
Precautions After Completion of Work.....698
After Cold Weather.....698
LONG-TERM STORAGE.....699
Before Storage.....699
During Storage.....699
After Storage.....699
AUTOMATIC AIR CONDITIONER.....700
Control Panel.....700
Main Power Switch.....701
Fan Switch.....701
Air Conditioner Switch.....702
Auto Switch.....703
Temperature Switch.....703
FRESH/RECIRC Selector Switch.....703
Mode Selector Switch.....704
Method of Operation.....705
Cooling Operation.....705
Heating Operation.....705
Drying-Heating and Demisting Operation.....706
When Not Using the Air Conditioner Regularly.....706
Precautions When Using Air Conditioner.....706
Inspection and Maintenance.....707
Cool Box.....707
KOMTRAX.....708
Basic Precautions.....708
TROUBLESHOOTING.....709
When Machine Runs Out of Fuel.....709
Towing the Machine.....709
When Engine Can Be Used.....710
When Engine Cannot Be Used.....710
Releasing Parking Brake.....711
Emergency Travel Operation.....713
If Battery is Discharged.....714
Precautions.....714
Removal and Installation of Battery.....714
Precautions for Charging Battery.....715
Starting Engine With Booster Cables.....716
Precautions When Connecting or Disconnecting Booster Cable.....716
Connecting Booster Cable.....716
Starting Engine.....717
Disconnecting Booster Cable.....717
Lowering Work Equipment When Engine Has Stopped.....718
Other Troubleshooting.....719
Electrical System.....719
Chassis.....720
Engine.....722
MAINTENANCE.....725
GUIDES TO MAINTENANCE.....726
Check Service Meter.....726
Komatsu Genuine Replacement Parts.....726
Komatsu Genuine Oils.....726
Always Use Clean Washer Fluid.....726
Always Use Clean Oil and Grease.....726
Checking for Foreign Materials in Drained Oil and On Filters.....726
Fuel Strainer.....726
Welding Instructions.....727
Do Not Drop Things Inside Machine.....727
Dusty Work Sites.....727
Avoid Mixing Oil.....727
Locking Inspection Covers.....727
Bleeding Air from Hydraulic Circuit.....727
Precautions When Installing Hydraulic Hoses.....728
Checks After Inspection and Maintenance.....728
OUTLINES OF SERVICE.....729
Handling Oil, Fuel, Coolant, and Performing Oil Clinic.....729
Oil.....729
Fuel.....730
Coolant and Water for Dilution.....730
Grease.....731
Storing Oil and Fuel.....731
Filters.....731
Performing KOWA (Komatsu Oil Wear Analysis).....732
KOWA Analysis Items.....732
Oil Sampling.....732
Outline of Electric System.....733
WEAR PARTS.....734
Wear Parts List.....734
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS.....735
Fuel, Coolant, and Lubricant Ambient Temperature Chart.....736
Recommended Brands, Other Than Komatsu Genuine Oil.....737
Biodiesel Usage.....738
Biodiesel Recommendation for Komatsu Engines.....738
Biodiesel Terminology.....738
Certification and Standards.....739
Warranty and Use of Biodiesel Fuel in Komatsu Engines.....739
Requirements for Using Biodiesel Fuel in Komatsu Engines.....739
Properties of Biodiesel.....740
Komatsu Biodiesel Blend Specification for B5 to B20.....741
Summary of Recommendations.....742
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....743
Torque List.....743
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....745
Safety Critical Parts List.....746
MAINTENANCE SCHEDULE CHART.....748
SERVICE PROCEDURE.....750
Initial 250 Hours Service.....750
Initial 1000 Hours Service.....750
When Required.....751
Clean, Replace Air Cleaner Element.....751
Clean Inside of Cooling System.....755
Check Transmission Oil, Add Oil.....759
Check Axle Oil Level, Add Oil.....760
Clean Axle Case Breather.....762
Clean Air Conditioner Condenser.....763
Check Window Washing Fluid Level, Add Fluid.....763
Clean Radiator Fins and Cooler Fins.....764
Turn, Replace Bolt-On Cutting Edge.....768
Replace Bucket Teeth (if equipped).....769
Check Air Conditioner.....771
Replace Slow-Blow Fuse.....773
Check Function of Accumulator.....774
Select Tires.....775
Check Tire Pressure.....776
Check Before Starting.....777
Every 50 Hours Service.....778
Drain Water, Sediment from Fuel Tank.....778
Every 100 Hours Service.....779
Lubricate Rear Axle Pivot Pin.....779
Check Oil Level in Hydraulic Tank, Add Oil.....779
Clean Element in Air Conditioner Fresh Air Filter.....780
Every 250 Hours Service.....781
Check Battery Electrolyte Level.....781
Check Parking Brake.....782
Check Alternator Belt Tension, Adjust.....783
Check Air Conditioner Compressor Belt Tension, Adjust.....784
Check for Loose Wheel Hub Nuts, Tighten.....785
Clean Element in Air Conditioner Recirculation Filter.....785
Check Function of Brake Accumulator.....786
Lubricating.....787
Every 500 Hours Service.....788
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge.....788
Replace Fuel Prefilter Cartridge.....789
Every 1000 Hours Service.....791
Replace Fuel Main Filter Cartridge.....791
Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer.....794
Clean Transmission Case Breather.....795
Lubricating.....796
Replace Corrosion Resistor Cartridge.....796
Check Engine Air Intake Piping Clamps for Looseness.....796
Every 2000 Hours Service.....797
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element.....797
Replace Hydraulic Tank Breather Element.....800
Change Axle Oil.....801
Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter.....802
Check Brake Disc Wear.....803
Check Function of PPC Accumulator.....805
Check Alternator.....806
Check Engine Valve Clearance, Adjust.....806
Check Starting Motor.....806
Check Vibration Damper.....806
Every 4000 Hours Service.....807
Lubricating.....807
Check Water Pump.....809
Check Air Conditioner Compressor, Adjust.....809
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber.....809
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber.....810
Every 8000 Hours Service.....811
Replace High-Pressure Piping Clamps.....811
Replace Fuel Spray Prevention Cap.....811
SPECIFICATIONS.....813
SPECIFICATIONS.....814
OPTIONS, ATTACHMENTS.....817
JOYSTICK STEERING SYSTEM.....818
Structure and Function.....818
Components.....819
Shift UP, Shift DOWN Switches.....820
Directional Selector Switch.....820
Joystick Steering Lever.....820
Joystick ON/OFF Switch.....820
HI/LOW Selector Switch.....821
Horn Switch.....821
Console Tilt Lever.....821
Console Fore-and-Aft Adjustment Lever.....821
Joystick Pilot Lamp.....822
Armrest Adjustment Lever.....822
Steering with Joystick Lever or Steering Wheel.....823
Precautions for Steering with Joystick.....824
Operating the Joystick Steering System.....825
Getting In and Out of Operators Cab.....828
Adjustments.....829
Adjusting Joystick Console.....829
Adjusting Seat.....830
TORQUE CONVERTER LOCKUP.....833
Components.....833
Torque Converter Lockup Switch.....834
Torque Converter Lockup Pilot Lamp.....834
Shift Indicator.....834
Character Display.....834
Method of Operation.....835
Warning/Limit Functions for Travel Speed.....836
Travel Speed Warning Function.....836
Travel Speed Limit Function.....836
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM.....837
Sound System Components.....839
Power Switch/Volume.....839
Auto-Store/Preset Scan Button.....839
Bass Control Knob.....839
Treble Control Knob.....840
Loudness Button.....840
Time/Radio Display Selector Button.....840
Tape Eject Button.....841
Cassette Door.....841
Fast-Forward, Rewind Buttons.....841
Preset Buttons.....841
Metal Tape Button.....842
Manual Tuning Buttons.....842
Seek Tuning Buttons.....842
Band Selector Button.....842
Method of Operation.....843
Setting Preset Buttons.....843
Using Auto-Preset.....843
Using Manual Preset.....843
Listening to Radio.....844
Listening to Cassette Tape.....844
Reversing the Tape.....845
Precautions When Using.....845
Handling Cassette Tape.....845
MULTI-FUNCTION LEVER.....846
Components.....846
Work Equipment Lever.....847
Kickdown Switch.....847
Hold Switch.....848
FNR Switch.....848
Directional Selector Switch Actuation Switch.....849
Directional Selector Pilot Lamp.....849
Work Equipment Lock Switch.....849
Using FNR Switch to Change Between Forward and Reverse.....850
Cooling Fan Reverse Rotation Switch.....852
BUCKET AND TIRES.....853
CEBDW21020 - Wheel Loader WA450-2 Shop Manual.....855
CONTENTS.....859
10 ENGINE.....875
12 TESTING AND ADJUSTING.....875
STANDARD VALUE TABLE.....876
TOOL LIST FOR TESTING AND ADJUSTING.....879
ADJUSTING VALVE CLEARANCE.....880
FUEL INJECTION TIMING.....881
MEASURING BLOW-BY PRESSURE.....882
FAN BELT TENSION.....883
MEASURING EXHAUST GAS COLOR.....885
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE.....887
13 DISASSEMBLY AND ASSEMBLY.....889
STARTING MOTOR ASSEMBLY.....891
REMOVAL.....891
INSTALLATION.....891
ALTERNATOR ASSEMBLY.....892
REMOVAL.....892
INSTALLATION.....892
WATER PUMP ASSEMBLY.....893
REMOVAL.....893
INSTALLATION.....893
TURBOCHARGER ASSEMBLY.....894
REMOVAL.....894
INSTALLATION.....894
CYLINDER HEAD ASSEMBLY.....895
REMOVAL.....895
INSTALLATION.....896
RADIATOR ASSEMBLY.....897
REMOVAL.....897
INSTALLATION.....900
ENGINE.....902
REMOVAL.....902
INSTALLATlON.....908
FUEL TANK.....914
REMOVAL.....914
INSTALLATION.....914
14 MAINTENANCE STANDARD.....915
ENGINE MOUNT.....916
20 POWER TRAIN.....917
21 STRUCTURE AND FUNCTION.....917
GENERAL.....919
HYDRAULIC CIRCUIT FOR POWER TRAIN.....921
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.....922
DAMPER.....923
TORQUE CONVERTER AND TRANSMISSION PIPING.....924
TORQUE CONVERTER CHARGING PUMP.....925
TORQUE CONVERTER.....926
TORQUE CONVERTER OIL FILTER.....929
TORQUE CONVERTER OIL COOLER.....930
TORQUE CONVERTER RELIEF VALVE.....931
TRANSMISSION.....932
TRANSMISSION foldout # 1.....933
TRANSMISSION CONTROL VALVE.....940
UPPER VALVE.....942
LOWER VALVE.....943
TRANSMISSION SOLENOID VALVE.....944
EMERGENCY MANUAL SPOOL.....945
PRIORITY VALVE.....948
MODULATING VALVE AND QUICK RETURN VALVE.....949
ACCUMULATOR VALVE.....952
PILOT REDUCING VALVE.....954
TRANSMISSION PILOT FILTER.....955
TRANSFER.....956
DRIVE SHAFT.....957
AXLE MOUNT.....958
AXLE AND DIFFERENTIAL.....960
TORQUE PROPORTIONING DIFFERENTIAL.....965
FINAL DRIVE.....966
TIRE AND WHEEL.....967
22 TESTING AND ADJUSTING.....969
STANDARD VALUE TABLE.....970
TOOL LIST FOR TESTING AND ADJUSTING.....971
MEASURING ENGINE STALL SPEED.....972
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.....974
MEASURING SHIFT LEVER.....976
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.....977
TIRE AND WHEEL.....979
TROUBLESHOOTING.....980
PRECAUTIONS WHEN TROUBLESHOOTING.....981
METHOD OF READING TROUBLESHOOTING TABLES.....983
PREVENTING RECURRENCE OF TROUBLE.....985
JUDGMENT ON POWER TRAIN.....986
TROUBLESHOOTING TABLE.....988
Machine does not move.....988
Machine lacks power or speed (all speed range).....990
Excessive time lag when starting machine or shifting gear.....991
Torque converter oil temperature too high.....992
23 DISASSEMBLY AND ASSEMBLY.....993
DAMPER.....995
REMOVAL.....995
INSTALLATlON.....995
DISASSEMBLY.....996
ASSEMBLY.....998
TORQUE CONVERTER CHARGING PUMP.....1002
REMOVAL.....1002
INSTALLATION.....1003
TORQUE CONVERTER AND TRANSMISSION.....1004
REMOVAL.....1004
INSTALLATION.....1013
TORQUE CONVERTER ASSEMBLY.....1023
DISASSEMBLY.....1023
ASSEMBLY.....1027
TRANSMISSION ASSEMBLY.....1033
DISASSEMBLY.....1033
DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER.....1041
DISASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY.....1043
DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING.....1044
DISASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY.....1045
ASSEMBLY.....1046
ASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY.....1046
ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING.....1047
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY.....1048
ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER.....1049
ASSEMBLY OF TRANSMISSION.....1051
TRANSFER ASSEMBLY.....1059
DISASSEMBLY.....1059
DISASSEMBLY OF OUTPUT SHAFT GEAR CASE.....1061
ASSEMBLY.....1062
ASSEMBLY OF OUTPUT SHAFT, GEAR CASE.....1062
TRANSMISSION CONTROL VALVE.....1067
REMOVAL.....1067
INSTALLATION.....1069
DISASSEMBLY AND ASSEMBLY.....1071
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE.....1071
DISASSEMBLY AND ASSEMBLY OF SPEED VALVE.....1072
DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE.....1073
FRONT DIFFERENTIAL.....1075
REMOVAL.....1075
INSTALLATION.....1079
REAR DIFFERENTIAL.....1083
REMOVAL.....1083
INSTALLATION.....1087
DIFFERENTIAL.....1091
DISASSEMBLY.....1091
ASSEMBLY.....1094
FRONT AXLE.....1103
REMOVAL.....1103
INSTALLATION.....1106
REAR AXLE.....1109
REMOVAL.....1109
INSTALLATION.....1114
DRIVE SHAFT.....1119
DISASSEMBLY.....1119
ASSEMBLY.....1121
FINAL DRIVE.....1123
DISASSEMBLY.....1123
ASSEMBLY.....1126
24 MAINTENANCE STANDARD.....1131
TRANSMISSION MOUNT.....1132
TORQUE CONVERTER CHARGING PUMP.....1133
DAMPER.....1134
TORQUE CONVERTER.....1135
TORQFLOW TRANSMISSION.....1137
TRANSMISSION.....1137
TRANSMISSION CONTROL VALVE.....1140
UPPER VALVE.....1140
LOWER VALVE.....1142
SOLENOID VALVE.....1144
TRANSFER.....1145
DIFFERENTIAL.....1147
FINAL DRIVE.....1149
DRIVE SHAFT.....1150
AXLE MOUNT.....1151
40 STEERING SYSTEM.....1153
41 STRUCTURE AND FUNCTION.....1153
STEERING PIPING.....1154
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING.....1155
STEERING VALVE.....1156
ORBIT-ROLL VALVE.....1157
STOP VALVE.....1158
STEERING PUMP.....1159
STEERING CYLINDER.....1160
STEERING COLUMN AND ORBIT-ROLL.....1161
CENTER HINGE PIN.....1162
42 TESTING AND ADJUSTING.....1163
STANDARD VALUE TABLE.....1164
TOOL LIST .....1164
MEASURING STEERING WHEEL PLAY.....1165
MEASURING OPERATING FORCE OF STEERING WHEEL.....1166
OPERATING TIME OF STEERING WHEEL.....1167
STEERING OIL PRESSURE.....1168
TROUBLESHOOTING TABLES.....1170
1. Steering wheel does not turn.....1171
2. Steering wheel is sluggish.....1172
3. Steering wheel moves unsteadily or is subject to large shock.....1173
4. Machine tends to turn naturally in one particular direction when traveling.....1173
5. Left and right turning radii are different.....1173
43 DISASSEMBLY AND ASSEMBLY.....1175
STEERING VALVE.....1176
REMOVAL.....1176
INSTALLATION.....1178
DISASSEMBLY.....1181
ASSEMBLY.....1184
STEERING DEMAND VALVE.....1189
REMOVAL.....1189
INSTALLATION.....1191
DISASSEMBLY.....1194
ASSEMBLY.....1198
STEERING PUMP.....1202
REMOVAL.....1202
INSTALLATION.....1203
STEERING CYLINDER.....1204
REMOVAL.....1204
INSTALLATION.....1205
DISASSEMBLY.....1206
ASSEMBLY.....1208
CENTER HINGE PIN.....1211
REMOVAL.....1211
INSTALLATION.....1220
44 MAINTENANCE STANDARD.....1231
STEERING COLUMN AND ORBIT-ROLL.....1232
STEERING PUMP.....1233
STEERING VALVE.....1234
STEERING CYLINDER MOUNT.....1235
STEERING CYLINDER.....1236
CENTER HINGE PIN.....1238
50 BRAKE AND AIR SYSTEM.....1241
51 STRUCTURE AND FUNCTION.....1241
GENERAL.....1242
BRAKE AND AIR PIPING.....1243
BRAKE AND AIR CIRCUIT SYSTEM.....1244
AIR TANK.....1245
SAFETY VALVE.....1247
BRAKE VALVE.....1248
BRAKE ACTUATED.....1249
OPERATING IN BALANCE.....1250
BRAKE RELEASED.....1251
AIR GOVERNOR.....1252
TWO-WAY VALVE.....1254
BRAKE CHAMBER.....1255
SLACK ADJUSTER.....1257
BRAKE.....1260
PARKING BRAKE.....1262
PARKING BRAKE SOLENOID VALVE.....1264
SPRING CYLINDER.....1265
BRAKE CALIPER.....1266
52 TESTING AND ADJUSTING.....1269
STANDARD VALUE TABLE.....1271
TOOL LIST .....1272
MEASURING BRAKE PEDAL.....1273
MEASURING AIR.....1274
BRAKE PERFORMANCE.....1277
CHECKING BRAKE OIL PRESSURE.....1278
MEASURING WEAR OF BRAKE DISC.....1279
AIR BLEEDING FROM BRAKE LINE.....1280
PARKING BRAKE PERFORMANCE.....1281
CHECKING AND ADJUSTING PARKING BRAKE.....1282
TROUBLESHOOTING.....1285
TROUBLESHOOTING TABLE.....1286
1. Air pressure does not rise at all.....1286
2. Air pressure does not rise to the specified range.....1287
3. Brake is ineffective or not very effective.....1288
4. Brake does not release, or drags.....1289
5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.).....1290
53 DISASSEMBLY AND ASSEMBLY.....1291
AIR GOVERNOR .....1293
DISASSEMBLY.....1293
ASSEMBLY.....1294
BRAKE VALVE .....1295
REMOVAL.....1295
INSTALLATION.....1296
DISASSEMBLY.....1297
ASSEMBLY.....1299
BRAKE CHAMBER.....1301
REMOVAL.....1301
INSTALLATION.....1303
DISASSEMBLY.....1305
ASSEMBLY.....1308
SLACK ADJUSTER.....1311
REMOVAL.....1311
INSTALLATION.....1313
DISASSEMBLY.....1315
ASSEMBLY.....1316
BRAKE ASSEMBLY .....1317
DISASSEMBLY .....1317
ASSEMBLY.....1323
SPRING CYLINDER.....1331
REMOVAL.....1331
INSTALLATION.....1332
DISASSEMBLY.....1333
ASSEMBLY.....1335
PARKING BRAKE.....1337
REMOVAL.....1337
INSTALLATION.....1339
PARKING BRAKE PAD.....1342
REMOVAL.....1342
INSTALLATION.....1342
54 MAINTENANCE STANDARD.....1343
BRAKE VALVE.....1344
BRAKE CHAMBER.....1346
SLACK ADJUSTER.....1347
BRAKE.....1348
PARKING BRAKE.....1350
SPRING CYLINDER.....1352
60 WORK EQUIPMENT SYSTEM.....1355
61 STRUCTURE AND FUNCTION.....1355
GENERAL.....1356
HYDRAULIC PIPING.....1357
HYDRAULIC CIRCUIT DIAGRAM.....1358
HYDRAULIC TANK.....1360
OIL FILTER BYPASS VALVE.....1362
BREATHER.....1363
HYDRAULIC PUMPS.....1364
HYDRAULIC PUMP.....1364
SWITCH AND PPC PUMP.....1365
PPC VALVE.....1366
PPC RELIEF VALVE.....1368
FUNCTION OF PPC VALVE.....1369
MAIN CONTROL VALVE.....1371
RELIEF VALVE.....1377
SAFETY VALVE.....1378
SUCTION VALVE.....1379
FLOAT SELECTOR VALVE AND UNLOADER VALVE.....1380
ACCUMULATOR.....1382
HYDRAULIC CYLINDER.....1383
BUCKET LINKAGE.....1385
BUCKET POSITIONER AND BOOM KICK-OUT.....1387
WORK EQUIPMENT LEVER LINKAGE.....1389
62 TESTING AND ADJUSTING.....1391
STANDARD VALUE TABLE.....1393
TOOL LIST FOR TESTING AND ADJUSTING.....1395
MEASURING DUMP AND LEFT CONTROL LEVERS.....1396
ADJUSTING DUMP AND LIFT CONTROL LEVERS.....1397
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT.....1399
MEASURING WORK EQUIPMENT.....1402
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT.....1403
ADJUSTING BUCKET POSITIONER.....1404
ADJUSTING BOOM KICK-OUT.....1405
TROUBLESHOOTING.....1406
TROUBLESHOOTING TABLE.....1406
1. Lift arm does not rise.....1406
2. Lift arm moves slowly or does not have sufficient lifting power.....1407
3. Lift arm movement becomes slow after it reaches a certain height.....1408
4. Bucket cannot be held down with lift arm cylinder.....1408
5. Lift arm has large hydraulic drift.....1408
6. Lift arm movement is unsteady during work.....1408
7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise".....1408
8. Bucket does not tilt beck.....1409
9. Bucket moves slowly or has insufficient tilt back power.....1410
10. Bucket movement becomes slow during tilt back.....1411
11. Bucket cannot be held down by the bucket cylinder.....1411
12. Bucket has large hydraulic drift.....1411
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....1411
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".....1411
15. Control levers of lift arm and dump move stiffly and sluggishly.....1412
63 DISASSEMBLY AND ASSEMBLY.....1413
HYDRAULIC TANK .....1415
REMOVAL .....1415
INSTALLATION.....1419
HYDRAULIC PUMP .....1422
REMOVAL .....1422
INSTALLATION .....1423
HYDRAULIC FILTER.....1424
REMOVAL .....1424
INSTALLATION.....1424
SWITCH, PPC PUMP.....1425
REMOVAL.....1425
INSTALLATION .....1426
PPC VALVE .....1427
REMOVAL .....1427
INSTALLATION.....1429
DISASSEMBLY .....1431
ASSEMBLY .....1431
MAIN CONTROL VALVE .....1432
REMOVAL .....1432
INSTALLATION .....1435
DISASSEMBLY.....1438
ASSEMBLY.....1440
DUMP CYLINDER.....1442
REMOVAL.....1442
INSTALLATION.....1444
LIFT CYLINDER .....1445
REMOVAL .....1445
INSTALLATION .....1446
LIFT AND DUMP CYLINDERS.....1447
DISASSEMBLY.....1447
ASSEMBLY.....1449
WORK EQUIPMENT .....1452
REMOVAL .....1452
INSTALLATION.....1455
COUNTERWEIGHT.....1458
REMOVAL.....1458
INSTALLATION.....1458
64 MAINTENANCE STANDARD.....1459
MAIN CONTROL VALVE.....1460
SWITCH AND PPC PUMP.....1464
HYDRAULIC PUMP.....1466
PPC VALVE.....1468
DUMP CYLINDER.....1470
LIFT CYLINDER.....1472
BUCKET LINKAGE.....1474
BUCKET POSITIONER AND BOOM KICK-OUT.....1477
BUCKET.....1478
80 ELECTRIC AND ELECTRONIC SYSTEM.....1479
81 STRUCTURE AND FUNCTION.....1479
ELECTRICAL WIRING DIAGRAM.....1480
ENGINE STARTING CIRCUIT.....1481
ENGINE STOP CIRCUIT.....1483
COMBINATION SWITCH.....1484
ELECTRICALTRANSMISSION CONTROL.....1485
TRANSMISSION CUT-OFF SWITCH.....1485
TRANSMISSION CUT-OFF SELECTOR SWITCH.....1486
NEUTRALIZER RELAY.....1487
KICK-DOWN SWITCH.....1488
KICK-DOWN ELECTRIC CIRCUIT.....1489
ELECTRICAL PARKING BRAKE CONTROL.....1495
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).....1504
INDICATION ON MONITOR PANEL.....1506
SENSORS.....1509
WIRING HARNESS.....1517
OPERATION OF PROXIMITY SWITCH.....1518
82 TESTING AND ADJUSTING.....1523
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.....1526
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE).....1529
TROUBLESHOOTING.....1531
CHECKS BEFORE TROUBLESHOOTING.....1532
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.....1533
CONNECTOR TERMINAL NUMBERS.....1535
PRECAUTION WHEN HANDLING CONNECTOR.....1541
ELECTRICAL WIRING DIAGRAM.....1543
ELECTRICAL CIRCUIT SYSTEM.....1545
TRANSMISSION CONTROL, PARKING CIRCUIT SYSTEM.....1546
ETHER INJECTION CIRCUIT SYSTEM.....1547
KICK-DOWN CIRCUIT SYSTEM.....1548
VEHICLE MONITOR SYSTEM.....1549
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM.....1551
POSITION OF CONNECTORS FOR TROUBLESHOOTING.....1552
E-1 ENGINE DOES NOT START.....1558
E-2 ENGINE DOES NOT STOP.....1560
E-3 ENGINE STOPS WHEN TRAVELING.....1560
E-4 PARKING BRAKE DOES NOT WORK.....1561
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING .....1562
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON .....1564
E-7 WHEN PARKING BRAKE IS APPLIED. SHIFT LEVER DOES .....1564
E-8 TRANSMISSION DOES NOT WORK NORMALLY.....1565
E-9 KICK-DOWN SWITCH DOES NOT WORK.....1586
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.....1589
E-11 KICK-DOWN OPERATION IS NOT CANCELED.....1590
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.....1592
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.....1592
TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM) .....1594
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM.....1595
POSITION OF CONNECTORS FOR TROUBLESHOOTING .....1596
M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS .....1603
a) None of monitor panel lights up.....1603
b) Except for speedometer module, none of monitor panel lights up.....1603
c) None of CAUTION items light up. .....1604
d) Some other parts do not light up. .....1604
M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT.....1605
M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT) .....1606
a) (Engine oil level) flashes. .....1606
b) (Radiator water level) flashes.....1607
M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. (SWITCH POSITIONS ARE NORMAL) .....1609
a) (Transmission cut-off) lights up. .....1609
b) (Parking brake) lights up.....1610
c) (Working lamp) lights up.....1610
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES .....1612
a) Engine oil pressure system.....1612
b) Alternator system.....1612
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK.....1613
a) Engine oil pressure system.....1613
b) Alternator system.....1613
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE).....1615
a) (Charge level) flashes.....1615
b) (Fuel level) flashes.....1615
c) (Brake line failure) flashes.....1615
d) (Engine oil pressure) flashes.....1615
e) (Radiator water level) flashes.....1615
f) (Air pressure) flashes.....1616
g) (Engine water temperature) flashes.....1616
h) (Torque converter oil temperature) flashes.....1616
M-8 SPEED SENSOR DISPLAY STAYS AT 0.....1619
M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.....1620
a) If high beam does not light up.....1620
b) If high beam lights up when head lamp switch is OFF.....1620
c) If Hi beam display lights up when head lamp dimmer switch is at Lo beam position.....1621
M-10 TURN SIGNAL LAMP DOES NOT FLASH TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING.....1622
a) If turn signal lamp does not flash.....1622
b) If turn signal lamp stays ON or does not stop flashing.....1622
M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND + Cause Remedy .....1623
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.....1624
M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH .....1625
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP. .....1625
M-15 WHEN STARTING SWITCH IS TURNED TO ON IS ON, .....1626
a) None of panel lights up.....1626
b) Some of panel lamps do not light up.....1626
M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON .....1627
M-17 SERVICE METER DOES NOT WORK.....1628
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED .....1628
M-19 ABNORMALITY IN AIR PRESSURE GAUGE .....1629
a) If nothing is displayed in display area.....1629
b) If indicator remains at maximum level.....1629
M-20 ENGINE WATER TEMPERATURE GAUGE .....1630
a) If nothing is displayed in display area.....1630
b) If indicator remains at minimum level.....1630
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....1631
a) If nothing is displayed in display area.....1631
b) If indicator remains at minimum level.....1631
M-22 ABNORMALITY IN FUEL GAUGE.....1632
a) If nothing is displayed in display area.....1632
b) If indicator remains at FULL.....1632
83 DISASSEMBLY AND ASSEMBLY.....1633
REMOVAL OF MACHINE MONITOR.....1634
INSTALLATION OF MACHINE MONITOR.....1634
90 OTHERS.....1635
91 LOGGING SPECIFICATIONS.....1635
STRUCTURE AND FUNCTION .....1636
HYDRAULIC CIRCUIT DIAGRAM .....1636
MAIN CONTROL VALVE .....1638
ARM CYLINDER .....1640
WORK EQUIPMENT .....1641
DISASSEMBLY AND ASSEMBLY .....1642
MAIN CONTROL VALVE .....1642
DISASSEMBLY.....1642
ASSEMBLY.....1644
MAINTENANCE STANDARD .....1646
MAIN CONTROL VALVE.....1646
WORK EQUIPMENT .....1648
ARM CYLINDER .....1651
93 DISASSEMBLY AND ASSEMBLY.....1653
REMOVAL OF CAB .....1654
INSTALLATION OF CAB .....1654
97 GEAR PUMP.....1655
GENERAL.....1656
PRINCIPLE OF OPERATION.....1657
PRESSURE LOADED TYPE GEAR PUMP.....1660
FIXED SIDE PLATE TYPE GEAR PUMP.....1662
SA SERIES.....1663
STRUCTURE.....1663
TESTING AND ADJUSTING.....1667
DISASSEMBLY.....1670
ASSEMBLY.....1674
MAINTENANCE STANDARD.....1679
99 METRIC CONVERSIONS.....1681
CEBM000401 - Wheel Loader WA450-3 Shop Manual.....1704
CONTENTS.....1705
01 GENERAL.....1727
SPECIFICATION DRAWINGS.....1728
SPECIFICATIONS.....1729
WEIGHT TABLE.....1732
FUEL, COOLANT AND LUBRICANTS.....1733
ENGINE OIL SPECIFICATIONS.....1734
DIESEL FUEL SPECIFICATIONS.....1735
COOLANT SPECIFICATIONS.....1736
10 STRUCTURE AND FUNCTION.....1741
POWER TRAIN .....1742
POWER TRAIN SYSTEM.....1743
TORQUE CONVERTER, TRANSMISSION PIPING .....1745
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM .....1746
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .....1747
TORQUE CONVERTER .....1748
TORQUE CONVERTER OIL FILTER .....1751
TRANSMISSION .....1752
TRANSMISSION CONTROL VALVE.....1762
MODULATION VALVE.....1777
TRANSMISSION SOLENOID VALVE.....1777
ELECTRONIC CONTROL MODULATION VALVE (ECMV).....1778
PILOT OIL FILTER .....1781
DRIVE SHAFT .....1782
AXLE .....1783
DIFFERENTIAL .....1785
FINAL DRIVE .....1789
AXLE MOUNT, CENTER HINGE PIN .....1790
STEERING PIPING.....1791
STEERING COLUMN .....1792
STEERING VALVE .....1793
ORBIT-ROLL VALVE .....1807
STOP VALVE .....1811
EMERGENCY STEERING PUMP .....1812
DIVERTER VALVE .....1813
BRAKE PIPING.....1816
BRAKE CIRCUIT DIAGRAM .....1817
BRAKE VALVE.....1818
CHARGE VALVE .....1823
ACCUMULATOR (FOR BRAKE) .....1827
SLACK ADJUSTER .....1828
BRAKE.....1831
PARKING BRAKE CONTROL .....1833
PARKING BRAKE.....1834
PARKING BRAKE SOLENOID VALVE .....1835
PARKING BRAKE VALVE .....1836
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE .....1837
HYDRAULIC PIPING.....1838
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....1839
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....1840
WORK EQUIPMENT LEVER LINKAGE.....1841
HYDRAULIC TANK .....1842
PPC VALVE .....1844
PPC RELIEF VALVE .....1849
ACCUMULATOR (FOR PPC VALVE) .....1850
CUT-OFF VALVE .....1851
MAIN CONTROL VALVE .....1854
WORK EQUIPMENT LINKAGE .....1868
BUCKET .....1870
BUCKET POSITIONER AND BOOM KICK-OUT .....1871
CAB .....1877
AIR CONDITIONER .....1878
AIR CONDITIONER CONTROL PANEL (EAGLE) .....1879
ELECTRIC CIRCUIT DIAGRAM.....1881
ELECTRICAL CIRCUIT DIAGRAM (EAGLE A/C).....1884
ELECTRIC CIRCUIT DIAGRAM (WORK EQUIPMENT CONTROLLER).....1885
ELECTRIC CIRCUIT DIAGRAM (E.C.S.S.).....1886
ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING).....1887
MACHINE MONITOR SYSTEM .....1888
MAIN MONITOR .....1889
MAINTENANCE MONITOR .....1894
20 TESTING AND ADJUSTING.....1933
STANDARD VALUE TABLE FOR ENGINE.....1934
STANDARD VALUE TABLE FOR CHASSIS .....1935
STANDARD VALUE TABLE FOR ELECTRICAL PARTS .....1938
TOOLS FOR TESTING, ADJUSTING, & TROUBLESHOOTING.....1942
MEASURING ENGINE SPEEDS .....1943
MEASURING INTAKE MANIFOLD PRESSURE.....1944
MEASURING INTAKE AIR RESTRICTION .....1945
MEASURING ENGINE LUBRICATION OIL PRESSURE .....1946
MEASURING FUEL FILTER INLET RESTRICTION .....1947
MEASURING BLOW-BY PRESSURE .....1948
MEASURING ENGINE BACK PRESSURE .....1949
MEASURING COOLANT TEMPERATURE .....1950
MEASURING AND ADJUSTING VALVE CLEARANCE .....1951
MEASURING ACCELERATOR PEDAL .....1954
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER .....1956
MEASURING STALL SPEED .....1952
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE .....1957
METHOD OF OPERATING EMERGENCY MANUAL SPOOL .....1959
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL .....1961
TESTING AND ADJUSTING STEERING WHEEL .....1962
TESTING AND ADJUSTING STEERING CONTROL.....1965
MEASURING STEERING OIL PRESSURE .....1966
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL .....1968
TESTING BRAKE OIL PRESSURE .....1969
MEASURING BRAKE PERFORMANCE .....1970
MEASURING BRAKE DISC WEAR .....1971
BLEEDING AIR FROM BRAKE SYSTEM .....1972
MEASURING PARKING BRAKE PERFORMANCE .....1973
MANUAL RELEASE METHOD FOR PARKING BRAKE .....1974
TESTING WEAR OF PARKING BRAKE DISC .....1975
MEASURING WORK EQUIPMENT CONTROL LEVER .....1976
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE .....1978
MEASURING WORK EQUIPMENT .....1982
TESTING AND ADJUSTING BUCKET POSITIONER .....1984
TESTING AND ADJUSTING BOOM KICK-OUT.....1985
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).....1987
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR .....1988
TROUBLESHOOTING.....1989
POINTS TO REMEMBER WHEN TROUBLESHOOTING .....1990
SEQUENCE OF EVENTS IN TROUBLESHOOTING .....1991
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....1992
HANDLING CONNECTORS .....1999
CHECKS BEFORE TROUBLESHOOTING .....2000
METHOD OF USING TROUBLESHOOTING CHARTS .....2001
CONNECTOR TYPES AND MOUNTING LOCATIONS, CONNECTOR PIN ARRANGEMENT DIAGRAM .....2009
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS.....2013
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....2020
S-1 Starting performance is poor (Starting always takes time) .....2021
S-2 Engine does not start.....2022
(1) Engine does not turn.....2022
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....2023
(3) Exhaust gas comes out but engine does not start (Fuel is being injected).....2024
S-3 Engine does not pick up smoothly (Follow-up is poor) .....2025
S-4 Engine stops during operations .....2026
S-5 Engine does not rotate smoothly (hunting) .....2027
S-6 Engine lacks output (no power) .....2028
S-7 Exhaust gas is black (incomplete combustion) .....2029
S-8 Oil consumption is excessive (or exhaust gas is blue) .....2030
S-9 Oil becomes contaminated quickly .....2031
S-10 Fuel consumption is excessive .....2032
S-11 Oil is in cooling water, or water spurts back, or water level goes down .....2033
S-12 Oil pressure lamp lights up (drop in oil pressure) .....2034
S-13 Oil level rises .....2035
S-14 Water temperature becomes too high (overheating) .....2036
S-15 Abnormal noise is made .....2037
S-16 Vibration is excessive .....2038
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).....2039
TROUBLE DATA DISPLAY .....2041
M-1 Main monitor does not work .....2044
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up .....2045
M-3 Speedometer display does not work properly .....2046
M-4 Abnormality in shift indicator .....2047
(a) Stays at N even when directional lever is at F.....2047
(b) Stays at N even when directional lever is at R.....2047
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F.....2047
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R.....2048
(e) Does not display 1st, 4th.....2048
(f) Does not display 3rd, 4th.....2049
(g) Does not display 2nd, 3rd.....2049
(h) Does not display 1st, 2nd.....2050
M-5 High beam does not light up .....2051
M-6 Turn signal display does not light up .....2052
(a) L.H. turn signal does not light up.....2052
(b) R.H. turn signal does not light up.....2052
M-7 Abnormality in parking display .....2053
(a) Parking lamp does not light up.....2053
(b) Parking lamp stays lighted up.....2053
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).....2071
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, monitor does not work .....2072
(a) All lamps on maintenance monitor do not light up for 3 seconds.....2072
(b) Some lamps do not light up.....2073
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out .....2073
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), all lamps on maintenance monitor do not go out .....2074
K-4 When starting switch is turned ON (engine stopped), CHECK items flash .....2075
(a) Engine oil level display flashes .....2075
(b) Engine water level display flashes.....2076
K-5 When starting switch is turned ON (engine started), CAUTION items flash .....2077
(a) Engine oil pressure display flashes.....2077
(b) Battery charge level display flashes.....2078
(c) Brake oil pressure display flashes.....2079
(d) Air cleaner display flashes.....2080
K-6 CAUTION items are flashing but alarm buzzer does not sound .....2081
K-7 There is no abnormality in monitor display but alarm buzzer sounds .....2082
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up .....2083
(a) CHECK lamp.....2083
(b) CAUTION lamp.....2083
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up .....2084
(a) CHECK lamp.....2084
(b) CAUTION lamp.....2084
Before carrying out troubleshooting, check that there is no abnormality display on the main .....2084
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) .....2085
K-11 Night lighting lights up even when lamp switch is OFF, night lighting ,stays lighted up .....2086
K-12 Service meter does not work .....2087
K-13 Service meter is running even when engine is stopped.....2087
K-14 Abnormality in gauge items .....2088
(a) Abnormality in fuel gauge.....2088
(b) Abnormality in engine water temperature gauge.....2089
(c) Abnormality in torque converter oil temperature gauge.....2090
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....2091
E-1 Engine does not start .....2092
(a) Starting motor does not turn .....2092
(b) Starting motor turns.....2096
E-2 Engine does not stop .....2098
E-3 Engine stops when machine is traveling .....2098
E-4 Parking brake does not work .....2099
(a) Parking brake has no effect when parking brake switch is turned ON (parking).....2099
(b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake).....2099
E-5 Parking brake is applied when machine is traveling .....2100
E-6 Parking brake is released when starting switch is turned ON .....2102
E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) .....2102
E-8 Transmission does not work normally .....2103
(a) Problem in common circuit for transmission (always stays in 2nd).....2105
(b) Problem in H-L circuit.....2105
(c) Problem in speed circuit.....2106
(d) Problem in 4th circuit (does not enter 4th).....2106
(e) Contact in H-L circuit.....2107
(f) Contact in speed circuit.....2109
(g) Contact in 4th circuit (always stays in 4th).....2111
(h) Problem in FORWARD circuit (REVERSE is normal).....2112
(i) Problem in REVERSE circuit (FORWARD is normal).....2114
(j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal).....2116
(k) Contact in FORWARD circuit.....2118
(I) Contact in REVERSE circuit.....2120
(m) Problem in common circuit for FORWARD and REVERSE.....2122
E-9 Kick-down switch does not work (the regular Fl to F4 shifts normally) .....2123
E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function) .....2125
E-11 Kick-down operation cannot be canceled .....2125
(a) Not canceled even when directional lever is moved from F to N or R.....2125
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th).....2126
E-12 Kick-down switch is actuated by mistake when traveling in 2nd .....2128
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE).....2129
POWER TRAIN .....2130
T-1 Machine does not start .....2130
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes .....2132
T-3 Excessive shock when starting machine or shifting gear .....2134
T-4 Excessive time lag when starting machine or shifting gear .....2135
T-5 Torque converter oil temperature is high .....2136
STEERING SYSTEM .....2137
T-6 Steering does not turn .....2137
T-7 Steering wheel is heavy .....2138
T-8 Steering wheel wobbles or there is excessive shock .....2139
T-9 Machine steers to one side when traveling .....2139
T-10 Turning radius to left and right is different .....2139
BRAKE SYSTEM .....2140
T-11 Brakes do not work or braking effect is poor.....2140
T-12 Brakes are not released or brakes drag .....2141
T-13 Parking brake is not released or brake drags .....2142
WORK EQUIPMENT .....2143
T-14 Boom does not rise .....2143
T-15 Boom movement is slow or boom lacks lifting power .....2144
T-16 When boom is raised, it moves slowly at a certain height .....2145
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) .....2145
T-18 Excessive hydraulic drift of boom .....2145
T-19 Boom shakes during operation .....2145
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE .....2146
T-21 Bucket does not tilt back .....2147
T-22 Bucket movement is slow or tilt-back lacks power .....2148
T-23 Bucket movement becomes slow during tilt-back operation .....2149
T-24 Bucket cannot be pushed with bucket cylinder.....2149
T-25 Excessive hydraulic drift of bucket .....2149
T-26 Bucket shakes during loading operation (Main control valve at HOLD) .....2150
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT .....2150
T-28 Boom, bucket control levers are heavy or do not move smoothly .....2151
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).....2152
OUTLINE .....2153
1. Function.....2153
2. When carrying out troubleshooting.....2153
3. Failure code table.....2153
4. Table of troubleshooting modes and causes.....2154
A-1 Troubleshooting code [10] Modulation valve solenoid system (disconnection, short circuit) .....2155
A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system .....2156
A-3 Troubleshooting code [12] F solenoid signal system.....2157
A-4 Troubleshooting code [13] R solenoid signal system.....2157
A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal system .....2158
A-6 Troubleshooting code [16] Abnormality in speed -solenoid signal system .....2159
A-7 Troubleshooting code [17] Brake output signal .....2160
A-8 Troubleshooting code [20] Abnormality in directional lever signal system .....2161
A-9 Troubleshooting code [21] Abnormality in speed lever signal system .....2162
A-10 Troubleshooting code [22] Abnormality in travel speed signal system .....2163
A-11 Troubleshooting code [23] Abnormality in engine speed signal .....2164
A-12 Hold switch system .....2165
A-13 Kick-down switch system .....2165
A-14 Kick-down output signal system .....2166
A-15 Transmission cut-off signal system .....2167
A-16 Neutralizer signal system .....2168
A-17 Buzzer signal system .....2169
A-18 Network signal system .....2170
A-19 Controller power source system .....2171
A-20 Abnormality in model selection wiring harness .....2172
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (IF EQUIPED) (D MODE).....2173
JUDGEMENT TABLE FOR CONTROLLER ELECTRlCAL SYSTEM .....2174
D-1 ECSS does not work .....2175
(a) Error code [d0] is displayed.....2176
(b) Error code [d1] is displayed.....2176
(c) Error code [d2] is displayed.....2177
(d) Error code [d3] is displayed.....2177
(e) Error code [d4] is displayed.....2178
(f) No abnormality display is given.....2178
D-2 ECSS cannot be canceled.....2182
D-3 Output is turned ON (travel does not become 5 km/h) (deviates around 5 km/h) .....2183
D-4 Output is turned ON when transmission is in 1st .....2183
D-5 Output is turned ON when transmission is in 4th.....2184
D-6 Controller LED code is not displayed .....2185
D-7 ECSS is abnormal but main monitor does not give abnormality display .....2185
TROUBLESHOOTING - EAGLE AIR CONDITIONER.....2186
30 DISASSEMBLY AND ASSEMBLY.....2190
METHOD OF USING MANUAL .....2192
PRECAUTIONS WHEN CARRYING OUT OPERATION .....2193
SPECIAL TOOL LIST .....2195
STARTING MOTOR (SEE ENGINE SHOP MANUAL).....2197
ALTERNATOR (SEE ENGINE SHOP MANUAL).....2197
ENGINE OIL COOLER (SEE SHOP MANUAL).....2197
FUEL INJECTION PUMP (SEE ENGINE SHOP MANUAL).....2197
WATER PUMP (SEE ENGINE SHOP MANUAL).....2197
TURBOCHARGER (SEE ENGINE SHOP MANUAL).....2197
NOZZLE HOLDER (SEE ENGINE SHOP MANUAL).....2197
THERMOSTAT (SEE ENGINE SHOP MANUAL).....2197
CYLINDER HEAD (SEE ENGINE SHOP MANUAL).....2197
RADIATOR.....2198
REMOVAL.....2198
INSTALLATION .....2200
ENGINE.....2201
REMOVAL .....2201
INSTALLATION.....2206
TORQUE CONVERTER, TRANSMISSION.....2208
REMOVAL.....2208
INSTALLATION .....2215
TORQUE CONVERTER.....2217
DISASSEMBLY .....2217
ASSEMBLY .....2219
TRANSMISSION.....2222
DISASSEMBLY .....2222
ASSEMBLY .....2227
TRANSMISSION CLUTCH PACK.....2233
DISASSEMBLY.....2233
ASSEMBLY .....2242
PARKING BRAKE.....2254
DISASSEMBLY .....2254
ASSEMBLY .....2256
TRANSMISSION CONTROL VALVE.....2259
REMOVAL.....2259
INSTALLATION.....2261
DISASSEMBLY.....2262
ASSEMBLY.....2269
TRANSMISSION ACCUMULATOR VALVE.....2275
DISASSEMBLY.....2275
ASSEMBLY .....2276
DRIVE SHAFT.....2277
DISASSEMBLY .....2277
ASSEMBLY .....2279
FRONT AXLE.....2281
REMOVAL .....2281
INSTALLATION .....2283
REAR AXLE.....2284
REMOVAL.....2284
INSTALLATION .....2287
FRONT DIFFERENTIAL.....2289
REMOVAL.....2289
INSTALLATION.....2292
REAR DIFFERENTIAL.....2294
REMOVAL .....2294
INSTALLATION .....2297
DIFFERENTIAL.....2299
DISASSEMBLY .....2299
ASSEMBLY .....2302
FINAL DRIVE.....2310
DISASSEMBLY .....2310
ASSEMBLY .....2313
CENTER HINGE PIN.....2317
REMOVAL.....2317
INSTALLATION .....2326
STEERING VALVE (ORBIT-ROLL).....2332
REMOVAL.....2332
INSTALLATION .....2333
STEERING VALVE.....2337
DISASSEMBLY .....2334
ASSEMBLY .....2337
REMOVAL .....2342
INSTALLATION .....2343
STEERING DEMAND VALVE.....2344
DISASSEMBLY .....2344
ASSEMBLY .....2348
STEERING, SWITCH PUMP.....2352
REMOVAL .....2352
INSTALLATION .....2355
STEERING CYLINDER.....2356
REMOVAL.....2356
INSTALLATION .....2357
BRAKE VALVE.....2358
REMOVAL .....2358
INSTALLATION .....2359
RIGHT BRAKE VALVE (TANDEM).....2360
DISASSEMBLY.....2360
ASSEMBLY .....2361
LEFT BRAKE VALVE.....2362
DISASSEMBLY.....2362
ASSEMBLY .....2363
SLACK ADJUSTER.....2364
REMOVAL .....2364
INSTALLATION .....2365
DISASSEMBLY .....2366
ASSEMBLY.....2367
BRAKE.....2368
DISASSEMBLY.....2368
ASSEMBLY.....2374
PARKING BRAKE DISC.....2382
REMOVAL .....2382
INSTALLATION .....2384
HYDRAULIC TANK.....2385
REMOVAL.....2385
INSTALLATION .....2387
WORK EQUIPMENT, PPC PUMP.....2388
REMOVAL .....2388
INSTALLATION .....2391
PPC VALVE.....2392
REMOVAL .....2392
INSTALLATION .....2393
DISASSEMBLY .....2394
ASSEMBLY .....2395
MAIN CONTROL VALVE.....2396
REMOVAL.....2396
INSTALLATION .....2398
DISASSEMBLY .....2399
ASSEMBLY .....2401
BUCKET CYLINDER.....2403
REMOVAL .....2403
INSTALLATION .....2404
BOOM CYLINDER.....2405
REMOVAL.....2405
INSTALLATION .....2406
HYDRAULIC CYLINDER.....2407
DISASSEMBLY .....2407
ASSEMBLY .....2410
WORK EQUIPMENT.....2413
REMOVAL.....2413
INSTALLATION .....2416
COUNTERWEIGHT.....2418
REMOVAL .....2418
INSTALLATION .....2418
FUEL TANK.....2419
REMOVAL .....2419
INSTALLATION .....2420
CAB.....2421
REMOVAL .....2421
INSTALLATION .....2422
MAIN MONITOR.....2423
REMOVAL .....2423
INSTALLATION.....2424
MAINTENANCE MONITOR.....2425
REMOVAL .....2425
INSTALLATION .....2425
AIR CONDITIONER UNIT.....2426
REMOVAL .....2426
INSTALLATION .....2431
AIR CONDITIONER CONDENSER.....2432
REMOVAL .....2432
INSTALLATION .....2433
DRY RECEIVER.....2434
REMOVAL.....2434
INSTALLATION .....2434
AIR CONDITIONER COMPRESSOR.....2435
REMOVAL .....2435
INSTALLATION.....2436
40 MAINTENANCE STANDARD.....2437
ENGINE MOUNT, TRANSMISSION MOUNT .....2438
TORQUE CONVERTER.....2439
TRANSMISSION .....2440
TRANSMISSION CONTROL VALVE .....2447
DRIVE SHAFT .....2451
DIFFERENTIAL .....2452
FINAL DRIVE .....2454
AXLE MOUNT .....2455
STEERING COLUMN .....2456
STEERING VALVE .....2457
STEERING CYLINDER MOUNT .....2458
SLACK ADJUSTER .....2459
BRAKE VALVE .....2460
BRAKE.....2463
PARKING BRAKE.....2465
TORQUE CONVERTER, TRANSMISSION PUMP .....2466
STEERING, SWITCH PUMP .....2467
HYDRAULIC, PPC PUMP .....2468
PPC VALVE .....2469
CUT-OFF VALVE .....2470
MAIN CONTROL VALVE .....2471
BOOM CYLINDER .....2475
BUCKET CYLINDER .....2476
CENTER HINGE PIN.....2477
WORK EQUIPMENT LINKAGE .....2479
BUCKET .....2481
BUCKET POSITIONER AND BOOM KICK-OUT .....2482
CEBM003602 - Wheel Loader WA450-3 avance plus Shop Manual.....2484
COVER.....2484
CONTENTS.....2485
00 FOREWORD.....2496
SAFETY.....2497
GENERAL.....2499
HOW TO READ THE SHOP MANUAL.....2500
HOISTING INSTRUCTIONS.....2501
COATING MATERIALS.....2502
STANDARD TIGHTENING TORQUE.....2504
ELECTRIC WIRE CODE.....2507
CONVERSION TABLES.....2508
01 GENERAL.....2514
SPECIFICATION DRAWING.....2515
SPECIFICATIONS.....2517
WEIGHT TABLE.....2519
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....2520
10 STRUCTURE AND FUNCTION.....2527
POWER TRAIN.....2528
POWER TRAIN SYSTEM.....2529
TORQUE CONVERTER, TRANSMISSION PIPING.....2531
TRANSMISSION SYSTEM DIAGRAM.....2532
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.....2533
TORQUE CONVERTER.....2534
TORQUE CONVERTER OIL FILTER.....2537
TRANSMISSION.....2538
FORWARD AND 1ST CLUTCH.....2541
REVERSE AND 2ND CLUTCH.....2541
3RD AND 4TH CLUTCH.....2542
FORWARD 1ST.....2543
FORWARD 2ND.....2544
FORWARD 3RD.....2545
FORWARD 4TH.....2546
REVERSE 1ST.....2547
TRANSMISSION CONTROL VALVE.....2548
UPPER VALVE.....2549
LOWER VALVE.....2550
TRANSMISSION SOLENOID VALVE.....2551
FLOW VALVE.....2553
ACCUMULATOR VALVE.....2554
TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM.....2556
DIRECTIONAL SELECTOR VALVE.....2557
EMERGENCY MANUAL SPOOL.....2558
PRIORITY VALVE.....2558
TORQUE CONVERTER OUTLET PORT VALVE.....2560
PILOT REDUCING VALVE.....2561
PROPORTIONAL SOLENOID VALVE.....2562
TRANSMISSION SOLENOID VALVE.....2562
ELECTRONIC CONTROL MODULATION VALVE [ECMV].....2563
PILOT OIL FILTER.....2566
DRIVE SHAFT.....2567
FRONT AXLE.....2568
REAR AXLE.....2569
DIFFERENTIAL.....2570
FRONT DIFFERENTIAL.....2570
REAR DIFFERENTIAL.....2571
TORQUE PROPORTIONING DIFFERENTIAL.....2573
LIMITED SLIP DIFFERENTIAL.....2574
FINAL DRIVE.....2577
AXLE MOUNT, CENTER HINGE PIN.....2578
STEERING PIPING.....2579
STEERING COLUMN.....2580
STEERING VALVE.....2581
OPERATION OF DEMAND VALVE.....2582
STEERING PILOT.....2585
OPERATION OF STEERING VALVE.....2588
STEERING RELIEF VALVE.....2591
SAFETY VALVE.....2593
STEERING CONTROL VALVE.....2595
CONNECTION BETWEEN HAND PUMP AND SLEEVE.....2597
STOP VALVE.....2599
GROUND DRIVEN STEERING PUMP.....2600
DIVERTER VALVE.....2601
OPERATION.....2602
BRAKE PIPING.....2604
BRAKE CIRCUIT DIAGRAM.....2605
BRAKE VALVE.....2606
RIGHT BRAKE VALVE.....2606
LEFT BRAKE VALVE.....2607
OPERATION.....2608
ACCUMULATOR CHARGE VALVE.....2611
ACCUMULATOR.....2615
SLACK ADJUSTER.....2616
BRAKE.....2618
PARKING BRAKE CONTROL.....2620
PARKING BRAKE.....2621
PARKING BRAKE SOLENOID VALVE.....2622
PARKING BRAKE VALVE.....2623
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.....2624
HYDRAULIC PIPING.....2625
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....2627
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....2628
WORK EQUIPMENT LEVER LINKAGE.....2629
WORK EQUIPMENT LEVER LINKAGE.....2629
HYDRAULIC TANK.....2630
BREATHER.....2631
PPC VALVE.....2632
OPERATION OF PPC VALVE.....2633
FUNCTION OF PPC VALVE.....2634
PPC RELIEF VALVE.....2636
PPC VALVE ACCUMULATOR.....2637
CUT OFF VALVE.....2638
OPERATION.....2639
MAIN CONTROL VALVE - TWO SPOOL [1/2].....2640
MAIN CONTROL VALVE [2/2].....2641
MAIN CONTROL VALVE - THREE SPOOL [1/2].....2642
MAIN CONTROL VALVE [2/2].....2643
MAIN CONTROL VALVE.....2644
RELIEF VALVE.....2644
SAFETY SUCTION VALVE.....2645
SUCTION VALVE.....2646
FLOAT SELECTOR VALVE AND UNLOAD VALVE.....2647
BOOM AND BUCKET SPOOL HOLD POSITION.....2648
BOOM SPOOL AT RAISE POSITION.....2649
BOOM SPOOL AT LOWER POSITION.....2650
BOOM SPOOL AT FLOAT POSITION.....2651
BUCKET SPOOL AT DUMP POSITION.....2652
BUCKET SPOOL AT TILT POSITION.....2653
WORK EQUIPMENT LINKAGE.....2654
BUCKET.....2656
BUCKET POSITIONER AND BOOM KICK OUT.....2657
BUCKET POSITIONER.....2658
BOOM KICK OUT.....2658
BOOM PROXIMITY SWITCH.....2659
BUCKET PROXIMITY SWITCH.....2661
ROPS CAB.....2663
HEATER AND DEFROSTER.....2664
AIR CONDITIONER.....2665
ELECTRIC CIRCUIT DIAGRAM.....2666
MACHINE MONITOR SYSTEM.....2667
MAIN MONITOR.....2668
MAIN MONITOR DISPLAY FUNCTION.....2669
PREHEATING OUTPUT FUNCTION.....2670
TROUBLE DATA DISPLAY MODE.....2671
MAINTENANCE MONITOR.....2672
MAINTENANCE MONITOR DISPLAY FUNCTION.....2673
TRANSMISSION AUTO SHIFT.....2674
SYSTEM STRUCTURE DIAGRAM.....2674
SHIFT CONTROL SYSTEM FUNCTION.....2675
SAFETY FUNCTION.....2677
TROUBLESHOOTING.....2677
TRANSMISSION CONTROLLER.....2678
LOAD METER SYSTEM.....2679
ADJUSTING LOAD MEASUREMENT POINTS.....2680
CALIBRATION, ADJUSTING 0 POINT.....2681
MEASURING.....2682
SETTING TARGET AMOUNT IN REMAIN MODE.....2685
PRINTING DATA.....2686
DELETING DATA FROM STORAGE DEVICE.....2687
SETTING TIME ON CLOCK.....2688
REPLACING PRINTER PAPER.....2689
TROUBLESHOOTING FUNCTION.....2691
SPARE PARTS.....2691
ECSS.....2692
SENSORS.....2696
ENGINE OIL LEVEL SENSOR.....2697
RADIATOR COOLANT LEVEL SENSOR.....2697
ENGINE OIL PRESSURE SENSOR.....2698
ENGINE WATER TEMPERATURE SENSOR.....2698
TORQUE CONVERTER OIL TEMPERATURE SENSOR.....2699
ENGINE SPEED SENSOR.....2699
FUEL LEVEL SENSOR.....2700
ENGINE START CIRCUIT.....2701
ENGINE STOP CIRCUIT.....2702
PREHEATING CIRCUIT.....2704
ELECTRIC TRANSMISSION CONTROL.....2706
COMBINATION SWITCH.....2707
KICK DOWN, HOLD SWITCH.....2709
KICK DOWN CIRCUIT DIAGRAM.....2710
TRANSMISSION CUT OFF SWITCH.....2716
TRANSMISSION CUT OFF FUNCTION.....2717
ELECTRIC PARKING BRAKE CONTROL.....2720
EMERGENCY BRAKE SWITCH.....2722
PARKING BRAKE SAFETY RELAY NEUTRALIZER RELAY.....2722
OPERATION.....2723
PARKING BRAKE SWITCH OFF.....2727
PARKING BRAKE SWITCH ON.....2730
WHEN MAIN BRAKE OIL PRESSURE DROPS.....2730
PARKING BRAKE EMERGENCY RELEASE.....2732
FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY.....2733
20 TESTING AND ADJUSTING.....2734
STANDARD VALUE TABLES FOR ENGINE.....2735
STANDARD VALUE FOR CHASSIS.....2736
STANDARD VALUE TABLES FOR ELECTRICAL PARTS.....2739
TESTING AND ADJUSTING.....2742
TOOLS FOR TESTING AND ADJUSTING.....2743
ENGINE SPEED.....2744
INTAKE AIR PRESSURE.....2745
VALVE CLEARANCE.....2746
EXHAUST COLOR.....2747
EXHAUST TEMPERATURE.....2748
BLOW BY PRESSURE.....2749
COMPRESSION PRESSURE.....2750
ENGINE OIL PRESSURE.....2751
FUEL INJECTION TIMING.....2752
ENGINE STOP MOTOR CABLE.....2755
FAN BELT TENSION.....2757
ACCELERATOR PEDAL.....2758
SPEED CONTROL LEVER.....2760
STALL SPEED.....2761
POWER TRAIN OIL PRESSURE.....2763
EMERGENCY MANUAL SPOOL.....2764
TIRE AND WHEEL.....2765
STEERING WHEEL.....2766
STEERING CONTROL.....2768
STEERING OIL PRESSURE.....2769
BRAKE PEDAL.....2770
BRAKE OIL PRESSURE.....2771
BRAKE PERFORMANCE.....2772
BRAKE DISC WEAR.....2773
BLEED AIR FROM BRAKE SYSTEM.....2774
ACCUMULATOR CHARGE PRESSURE.....2775
PARKING BRAKE PERFORMANCE.....2776
MANUAL RELEASE OF PARKING BRAKE.....2777
WEAR OF PARKING BRAKE DISC.....2778
WORK EQUIPMENT CONTROL LEVER.....2779
WORK EQUIPMENT PRESSURE.....2781
WORK EQUIPMENT.....2785
BUCKET POSITIONER.....2787
BOOM KICK OUT.....2788
LOAD METER.....2790
MAIN MONITOR.....2792
FUEL LEVEL SENSOR.....2793
TROUBLESHOOTING.....2794
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....2795
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....2796
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....2797
CHECKS BEFORE TROUBLESHOOTING.....2805
METHOD OF USING CHARTS.....2806
CONNECTOR TYPES AND MOUNTING LOCATIONS.....2813
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....2817
TROUBLESHOOTING OF ENGINE SYSTEM S MODE.....2827
S-1 STARTING PERFORMANCE IS POOR.....2828
S-2 ENGINE DOES NOT START.....2829
S-3 ENGINE DOES NOT PICK UP SMOOTHLY.....2832
S-4 ENGINE STOPS DURING OPERATIONS.....2833
S-5 ENGINE DOES NOT ROTATE SMOOTHLY.....2834
S-6 ENGINE LACKS POWER.....2835
S-7 EXHAUST GAS IS BLACK.....2836
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST GAS IS BLUE.....2837
S-9 OIL BECOMES CONTAMINATED QUICKLY.....2838
S-10 FUEL CONSUMPTION IS EXCESSIVE.....2839
S-11 OIL IS IN COOLANT, COOLANT SPURTS OR COOLANT LEVEL GOES DOWN.....2840
S-12 OIL PRESSURE LAMP LIGHTS UP.....2841
S-13 OIL LEVEL RISES.....2842
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH.....2843
S-15 ABNORMAL NOISE IS MADE.....2844
S-16 VIBRATION IS EXCESSIVE.....2845
TROUBLESHOOTING OF MAIN MONITOR SYSTEM M MODE.....2846
FAILURE CODE.....2847
M-1 MAIN MONITOR DOES NOT WORK.....2849
M-2 WHEN START SWITCH IS TURNED ON AND ENGINE IS STARTED, ALL LAMPS STAY LIT.....2850
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.....2851
M-4 ABNORMALITY IN SHIFT INDICATOR.....2852
M-5 HIGH BEAM DOES NOT LIGHT UP.....2854
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP.....2855
M-7 ABNORMALITY IN PARKING DISPLAY.....2856
M-8 ABNORMALITY IN PREHEATING SYSTEM.....2857
M-9 TAIL LIGHTS DO NOT ILLUMINATE.....2859
M-10 ABNORMALITY IN FRONT WORKING LAMP.....2860
M-11 ABNORMALITY IN REAR WORKING LAMP.....2862
M-12 ABNORMALITY IN TRANSMISSION CUT OFF.....2863
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.....2864
M-14 WHEN PARKING BRAKE DRAG WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY OR THEY ARE NOT ACTUATED.....2865
M-15 ABNORMALITY IN BUZZER.....2866
M-16 CONDITIONER OF MONITOR SWITCHES IS NOT STORED IN MEMORY.....2867
M-17 ABNORMALITY IN FAILURE DISPLAY MODE.....2868
M-18 ABNORMALITY IN GROUND DRIVEN STEERING NORMAL DISPLAY.....2869
M-19 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY.....2870
M-20 ABNORMALITY IN ECSS SYSTEM.....2871
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM K MODE.....2872
K-1 WHEN START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOE.....2873
K-2 WHEN START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR ILLUMINATE, BUT DO NOT GO OUT.....2873
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER START SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT.....2874
K-4 WHEN START SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.....2875
K-5 WHEN START SWITCH IS TURNED ON, ENGINE STARTED, CAUTION ITEMS FLASH.....2876
K-6 CAUTION ITEMS ARE FLASHING, BUT ALARM BUZZER DOES NOT SOUND.....2880
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.....2881
K-8 CHECK OR CAUTION ITEMS ARE FLASHING, BUT CHECK OR CAUTION LAMP DOES NOT LIGHT UP.....2882
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY, BUT CHECK OR CAUTION LAMP LIGHTS UP.....2883
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON.....2884
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF.....2885
K-12 SERVICE METER DOES NOT WORK.....2886
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.....2886
K-14 ABNORMALITY IN GAUGE ITEMS.....2887
TROUBLESHOOTING OF ELECTRICAL SYSTEM E MODE.....2890
E-1 ENGINE DOES NOT START.....2892
E-2 ENGINE DOES NOT STOP.....2895
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.....2896
E-4 PARKING BRAKE DOES NOT WORK.....2897
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.....2898
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.....2899
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.....2899
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM A MODE.....2900
FUNCTION.....2901
WHEN CARRYING OUT TROUBLESHOOTING.....2901
FAILURE CODE.....2901
TABLE OF FAILURE MODES AND CAUSES.....2902
A-1 FAILURE CODE [10] MODULATION VALVE SOLENOID SYSTEM.....2903
A-2 FAILURE CODE [11] SHORT CIRCUIT IN POWER SUPPLY FOR MODULATION VALVE SOLENOID SYSTEM.....2904
A-3 FAILURE CODE [12] F SOLENOID SIGNAL SYSTEM.....2905
A-4 FAILURE CODE [13] R SOLENOID SIGNAL SYSTEM.....2906
A-5 FAILURE CODE [14] ABNORMALITY IN HI LO SOLENOID SIGNAL SYSTEM.....2907
A-6 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.....2908
A-7 FAILURE CODE [17] BRAKE OUTPUT SIGNAL SYSTEM.....2909
A-8 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM.....2910
A-9 FAILURE CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.....2911
A-10 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM.....2912
A-11 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL.....2913
A-12 HOLD SWITCH SYSTEM.....2914
A-13 KICK DOWN SWITCH SYSTEM.....2915
A-14 TRANSMISSION CUT OFF SIGNAL SYSTEM.....2916
A-15 NEUTRALIZER RELAY SIGNAL SYSTEM.....2917
A-16 BUZZER SIGNAL SYSTEM.....2918
A-17 NETWORK SIGNAL SYSTEM.....2919
A-18 CONTROLLER POWER SOURCE SYSTEM.....2920
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM T MODE.....2921
T-1 MACHINE DOES NOT MOVE.....2922
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.....2923
T-3 EXCESIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS.....2924
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.....2925
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....2926
T-6 STEERING DOES NOT TURN.....2927
T-7 STEERING WHEEL IS HEAVY.....2928
T-8 STEERING WHEEL SHAKES OR JERKS.....2929
T-9 MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING.....2929
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT.....2929
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.....2930
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG.....2931
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.....2932
T-14 BOOM DOES NOT RISE.....2933
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.....2934
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.....2935
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDERS.....2935
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM.....2935
T-19 BOOM SHAKES DURING OPERATION.....2935
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.....2935
T-21 BUCKET DOES NOT TILT BACK.....2936
T-22 BUCKET MOVEMENT IS SLOW OR TILT BACK LACKS POWER.....2937
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK OPERATION.....2938
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.....2938
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.....2938
T-26 BUCKET SHAKES DURING LOADING OPERATION.....2938
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.....2938
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY.....2939
TROUBLESHOOTING OF ECSS E MODE.....2940
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.....2941
D-1 ECSS DOES NOT WORK.....2942
D-2 ECSS CANNOT BE CANCELED.....2947
D-3 OUTPUT IS TURNED ON, TRAVEL SPEED DOES NOT BECOME 5 KM/H (DEVIATES AT AROUND 5 KM/H).....2948
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST.....2948
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH.....2949
D-6 CONTROLLER LED CODE IS NOT DISPLAYED.....2950
D-7 ECSS IS ABNORMAL, BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY.....2950
30 DISASSEMBLY AND ASSEMBLY.....2951
HOW TO USE THIS MANUAL.....2955
When removing or installing unit assemblies.....2955
PRECAUTIONS DURING OPERATION.....2956
Precautions when carrying out removal work.....2956
Precautions when carrying out installation work.....2957
Precautions when completing the operations.....2958
SPECIAL TOOL LIST.....2959
STARTING MOTOR.....2961
Removal.....2961
Installation.....2961
ALTERNATOR.....2962
Removal.....2962
Installation.....2962
ENGINE COMPONENTS.....2963
RADIATOR.....2964
Removal.....2964
Installation.....2967
ENGINE.....2968
Removal.....2488
Installation.....2973
TORQUE CONVERTER, TRANSMISSION.....2976
Removal.....2976
Installation.....2986
TORQUE CONVERTER.....2990
Disassembly.....2990
Assembly.....2992
TRANSMISSION.....2996
Disassembly.....2996
Torque Converter.....2998
Transmission.....3000
Assembly.....3003
TRANSMISSION CLUTCH PACK.....3010
Disassembly.....3010
FORWARD, 1st Clutch Assembly.....3010
REVERSE, 2ND CLUTCH ASSEMBLY.....3013
3RD, 4TH CLUTCH ASSEMBLY.....3016
Assembly.....3020
FORWARD, 1ST CLUTCH ASSEMBLY.....3020
REVERSE, 2ND CLUTCH ASSEMBLY.....3024
3RD, 4TH CLUTCH ASSEMBLY.....3028
PARKING BRAKE.....3034
disASSEMBLY.....3034
Assembly.....3036
TRANSMISSION CONTROL VALVE.....3040
removal.....3040
Installation.....3043
Disassembly.....3044
Assembly.....3049
TRANSMISSION ACCUMULATOR VALVE.....3056
Disassembly.....3056
Assembly.....3057
DRIVE SHAFT ASSEMBLY.....3058
Disassembly.....3058
ASSEMBLY.....3060
FRONT AXLE.....3062
Removal.....3062
Installation.....3064
REAR AXLE.....3066
REMOVAL.....3066
Installation.....3070
FRONT DIFFERENTIAL.....3074
REMOVAL.....3074
Installation.....3077
REAR DIFFERENTIAL.....3080
Removal.....3080
Installation.....3083
DIFFERENTIAL.....3086
Disassembly.....3086
Assembly.....3090
FINAL DRIVE.....3100
Disassembly.....3100
Assembly.....3103
CENTER HINGE PIN.....3108
Removal.....3108
Installation.....3119
Upper hinge.....3120
Connection of frame.....3121
Lower hinge.....3121
Upper hinge.....3123
STEERING VALVE (ORIBITROL).....3126
Removal.....3126
Installation.....3128
Disassembly.....3129
Rotor.....3129
Control Side.....3130
Assembly.....3132
Control Side.....3132
Rotor.....3134
STEERING DEMAND VALVE.....3138
Removal.....3138
Installation.....3139
Disassembly.....3140
Assembly.....3145
STEERING AND SWITCH PUMP.....3150
Removal.....3150
Installation.....3154
STEERING CYLINDER.....3156
Removal.....3156
Installation.....3157
BRAKE VALVE.....3158
Removal.....3158
Installation.....3160
RIGHT BRAKE VALVE (TANDEM).....3162
Disassembly.....3162
Assembly.....3163
LEFT BRAKE VALVE (SINGLE).....3166
Disassembly.....3166
Assembly.....3167
SLACK ADJUSTER.....3168
Removal.....3168
Installation.....3169
Disassembly.....3170
Assembly.....3171
WHEEL BRAKE.....3172
Disassembly.....3172
ASSEMBLY.....3178
PARKING BRAKE DISC.....3188
Removal.....3188
Installation.....3190
ACCUMULATOR CHARGE VALVE.....3191
Removal.....3191
Installation.....3191
Disassembly.....3192
assembly.....3194
HYDRAULIC TANK.....3196
Removal.....3196
Installation.....3198
WORK EQUIPMENT, PPC PUMP ASSEMBLY.....3200
Removal.....3200
Installation.....3204
PPC VALVE ASSEMBLY.....3206
Removal.....3206
INSTALLATION.....3208
Disassembly.....3209
Assembly.....3210
MAIN CONTROL VALVE.....3212
Removal.....3212
INSTALLATION.....3215
Disassembly (2-spool version).....3216
Hydraulic Lines.....3217
Valves.....3217
Spools.....3217
Assembly (2-Spool Version).....3218
Spools.....3219
Valves.....3219
Assembly (2-Spool Version).....3220
Hydraulic Lines.....3221
Disassembly (3-spool version; Hydraulic Lines).....3222
Hydraulic Lines.....3223
Valves.....3225
Spools.....3225
Assembly (3-spool version; VALVES, SPOOLS).....3228
Spools.....3229
Valves.....3229
Assembly (3-spool version; VALVES, SPOOLS).....3230
assembly (3-spool version; Hydraulic Lines).....3232
Hydraulic Lines.....3233
DUMP CYLINDER.....3234
Removal.....3234
INSTALLATION.....3236
LIFT CYLINDER.....3238
Removal.....3238
INSTALLATION.....3240
HYDRAULIC CYLINDERS.....3242
Disassembly.....3242
Assembly.....3245
WORK EQUIPMENT.....3250
Removal.....3250
INSTALLATION.....3254
Bucket and bucket link.....3254
Dump cylinder.....3254
Lift cylinder.....3254
Lift arm, bellcrank, bucket link.....3254
Bellcrank, bucket link.....3255
COUNTERWEIGHT.....3256
Removal.....3256
INSTALLATION.....3257
FUEL TANK.....3258
Removal.....3258
INSTALLATION.....3260
CAB ASSEMBLY.....3262
Removal.....3262
INSTALLATION.....3263
MAIN MONITOR.....3264
Removal.....3264
Installation.....3265
MAINTENANCE MONITOR.....3266
Removal.....3266
INSTALLATION.....3266
AIR CONDITIONER UNIT.....3268
Removal.....3268
INSTALLATION.....3274
AIR CONDITIONER CONDENSER.....3276
Removal.....3276
INSTALLATION.....3278
RECEIVER-DRIER.....3280
Removal.....3280
INSTALLATION.....3281
AIR CONDITIONER COMPRESSOR.....3282
Removal.....3282
INSTALLATION.....3283
40 MAINTENANCE STANDARD.....3285
ENGINE AND TRANSMISSION MOUNT.....3286
TORQUE CONVERTER.....3287
TRANSMISSION.....3288
TRANSMISSION.....3289
FORWARD, 1ST CLUTCH.....3290
REVERSE, 2ND CLUTCH.....3291
3RD, 4TH CLUTCH.....3292
TRANSMISSION VALVES.....3293
UPPER VALVE.....3293
LOWER VALVE.....3294
FLOW VALVE.....3295
ACCUMULATOR VALVE.....3296
DRIVE SHAFTS.....3297
AXLE MOUNT.....3298
FRONT AXLE.....3299
REAR AXLE.....3300
DIFFERENTIAL.....3302
LIMITED SLIP DIFFERENTIAL.....3304
FINAL DRIVE.....3306
STEERING COLUMN.....3307
STEERING VALVE.....3308
STEERING CYLINDER MOUNT.....3309
SLACK ADJUSTER.....3310
LEFT BRAKE VALVE.....3311
RIGHT BRAKE VALVE.....3312
BRAKE.....3313
PARKING BRAKE.....3314
TORQUE CONVERTER, TRANSMISSION PUMP.....3315
STEERING, SWITCH PUMP.....3316
EQUIPMENT, PPC PUMP.....3317
2 SPOOL CONTROL VALVE.....3318
3 SPOOL CONTROL VALVE.....3320
PPC VALVE.....3322
CUT OFF VALVE.....3323
CENTER HINGE PIN.....3324
WORK EQUIPMENT LINKAGE.....3326
BOOM CYLINDER.....3328
BUCKET CYLINDER.....3329
STEERING CYLINDER.....3330
BUCKET.....3331
BUCKET POSITIONER AND BOOM KICK OUT.....3332
90 OTHERS.....3333
ELECTRICAL CIRCUIT DIAGRAM (1 OF 4).....3334
ELECTRICAL CIRCUIT DIAGRAM (2 OF 4).....3335
ELECTRICAL CIRCUIT DIAGRAM (3 OF 4).....3336
ELECTRICAL CIRCUIT DIAGRAM (4 OF 4).....3337
CEBMW21020 - Wheel Loader WA450-2 Shop Manual.....3338
CONTENTS.....3342
10 ENGINE.....3358
12 TESTING AND ADJUSTING.....3358
STANDARD VALUE TABLE.....3359
TOOL LIST FOR TESTING AND ADJUSTING.....3362
ADJUSTING VALVE CLEARANCE.....3363
FUEL INJECTION TIMING.....3364
MEASURING BLOW-BY PRESSURE.....3365
FAN BELT TENSION.....3366
MEASURING EXHAUST GAS COLOR.....3368
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE.....3370
13 DISASSEMBLY AND ASSEMBLY.....3372
STARTING MOTOR ASSEMBLY.....3374
REMOVAL.....3374
INSTALLATION.....3374
ALTERNATOR ASSEMBLY.....3375
REMOVAL.....3375
INSTALLATION.....3375
WATER PUMP ASSEMBLY.....3376
REMOVAL.....3376
INSTALLATION.....3376
TURBOCHARGER ASSEMBLY.....3377
REMOVAL.....3377
INSTALLATION.....3377
CYLINDER HEAD ASSEMBLY.....3378
REMOVAL.....3378
INSTALLATION.....3379
RADIATOR ASSEMBLY.....3380
REMOVAL.....3380
INSTALLATION.....3383
ENGINE.....3385
REMOVAL.....3385
INSTALLATlON.....3391
FUEL TANK.....3397
REMOVAL.....3397
INSTALLATION.....3397
14 MAINTENANCE STANDARD.....3398
ENGINE MOUNT.....3399
20 POWER TRAIN.....3400
21 STRUCTURE AND FUNCTION.....3400
GENERAL.....3402
HYDRAULIC CIRCUIT FOR POWER TRAIN.....3404
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.....3405
DAMPER.....3406
TORQUE CONVERTER AND TRANSMISSION PIPING.....3407
TORQUE CONVERTER CHARGING PUMP.....3408
TORQUE CONVERTER.....3409
TORQUE CONVERTER OIL FILTER.....3412
TORQUE CONVERTER OIL COOLER.....3413
TORQUE CONVERTER RELIEF VALVE.....3414
TRANSMISSION.....3415
TRANSMISSION foldout # 1.....3416
TRANSMISSION CONTROL VALVE.....3423
UPPER VALVE.....3425
LOWER VALVE.....3426
TRANSMISSION SOLENOID VALVE.....3427
EMERGENCY MANUAL SPOOL.....3428
PRIORITY VALVE.....3431
MODULATING VALVE AND QUICK RETURN VALVE.....3432
ACCUMULATOR VALVE.....3435
PILOT REDUCING VALVE.....3437
TRANSMISSION PILOT FILTER.....3438
TRANSFER.....3439
DRIVE SHAFT.....3440
AXLE MOUNT.....3441
AXLE AND DIFFERENTIAL.....3443
TORQUE PROPORTIONING DIFFERENTIAL.....3448
FINAL DRIVE.....3449
TIRE AND WHEEL.....3450
22 TESTING AND ADJUSTING.....3452
STANDARD VALUE TABLE.....3453
TOOL LIST FOR TESTING AND ADJUSTING.....3454
MEASURING ENGINE STALL SPEED.....3455
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.....3457
MEASURING SHIFT LEVER.....3459
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL.....3460
TIRE AND WHEEL.....3462
TROUBLESHOOTING.....3463
PRECAUTIONS WHEN TROUBLESHOOTING.....3464
METHOD OF READING TROUBLESHOOTING TABLES.....3466
PREVENTING RECURRENCE OF TROUBLE.....3468
JUDGMENT ON POWER TRAIN.....3469
TROUBLESHOOTING TABLE.....3471
Machine does not move.....3471
Machine lacks power or speed (all speed range).....3473
Excessive time lag when starting machine or shifting gear.....3474
Torque converter oil temperature too high.....3475
23 DISASSEMBLY AND ASSEMBLY.....3476
DAMPER.....3478
REMOVAL.....3478
INSTALLATlON.....3478
DISASSEMBLY.....3479
ASSEMBLY.....3481
TORQUE CONVERTER CHARGING PUMP.....3485
REMOVAL.....3485
INSTALLATION.....3486
TORQUE CONVERTER AND TRANSMISSION.....3487
REMOVAL.....3487
INSTALLATION.....3496
TORQUE CONVERTER ASSEMBLY.....3506
DISASSEMBLY.....3506
ASSEMBLY.....3510
TRANSMISSION ASSEMBLY.....3516
DISASSEMBLY.....3516
DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER.....3524
DISASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY.....3526
DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING.....3527
DISASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY.....3528
ASSEMBLY.....3529
ASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY.....3529
ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING.....3530
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY.....3531
ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER.....3532
ASSEMBLY OF TRANSMISSION.....3534
TRANSFER ASSEMBLY.....3542
DISASSEMBLY.....3542
DISASSEMBLY OF OUTPUT SHAFT GEAR CASE.....3544
ASSEMBLY.....3545
ASSEMBLY OF OUTPUT SHAFT, GEAR CASE.....3545
TRANSMISSION CONTROL VALVE.....3550
REMOVAL.....3550
INSTALLATION.....3552
DISASSEMBLY AND ASSEMBLY.....3554
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE.....3554
DISASSEMBLY AND ASSEMBLY OF SPEED VALVE.....3555
DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE.....3556
FRONT DIFFERENTIAL.....3558
REMOVAL.....3558
INSTALLATION.....3562
REAR DIFFERENTIAL.....3566
REMOVAL.....3566
INSTALLATION.....3570
DIFFERENTIAL.....3574
DISASSEMBLY.....3574
ASSEMBLY.....3577
FRONT AXLE.....3586
REMOVAL.....3586
INSTALLATION.....3589
REAR AXLE.....3592
REMOVAL.....3592
INSTALLATION.....3597
DRIVE SHAFT.....3602
DISASSEMBLY.....3602
ASSEMBLY.....3604
FINAL DRIVE.....3606
DISASSEMBLY.....3606
ASSEMBLY.....3609
24 MAINTENANCE STANDARD.....3614
TRANSMISSION MOUNT.....3615
TORQUE CONVERTER CHARGING PUMP.....3616
DAMPER.....3617
TORQUE CONVERTER.....3618
TORQFLOW TRANSMISSION.....3620
TRANSMISSION.....3620
TRANSMISSION CONTROL VALVE.....3623
UPPER VALVE.....3623
LOWER VALVE.....3625
SOLENOID VALVE.....3627
TRANSFER.....3628
DIFFERENTIAL.....3630
FINAL DRIVE.....3632
DRIVE SHAFT.....3633
AXLE MOUNT.....3634
40 STEERING SYSTEM.....3636
41 STRUCTURE AND FUNCTION.....3636
STEERING PIPING.....3637
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING.....3638
STEERING VALVE.....3639
ORBIT-ROLL VALVE.....3640
STOP VALVE.....3641
STEERING PUMP.....3642
STEERING CYLINDER.....3643
STEERING COLUMN AND ORBIT-ROLL.....3644
CENTER HINGE PIN.....3645
42 TESTING AND ADJUSTING.....3646
STANDARD VALUE TABLE.....3647
TOOL LIST .....3647
MEASURING STEERING WHEEL PLAY.....3648
MEASURING OPERATING FORCE OF STEERING WHEEL.....3649
OPERATING TIME OF STEERING WHEEL.....3650
STEERING OIL PRESSURE.....3651
TROUBLESHOOTING TABLES.....3653
1. Steering wheel does not turn.....3654
2. Steering wheel is sluggish.....3655
3. Steering wheel moves unsteadily or is subject to large shock.....3656
4. Machine tends to turn naturally in one particular direction when traveling.....3656
5. Left and right turning radii are different.....3656
43 DISASSEMBLY AND ASSEMBLY.....3658
STEERING VALVE.....3659
REMOVAL.....3659
INSTALLATION.....3661
DISASSEMBLY.....3664
ASSEMBLY.....3667
STEERING DEMAND VALVE.....3672
REMOVAL.....3672
INSTALLATION.....3674
DISASSEMBLY.....3677
ASSEMBLY.....3681
STEERING PUMP.....3685
REMOVAL.....3685
INSTALLATION.....3686
STEERING CYLINDER.....3687
REMOVAL.....3687
INSTALLATION.....3688
DISASSEMBLY.....3689
ASSEMBLY.....3691
CENTER HINGE PIN.....3694
REMOVAL.....3694
INSTALLATION.....3703
44 MAINTENANCE STANDARD.....3714
STEERING COLUMN AND ORBIT-ROLL.....3715
STEERING PUMP.....3716
STEERING VALVE.....3717
STEERING CYLINDER MOUNT.....3718
STEERING CYLINDER.....3719
CENTER HINGE PIN.....3721
50 BRAKE AND AIR SYSTEM.....3724
51 STRUCTURE AND FUNCTION.....3724
GENERAL.....3725
BRAKE AND AIR PIPING.....3726
BRAKE AND AIR CIRCUIT SYSTEM.....3727
AIR TANK.....3728
SAFETY VALVE.....3730
BRAKE VALVE.....3731
BRAKE ACTUATED.....3732
OPERATING IN BALANCE.....3733
BRAKE RELEASED.....3734
AIR GOVERNOR.....3735
TWO-WAY VALVE.....3737
BRAKE CHAMBER.....3738
SLACK ADJUSTER.....3740
BRAKE.....3743
PARKING BRAKE.....3745
PARKING BRAKE SOLENOID VALVE.....3747
SPRING CYLINDER.....3748
BRAKE CALIPER.....3749
52 TESTING AND ADJUSTING.....3752
STANDARD VALUE TABLE.....3754
TOOL LIST .....3755
MEASURING BRAKE PEDAL.....3756
MEASURING AIR.....3757
BRAKE PERFORMANCE.....3760
CHECKING BRAKE OIL PRESSURE.....3761
MEASURING WEAR OF BRAKE DISC.....3762
AIR BLEEDING FROM BRAKE LINE.....3763
PARKING BRAKE PERFORMANCE.....3764
CHECKING AND ADJUSTING PARKING BRAKE.....3765
TROUBLESHOOTING.....3768
TROUBLESHOOTING TABLE.....3769
1. Air pressure does not rise at all.....3769
2. Air pressure does not rise to the specified range.....3770
3. Brake is ineffective or not very effective.....3771
4. Brake does not release, or drags.....3772
5. Parking brake does not release, or drags. (Applies to machine equipped with air parking brake.).....3773
53 DISASSEMBLY AND ASSEMBLY.....3774
AIR GOVERNOR .....3776
DISASSEMBLY.....3776
ASSEMBLY.....3777
BRAKE VALVE .....3778
REMOVAL.....3778
INSTALLATION.....3779
DISASSEMBLY.....3780
ASSEMBLY.....3782
BRAKE CHAMBER.....3784
REMOVAL.....3784
INSTALLATION.....3786
DISASSEMBLY.....3788
ASSEMBLY.....3791
SLACK ADJUSTER.....3794
REMOVAL.....3794
INSTALLATION.....3796
DISASSEMBLY.....3798
ASSEMBLY.....3799
BRAKE ASSEMBLY .....3800
DISASSEMBLY .....3800
ASSEMBLY.....3806
SPRING CYLINDER.....3814
REMOVAL.....3814
INSTALLATION.....3815
DISASSEMBLY.....3816
ASSEMBLY.....3818
PARKING BRAKE.....3820
REMOVAL.....3820
INSTALLATION.....3822
PARKING BRAKE PAD.....3825
REMOVAL.....3825
INSTALLATION.....3825
54 MAINTENANCE STANDARD.....3826
BRAKE VALVE.....3827
BRAKE CHAMBER.....3829
SLACK ADJUSTER.....3830
BRAKE.....3831
PARKING BRAKE.....3833
SPRING CYLINDER.....3835
60 WORK EQUIPMENT SYSTEM.....3838
61 STRUCTURE AND FUNCTION.....3838
GENERAL.....3839
HYDRAULIC PIPING.....3840
HYDRAULIC CIRCUIT DIAGRAM.....3841
HYDRAULIC TANK.....3843
OIL FILTER BYPASS VALVE.....3845
BREATHER.....3846
HYDRAULIC PUMPS.....3847
HYDRAULIC PUMP.....3847
SWITCH AND PPC PUMP.....3848
PPC VALVE.....3849
PPC RELIEF VALVE.....3851
FUNCTION OF PPC VALVE.....3852
MAIN CONTROL VALVE.....3854
RELIEF VALVE.....3860
SAFETY VALVE.....3861
SUCTION VALVE.....3862
FLOAT SELECTOR VALVE AND UNLOADER VALVE.....3863
ACCUMULATOR.....3865
HYDRAULIC CYLINDER.....3866
BUCKET LINKAGE.....3868
BUCKET POSITIONER AND BOOM KICK-OUT.....3870
WORK EQUIPMENT LEVER LINKAGE.....3872
62 TESTING AND ADJUSTING.....3874
STANDARD VALUE TABLE.....3876
TOOL LIST FOR TESTING AND ADJUSTING.....3878
MEASURING DUMP AND LEFT CONTROL LEVERS.....3879
ADJUSTING DUMP AND LIFT CONTROL LEVERS.....3880
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT.....3882
MEASURING WORK EQUIPMENT.....3885
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT.....3886
ADJUSTING BUCKET POSITIONER.....3887
ADJUSTING BOOM KICK-OUT.....3888
TROUBLESHOOTING.....3889
TROUBLESHOOTING TABLE.....3889
1. Lift arm does not rise.....3889
2. Lift arm moves slowly or does not have sufficient lifting power.....3890
3. Lift arm movement becomes slow after it reaches a certain height.....3891
4. Bucket cannot be held down with lift arm cylinder.....3891
5. Lift arm has large hydraulic drift.....3891
6. Lift arm movement is unsteady during work.....3891
7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise".....3891
8. Bucket does not tilt beck.....3892
9. Bucket moves slowly or has insufficient tilt back power.....3893
10. Bucket movement becomes slow during tilt back.....3894
11. Bucket cannot be held down by the bucket cylinder.....3894
12. Bucket has large hydraulic drift.....3894
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....3894
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".....3894
15. Control levers of lift arm and dump move stiffly and sluggishly.....3895
63 DISASSEMBLY AND ASSEMBLY.....3896
HYDRAULIC TANK .....3898
REMOVAL .....3898
INSTALLATION.....3902
HYDRAULIC PUMP .....3905
REMOVAL .....3905
INSTALLATION .....3906
HYDRAULIC FILTER.....3907
REMOVAL .....3907
INSTALLATION.....3907
SWITCH, PPC PUMP.....3908
REMOVAL.....3908
INSTALLATION .....3909
PPC VALVE .....3910
REMOVAL .....3910
INSTALLATION.....3912
DISASSEMBLY .....3914
ASSEMBLY .....3914
MAIN CONTROL VALVE .....3915
REMOVAL .....3915
INSTALLATION .....3918
DISASSEMBLY.....3921
ASSEMBLY.....3923
DUMP CYLINDER.....3925
REMOVAL.....3925
INSTALLATION.....3927
LIFT CYLINDER .....3928
REMOVAL .....3928
INSTALLATION .....3929
LIFT AND DUMP CYLINDERS.....3930
DISASSEMBLY.....3930
ASSEMBLY.....3932
WORK EQUIPMENT .....3935
REMOVAL .....3935
INSTALLATION.....3938
COUNTERWEIGHT.....3941
REMOVAL.....3941
INSTALLATION.....3941
64 MAINTENANCE STANDARD.....3942
MAIN CONTROL VALVE.....3943
SWITCH AND PPC PUMP.....3947
HYDRAULIC PUMP.....3949
PPC VALVE.....3951
DUMP CYLINDER.....3953
LIFT CYLINDER.....3955
BUCKET LINKAGE.....3957
BUCKET POSITIONER AND BOOM KICK-OUT.....3960
BUCKET.....3961
80 ELECTRIC AND ELECTRONIC SYSTEM.....3962
81 STRUCTURE AND FUNCTION.....3962
ELECTRICAL WIRING DIAGRAM.....3963
ENGINE STARTING CIRCUIT.....3964
ENGINE STOP CIRCUIT.....3966
COMBINATION SWITCH.....3967
ELECTRICALTRANSMISSION CONTROL.....3968
TRANSMISSION CUT-OFF SWITCH.....3968
TRANSMISSION CUT-OFF SELECTOR SWITCH.....3969
NEUTRALIZER RELAY.....3970
KICK-DOWN SWITCH.....3971
KICK-DOWN ELECTRIC CIRCUIT.....3972
ELECTRICAL PARKING BRAKE CONTROL.....3978
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS).....3987
INDICATION ON MONITOR PANEL.....3989
SENSORS.....3992
WIRING HARNESS.....4000
OPERATION OF PROXIMITY SWITCH.....4001
82 TESTING AND ADJUSTING.....4006
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.....4009
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE).....4012
TROUBLESHOOTING.....4014
CHECKS BEFORE TROUBLESHOOTING.....4015
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.....4016
CONNECTOR TERMINAL NUMBERS.....4018
PRECAUTION WHEN HANDLING CONNECTOR.....4024
ELECTRICAL WIRING DIAGRAM.....4026
ELECTRICAL CIRCUIT SYSTEM.....4028
TRANSMISSION CONTROL, PARKING CIRCUIT SYSTEM.....4029
ETHER INJECTION CIRCUIT SYSTEM.....4030
KICK-DOWN CIRCUIT SYSTEM.....4031
VEHICLE MONITOR SYSTEM.....4032
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM.....4034
POSITION OF CONNECTORS FOR TROUBLESHOOTING.....4035
E-1 ENGINE DOES NOT START.....4041
E-2 ENGINE DOES NOT STOP.....4043
E-3 ENGINE STOPS WHEN TRAVELING.....4043
E-4 PARKING BRAKE DOES NOT WORK.....4044
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING .....4045
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON .....4047
E-7 WHEN PARKING BRAKE IS APPLIED. SHIFT LEVER DOES .....4047
E-8 TRANSMISSION DOES NOT WORK NORMALLY.....4048
E-9 KICK-DOWN SWITCH DOES NOT WORK.....4069
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.....4072
E-11 KICK-DOWN OPERATION IS NOT CANCELED.....4073
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.....4075
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.....4075
TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM) .....4077
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM.....4078
POSITION OF CONNECTORS FOR TROUBLESHOOTING .....4079
M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS .....4086
a) None of monitor panel lights up.....4086
b) Except for speedometer module, none of monitor panel lights up.....4086
c) None of CAUTION items light up. .....4087
d) Some other parts do not light up. .....4087
M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT.....4088
M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT) .....4089
a) (Engine oil level) flashes. .....4089
b) (Radiator water level) flashes.....4090
M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. (SWITCH POSITIONS ARE NORMAL) .....4092
a) (Transmission cut-off) lights up. .....4092
b) (Parking brake) lights up.....4093
c) (Working lamp) lights up.....4093
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES .....4095
a) Engine oil pressure system.....4095
b) Alternator system.....4095
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK.....4096
a) Engine oil pressure system.....4096
b) Alternator system.....4096
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE).....4098
a) (Charge level) flashes.....4098
b) (Fuel level) flashes.....4098
c) (Brake line failure) flashes.....4098
d) (Engine oil pressure) flashes.....4098
e) (Radiator water level) flashes.....4098
f) (Air pressure) flashes.....4099
g) (Engine water temperature) flashes.....4099
h) (Torque converter oil temperature) flashes.....4099
M-8 SPEED SENSOR DISPLAY STAYS AT 0.....4102
M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.....4103
a) If high beam does not light up.....4103
b) If high beam lights up when head lamp switch is OFF.....4103
c) If Hi beam display lights up when head lamp dimmer switch is at Lo beam position.....4104
M-10 TURN SIGNAL LAMP DOES NOT FLASH TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING.....4105
a) If turn signal lamp does not flash.....4105
b) If turn signal lamp stays ON or does not stop flashing.....4105
M-11 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND + Cause Remedy .....4106
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.....4107
M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH .....4108
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP. .....4108
M-15 WHEN STARTING SWITCH IS TURNED TO ON IS ON, .....4109
a) None of panel lights up.....4109
b) Some of panel lamps do not light up.....4109
M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING STAYS ON .....4110
M-17 SERVICE METER DOES NOT WORK.....4111
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED .....4111
M-19 ABNORMALITY IN AIR PRESSURE GAUGE .....4112
a) If nothing is displayed in display area.....4112
b) If indicator remains at maximum level.....4112
M-20 ENGINE WATER TEMPERATURE GAUGE .....4113
a) If nothing is displayed in display area.....4113
b) If indicator remains at minimum level.....4113
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....4114
a) If nothing is displayed in display area.....4114
b) If indicator remains at minimum level.....4114
M-22 ABNORMALITY IN FUEL GAUGE.....4115
a) If nothing is displayed in display area.....4115
b) If indicator remains at FULL.....4115
83 DISASSEMBLY AND ASSEMBLY.....4116
REMOVAL OF MACHINE MONITOR.....4117
INSTALLATION OF MACHINE MONITOR.....4117
90 OTHERS.....4118
91 LOGGING SPECIFICATIONS.....4118
STRUCTURE AND FUNCTION .....4119
HYDRAULIC CIRCUIT DIAGRAM .....4119
MAIN CONTROL VALVE .....4121
ARM CYLINDER .....4123
WORK EQUIPMENT .....4124
DISASSEMBLY AND ASSEMBLY .....4125
MAIN CONTROL VALVE .....4125
DISASSEMBLY.....4125
ASSEMBLY.....4127
MAINTENANCE STANDARD .....4129
MAIN CONTROL VALVE.....4129
WORK EQUIPMENT .....4131
ARM CYLINDER .....4134
93 DISASSEMBLY AND ASSEMBLY.....4136
REMOVAL OF CAB .....4137
INSTALLATION OF CAB .....4137
97 GEAR PUMP.....4138
GENERAL.....4139
PRINCIPLE OF OPERATION.....4140
PRESSURE LOADED TYPE GEAR PUMP.....4143
FIXED SIDE PLATE TYPE GEAR PUMP.....4145
SA SERIES.....4146
STRUCTURE.....4146
TESTING AND ADJUSTING.....4150
DISASSEMBLY.....4153
ASSEMBLY.....4157
MAINTENANCE STANDARD.....4162
99 METRIC CONVERSIONS.....4164
SEAM020900 - Wheel Loader WA450-3 Operation & Maintenance Manual.....4187
1. FOREWORD.....4188
2. SAFETY INFORMATION.....4189
3. INTRODUCTION.....4190
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....4191
5. CONTENTS.....4192
SAFETY.....4196
6. GENERAL PRECAUTIONS .....4197
7. PRECAUTIONS DURING OPERATION .....4203
7.1 BEFORE STARTING ENGINE .....4203
7.2 AFTER STARTING ENGINE .....4205
7.3 TRANSPORTATION .....4214
7.4 BATTERY .....4215
7.5 TOWING .....4217
8. PRECAUTIONS FOR MAINTENANCE .....4218
8.1 BEFORE CARRYING OUT MAINTENANCE .....4218
8.2 DURING MAINTENANCE .....4223
8.3 TIRES .....4229
9. POSITION FOR ATTACHING SAFETY LABELS .....4231
OPERATION.....4236
10. GENERAL VIEW .....4237
10.1 GENERAL VIEW OF MACHINE .....4237
10.2 GENERAL VIEW OF CONTROLS AND GAUGES .....4238
11. EXPLANATION OF COMPONENTS .....4239
11.1 MACHINE MONITOR .....4239
11.2 SWITCHES .....4249
11.3 CONTROL LEVERS, PEDALS .....4256
11.4 STEERING COLUMN TILT LEVER .....4261
11.5 CAP WITH LOCK .....4262
11.6 SAFETY BAR .....4263
11.7 TOWING PIN .....4263
11.8 GREASE PUMP .....4264
11.9 BACKUP ALARM .....4264
11.10 FUSE .....4265
11.11 SLOW-BLOW FUSE .....4266
11.12 STORAGING PLACE OF THIS MANUAL .....4267
11.13 TAKING OFF POWER .....4267
11.14 TAKING OFF POWER (with ROPS CAB) .....4267
12. OPERATION .....4268
12.1 CHECK BEFORE STARTING ENGINE .....4268
12.2 STARTING ENGINE .....4281
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE .....4283
12.4 MOVING MACHINE OFF .....4284
12.5 CHANGING GEAR SPEED .....4286
12.6 CHANGING DIRECTION .....4287
12.7 TURNING .....4288
12.8 STOPPING MACHINE.....4289
12.9 OPERATION OF WORK EQUIPMENT .....4290
12.10 WORK POSSIBLE USING WHEEL LOADER.....4291
12.11 PRECAUTIONS FOR OPERATION.....4296
12.12 ADJUSTING WORK EQUIPMENT POSTURE .....4298
12.13 PARKING MACHINE .....4300
12.14 CHECKS AFTER COMPLETION OF OPERATION .....4301
12.15 STOPPING ENGINE .....4301
12.16 CHECK AFTER STOPPING ENGINE .....4302
12.17 LOCKING .....4302
12.18 HANDLING THE TIRES.....4303
13. TRANSPORTATION .....4305
13.1 LOADING, UNLOADING WORK .....4305
13.2 PRECAUTIONS FOR LOADING .....4306
13.3 LIFTING MACHINE .....4306
13.4 PRECAUTIONS FOR TRANSPORTATION .....4308
14. COLD WEATHER OPERATION .....4309
14.1 PRECAUTIONS FOR LOW TEMPERATURE .....4309
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....4311
14.3 AFTER COLD WEATHER .....4311
15. LONG-TERM STORAGE .....4312
15.1 BEFORE STORAGE.....4312
15.2 DURING STORAGE.....4312
15.3 AFTER STORAGE.....4312
16. TROUBLESHOOTING .....4313
16.1 WHEN MACHINE RUNS OUT OF FUEL .....4313
16.2 TOWING THE MACHINE .....4314
16.3 IF BATTERY IS DISCHARGED .....4319
16.4 OTHER TROUBLE.....4323
MAINTENANCE.....4330
17. GUIDES TO MAINTENANCE .....4331
18. OUTLINES OF SERVICE .....4334
18.1 OUTLINE OF OIL, FUEL, COOLANT .....4334
18.2 OUTLINE OF ELECTRIC SYSTEM .....4337
19. WEAR PARTS LIST .....4338
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .....4339
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....4343
21.1 INTRODUCTION OF NECESSARY TOOLS .....4343
21.2 TORQUE LIST .....4344
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....4345
23. MAINTENANCE SCHEDULE CHART .....4349
23.1 MAINTENANCE SCHEDULE CHART .....4349
24. SERVICE PROCEDURE .....4353
24.1 INITIAL 250 HOURS SERVICE .....4353
24.2 WHEN REQUIRED .....4354
24.3 CHECK BEFORE STARTING.....4367
24.4 EVERY 50 HOURS SERVICE.....4372
24.5 EVERY 100 HOURS SERVICE .....4373
24.6 EVERY 250 HOURS SERVICE .....4375
24.7 EVERY 500 HOURS SERVICE .....4382
24.8 EVERY 1000 HOURS SERVICE .....4386
24.9 EVERY 2000 HOURS SERVICE .....4391
24.10 EVERY 4000 HOURS SERVICE .....4397
SPECIFICATIONS.....4398
25. SPECIFICATIONS .....4399
OPTIONS, ATTACHMENTS.....4401
26. OPTIONAL PARTS AND ATTACHMENTS .....4402
27. SELECTING BUCKETS AND TIRES .....4403
28. AIR CONDITIONER .....4404
28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL .....4404
28.2 METHOD OF OPERATION .....4406
28.3 COOL BOX .....4406
29. HANDLING AUTO-GREASING SYSTEM .....4407
29.1 METHOD OF OPERATING AUTO-GREASING .....4407
29.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM .....4415
29.3 TROUBLESHOOTING .....4416
29.4 SPECIFICATIONS .....4416
SEAM042KD200 - Wheel Loader WA450-2 Operation & Maintenance Manual.....4419
CONTENTS.....4423
OPERATION.....4429
GENERAL LOCATIONS AND SPECIFICATIONS.....4430
PERFORMANCE.....4430
OPERATING WEIGHT.....4430
ENGINE.....4430
INSTRUMENTS AND CONTROLS.....4431
MONITOR PANEL.....4431
CHECK MONITOR GROUP.....4433
Engine Oil Level Monitor.....4433
Coolant Level Monitor.....4433
CAUTION MONITOR GROUP.....4434
Charge Monitor.....4434
Fuel Level Monitor.....4434
CAUTION MONITOR GROUP.....4435
Brake Line Failure Monitor.....4435
Engine Oil Pressure Monitor.....4435
Coolant Level Monitor.....4435
Air Pressure Monitor.....4436
Coolant Temperature Monitor.....4436
Torque Conveiior Oil Temperature Monitor.....4436
METER GROUP.....4437
Parking Brake Pilot Lamp.....4437
Pilot Lamp for Working Lamp.....4437
Transmission Cut-Off Selector Pilot Lamp.....4438
Air Pressure Gauge.....4438
Engine Cooling Water Temperature Gauge.....4438
Torque Converter Oil Temperature Gauge.....4439
Fuel Gauge.....4439
Turn Signal Pilot Lamp.....4439
High Beam Pilot Lamp.....4440
Speedometer.....4440
Service Meter.....4441
SWITCHES.....4441
TRANSMISSION CUT-OFF SELECTOR SWITCH.....4441
ETHER START SWITCH.....4442
HORN BUTTON.....4442
HAZARD LAMP SWITCH.....4442
PARKING BRAKE SWITCH.....4443
WORKING LAMP SWITCH.....4443
STARTING SWITCH.....4444
LAMP SWITCHES.....4444
Lamp switch.....4444
Turn signal lever.....4444
Dimmer switch.....4445
ROOM LAMP SWITCH.....4445
CIGARETTE LIGHTER.....4446
KICKDOWN SWITCH.....4446
FRONT WIPER SWITCH.....4447
REAR WIPER SWITCH.....4447
LEVERS AND PEDALS.....4448
DIRECTIONAL LEVER.....4448
SPEED CONTROL LEVER.....4448
SPEED CONTROL LEVER STOPPER.....4449
STEERING COLUMN TILT LEVER.....4449
ACCELERATOR PEDAL.....4449
BRAKE PEDALS.....4449
Right brake pedal.....4449
Left brake pedal.....4449
LIFT ARM CONTROL LEVER.....4450
BUCKET CONTROL LEVER.....4450
SAFETY LOCK.....4450
AIR CLEANER SERVICE INDICATOR.....4451
SAFETY BAR.....4451
WORK EQUIPMENT CONTROL LEVER (MONO-LEVER TYPE).....4451
CIRCUIT BREAKER (MAIN).....4452
DOOR-OPEN LOCK.....4452
FUSE BOX.....4452
OPERATOR'S SEAT.....4454
FORWARD-BACKWARD ADJUSTMENT.....4454
SEAT ANGLE ADJUSTMENT.....4454
SEAT CUSHION ADJUSTMENT.....4454
BACKREST ADJUSTMENT.....4454
SEAT HEIGHT ADJUSTMENT.....4454
RIGHT SIDE ARMREST.....4455
FORWARD-BACKWARD ADJUSTMENT.....4455
ANGLE ADJUSTMENT.....4455
SEAT BELT.....4455
CHECK BEFORE STARTING.....4456
WALK-AROUND CHECK.....4456
CHECK MONlTOR PANEL.....4456
CHECK AND REFILL COOLANT.....4457
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN.....4457
CHECK FUEL LEVEL AND REFILL FUEL.....4458
CHECK AIR CLEANER SERVICE INDICATOR.....4458
DRAIN WATER FROM AIR TANKS.....4459
FUEL-WATER SEPARATOR.....4459
FAN - INSPECTION.....4460
DRIVE BELT.....4460
FAN DRIVE BELT - INSPECTtON.....4460
BELT TENSION - CHECK.....4460
BELT TENSION - CHECK AND ADJUST.....4461
FAN DRIVE BELT - ADJUST.....4462
ALTERNATOR DRIVE BELT - ADJUST.....4462
OPERATING YOUR MACHINE.....4463
BEFORE STARTING THE ENGINE.....4463
TO START THE ENGINE.....4464
SPECIAL STARTING.....4464
CHECKS AFTER STARTING.....4465
TO MOVE THE MACHINE OFF.....4465
CHANGING GEAR SPEED.....4466
CHANGING DIRECTION.....4466
TURNING.....4467
TO STOP THE MACHINE.....4468
TO STOP THE ENGINE.....4469
MAXIMUM DEPTH OF WATER.....4469
IF WHEEL BRAKE DOES NOT WORK.....4469
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....4470
LOWER THE CENTER OF GRAVITY WHEN TURNING.....4470
BRAKING ON DOWNHILL SLOPES.....4470
IF ENGINE STOPS.....4470
PROPER BUCKET AND TIRE.....4470
ADJUSTMENT OF WORK EQUIPMENT.....4471
ADJUSTING BOOM KICKOUT.....4471
ADJUSTING BUCKET POSITIONER.....4472
BUCKET LEVEL INDICATOR.....4472
USING ACCUMULATORS.....4473
PRECAUTIONS FOR MAINTENANCE.....4473
HANDLING TIRES.....4473
PRECAUTIONS WHEN HANDLING TIRES.....4473
PRECAUTIONS WHEN DRIVING MACHINE.....4474
TIRE PRESSURE.....4474
INFLATING TIRES.....4475
TOWING.....4476
TOWING THE MACHINE.....4476
WHEN ENGINE CAN BE USED.....4476
WHEN ENGINE CANNOT BE USED.....4476
RELEASING PARKING BRAKE.....4476
COLD WEATHER OPERATION.....4477
PREPARATION FOR LOW TEMPERATURE.....4477
FUEL AND LUBRlCANTS.....4477
COOLANT.....4477
BATTERY.....4477
STARTING IN COLD WEATHER.....4478
CAUTIONS AFTER COMPLETION OF WORK.....4479
AFTER COLD WEATHER.....4479
MEMORANDA.....4480
MAINTENANCE.....4481
PERIODIC MAINTENANCE.....4482
BLEEDING AIR FROM CIRCUIT.....4482
BLEEDING AIR FROM HYDRAULIC CIRCUIT.....4482
PERIODICAL REPLACEMENT OF SAFETY PARTS.....4483
MAINTENANCE TABLE.....4484
OIL FILLER AND LEVEL GAUGE POSITIONS.....4488
CHECK BEFORE STARTING.....4489
EVERY 50 HOURS SERVICE.....4489
FUEL TANK.....4489
TIRE.....4489
EVERY 100 HOURS SERVICE.....4489
HYDRAULIC TANK.....4489
LUBRICATING.....4490
AIR CONDITIONER FILTER.....4490
INITIAL 250 HOURS SERVICE.....4491
TRANSMISSION OIL FILTER.....4491
EVERY 250 HOURS SERVICE.....4491
ENGINE OIL PAN AND FILTER.....4491
AIR INTAKE SYSTEM.....4493
CHECK ELECTROLYTE LEVEL IN BATTERY.....4493
FUEL FILTER.....4494
CRANKCASE BREATHER.....4495
CORROSION RESISTOR (Coolant filter).....4496
COOLANT ADDITIVE CONCENTRATION.....4497
LUBRICATING.....4498
AIR CONDITIONER COMPRESSOR BELT.....4500
WHEEL HUB NUTS.....4501
EVERY 500 HOURS SERVICE.....4501
TRANSMISSION OIL FILTER.....4501
LUBRICATING.....4502
AIR DRYER.....4502
EVERY 1000 HOURS SERVICE.....4503
TRANSMISSION CASE AND STRAINER.....4503
TRANSMISSION CASE BREATHER.....4504
LUBRICATING.....4504
EVERY 1500 HOURS SERVICE.....4507
VALVES AND INJECTORS.....4507
EVERY 2000 HOURS SERVICE.....4508
HYDRAULIC TANK AND FILTER.....4508
AIR CONDITIONER FILTER.....4509
HYDRAULIC TANK BREATHER.....4509
AXLE.....4509
PPC CIRCUIT STRAINER.....4511
ALTERNATOR AND STARTING MOTOR.....4511
BRAKE DISC.....4511
INTERNAL PART OF AIR DRYER.....4511
ACCUMULATOR.....4511
EVERY 6000 HOURS SERVICE.....4512
INJECTORS.....4512
FUEL PUMP.....4512
TURBOCHARGER.....4512
AIR COMPRESSOR.....4513
WATER PUMP.....4516
FAN IDLER PULLEY.....4516
FAN HUB (BELT DRIVEN).....4517
COOLANT CHANGE AND FLUSHING THE SYSTEM.....4517
COOLANT.....4517
DCA4 UNIT MAINTENANCE GUIDE.....4518
WHEN REQUIRED.....4520
TURBOCHARGER MOUNTING NUTS.....4520
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.....4521
CHECKING.....4521
CLEANING OR REpLACING OUTER ELEMENT.....4521
REPLACING INNER ELEMENT.....4522
CLEANING OUTER ELEMENT.....4522
With compressed air.....4522
With water.....4522
With cleaning agent.....4522
CHECK AND REFILL TRANSMISSION OIL.....4523
CLEAN RADIATOR FINS.....4523
CHECK AND REFILL AXLE OIL.....4524
CLEAN AXLE CASE BREATHER.....4524
LUBRlCATlNG.....4525
CLEAN CONDENSER OF AIR CONDITIONER.....4525
CHECK AIR CONDITIONER.....4526
CHECK LEVELS OF REFRIGERANT (GAS).....4526
CHECK AND REFILL WINDOW WASHING FLUID.....4527
REPLAClNG BUCKET TEETH.....4527
IF THE BUCKET EQUIPPED WITH BOLT-ON TOOTH.....4527
IF THE BUCKET EQUIPPED WITH TIP TOOTH.....4528
REVERSING AND REPLACING BOLT-ON CUTTING EDGE.....4528
IF THE BUCKET EQUIPPED WITH BOLT-ON CUTTING EDGE.....4528
ADJUSTMENT.....4529
ADJUSTING PARKING BRAKE.....4529
ADJUSTING LENGTH OF LEVER.....4530
TROUBLE SHOOTING GUIDE.....4531
ELECTRICAL SYSTEM.....4531
ENGINE.....4532
CHASSIS.....4533
TRANSMlSSlON.....4533
AXLE.....4533
DISC BRAKE.....4533
PARKING BRAKE.....4533
STEERING.....4534
SERVICE METER.....4534
MACHINE AND ENGINE SERIAL NUMBERS.....4535
FUEL, COOLANT AND LUBRICANTS.....4536
MEMORANDA.....4538
SAFETY AND OPERATION.....4539
SAFETY HINTS.....4540
OPERATION.....4540
GENERAL.....4540
CHECKING JOBSITE CONDITIONS.....4542
BEFORE STARTING OPERATION.....4543
CHECK BEFORE STARTING.....4543
PRECAUTIONS WHEN GETTING ON THE MACHINE.....4545
PRECAUTIONS WHEN STARTING THE ENGINE.....4545
CHECKS AFTER STARTING THE ENGINE.....4546
DURING OPERATION.....4546
ATTENTION TO SURROUNDINGS.....4547
RESTRICTIONS CREATED BY JOBSITE.....4549
PARKING.....4551
PRECAUTIONS FOR MAINTENANCE.....4552
GENERAL.....4552
BEFORE MAINTENANCE.....4554
DURING MAINTENANCE.....4555
MISCELLANEOUS.....4556
BUCKET OPERATION.....4557
EXCAVATION.....4557
LEVELING.....4560
LOAD AND CARRY OPERATIONS.....4560
LOADING.....4560
CROSS DRIVE LOADING.....4561
V-SHAPE LOADING.....4561
OPERATING THE AIR CONDITIONER.....4562
EQUIPMENT ON CONTROL PANEL.....4562
FAN SWITCH.....4562
AIR CONDITIONER SWITCH.....4562
AIR INTAKE SELECTOR LEVER.....4562
TEMPERATURE CONTROL LEVER.....4562
PRECAUTIONS FOR USING AIR CONDITIONER.....4563
HANDLING THE AIR CONDITIONER IN SEASON.....4564
HANDLING THE AIR CONDITIONER IN OFF-SEASONS.....4564
OPERATING CAB HEATER.....4564
EQUIPMENT ON CONTROL PANEL.....4564
FAN SWITCH.....4564
TEMPERATURE CONTROL LEVER.....4564
AIR INTAKE SELECTOR LEVER.....4564
LOCKING CAP.....4566
HANDLING OF BATTERY.....4567
PRECAUTIONS FOR CHARGING BATTERY.....4567
REMOVAL AND INSTALLATION OF BATTERY.....4567
STARTING ENGINE WITH A BOOSTER CABLE.....4568
TRANSPORTATION.....4569
STORAGE.....4570
BEFORE STORAGE.....4570
DURING STORAGE.....4570
AFTER STORAGE.....4570
COOLANT AND LUBRICANTS.....4571
SEBM015501 - Wheel Loader WA450-3 Shop Manual.....4574
CONTENTS.....4575
01 GENERAL.....4598
GENERAL ASSEMBLY DRAWING.....4599
SPECIFICATIONS .....4600
WEIGHT TABLE .....4603
LIST OF LUBRICANT AND WATER .....4605
10 STRUCTURE AND FUNCTION.....4607
POWER TRAIN .....4608
POWER TRAIN SYSTEM .....4609
TORQUE CONVERTER, TRANSMISSION PIPING .....4611
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM .....4612
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .....4613
TORQUE CONVERTER .....4614
TORQUE CONVERTER OIL FILTER .....4617
TRANSMISSION .....4618
TRANSMISSION CONTROL VALVE .....4629
PROPORTIONAL SOLENOID VALVE .....4644
ELECTRONIC CONTROL MODULATION VALVE .....4645
PILOT OIL FILTER .....4648
DRIVE SHAFT .....4649
AXLE .....4650
DIFFERENTIAL .....4652
FINAL DRIVE.....4656
AXLE MOUNT, CENTER HINGE PIN .....4657
STEERING PIPING .....4658
STEERING COLUMN .....4659
STEERING VALVE .....4660
ORBIT-ROLL VALVE .....4674
STOP VALVE .....4678
EMERGENCY STEERING PUMP .....4679
DIVERTER VALVE .....4680
BRAKE PIPING .....4683
BRAKE CIRCUIT DIAGRAM .....4685
BRAKE VALVE.....4687
CHARGE VALVE .....4692
ACCUMULATOR (FOR BRAKE) .....4696
SLACK ADJUSTER .....4697
BRAKE.....4700
PARKING BRAKE CONTROL .....4702
PARKING BRAKE .....4703
PARKING BRAKE SOLENOID VALVE .....4704
PARKING BRAKE VALVE .....4705
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE .....4706
HYDRAULIC PIPING .....4707
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM .....4709
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .....4710
WORK EQUIPMENT LEVER LINKAGE .....4712
HYDRAULIC TANK .....4713
PPC VALVE.....4715
PPC RELIEF VALVE .....4720
ACCUMULATOR (FOR PPC VALVE) .....4721
CUT-OFF VALVE .....4722
MAIN CONTROL VALVE .....4725
WORK EQUIPMENT LINKAGE .....4739
BUCKET .....4741
BUCKET POSITIONER AND BOOM KICK-OUT .....4742
ROPS CAB .....4748
HEATER AND DEFROSTER .....4749
AIR CONDITIONER (OPTION) .....4750
ELECTRIC CIRCUIT DIAGRAM.....4751
MACHINE MONITOR SYSTEM .....4756
MAIN MONITOR .....4757
MAINTENANCE MONITOR .....4762
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM .....4764
SENSORS .....4770
ENGINE STARTING CIRCUIT .....4775
ENGINE STOP CIRCUIT .....4776
PREHEATING CIRCUIT .....4777
ELECTRIC TRANSMISSION CONTROL .....4778
KICK-DOWN, HOLD SWITCH .....4781
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM .....4782
TRANSMISSION CUT-OFF SWITCH .....4786
TRANSMISSION CUT-OFF FUNCTION .....4787
ELECTRIC PARKING BRAKE CONTROL .....4789
20 TESTING AND ADJUSTING.....4801
STANDARD VALUE TABLE.....4802
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....4802
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.....4803
STANDARD VALUE TABLE FOR ELECTRICAL PARTS .....4806
TESTING AND ADJUSTING.....4809
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....4810
MEASURING ENGINE SPEED.....4811
MEASURING INTAKE AIR PRESSURE.....4812
ADJUSTING VALVE CLEARANCE.....4813
MEASURING EXHAUST GAS COLOR.....4814
MEASURING EXHAUST GAS TEMPERATURE.....4815
MEASURING BLOW-BY PRESSURE.....4816
MEASURING COMPRESSION PRESSURE.....4817
MEASURING ENGINE OIL PRESSURE.....4818
TESTING AND ADJUSTING FUEL INJECTION TIMING.....4819
ADJUSTING ENGINE STOP MOTOR CABLE.....4822
TESTING AND ADJUSTING FAN BELT TENSION.....4824
TESTING ACCELERATOR PEDAL.....4825
TESTING SPEED CONTROL LEVER.....4827
MEASURING STALL SPEED.....4828
MEASURING TORQUE CONVERTER, TRANSMISSION, AND PARKING BRAKE OIL PRESSURE.....4830
METHOD OF OPERATING EMERGENCY MANUAL SPOOL.....4832
TESTING AND ADJUSTING STEERING WHEEL.....4834
TESTING AND ADJUSTING STEERING CONTROL.....4837
TESTING AND ADJUSTING STEERING OIL PRESSURE.....4838
TESTING BRAKE PEDAL.....4840
TESTING BRAKE OIL PRESSURE.....4841
MEASURING BRAKE PERFORMANCE.....4842
MEASURING BRAKE DISC WEAR.....4843
BLEEDING AIR FROM BRAKE SYSTEM.....4844
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.....4845
MEASURING PARKING BRAKE PERFORMANCE.....4846
MANUAL RELEASE OF PARKING BRAKE.....4847
TESTING WEAR OF PARKING BRAKE DISC.....4848
TESTING WORK EQUIPMENT CONTROL LEVER.....4849
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE.....4851
TESTING WORK EQUIPMENT.....4855
TESTING AND ADJUSTING BUCKET POSITIONER.....4857
TESTING AND ADJUSTING BOOM KICK-OUT.....4858
ADJUSTING MAIN MONITOR.....4860
TESTING FUEL LEVEL SENSOR.....4861
TROUBLESHOOTING.....4862
POINTS TO REMEMBER WHEN TROUBLESHOOTING .....4863
SEQUENCE OF EVENTS IN TROUBLESHOOTING .....4864
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....4865
CHECKS BEFORE TROUBLESHOOTING .....4873
METHOD OF USING TROUBLESHOOTING CHARTS .....4874
CONNECTOR TYPES AND MOUNTING LOCATIONS .....4882
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....4889
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....4899
S-1 Starting performance is poor.....4900
S-2 Engine does not start.....4901
(1) Engine does not turn.....4901
(2) Engine turns but no exhaust gas comes out.....4902
(3) Exhaust gas comes out but engine does not start.....4903
S-3 Engine does not pick up smoothly.....4904
S-4 Engine stops during operations.....4905
S-5 Engine does not rotate smoothly.....4906
S-6 Engine lacks power.....4907
S-7 Exhaust gas is black.....4908
S-8 Oil consumption is excessive or exhaust gas is blue.....4909
S-9 Oil becomes contaminated quickly.....4910
S-10 Fuel consumption is excessive.....4911
S-11 Oil is in cooling water, or water spurts or water level goes down.....4912
S-12 Oil pressure lamp lights up.....4913
S-13 Oil level rises.....4914
S-14 Water temperature becomes too high.....4915
S-15 Abnormal noise is made.....4916
S-16 Vibration is excessive.....4917
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).....4918
