Komatsu Wheel Loader WA450 Repair Service Manual

Make: 
Model: 
Price: US$ 75.00

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

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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

 

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