Komatsu Wheel Loader WA180-1, WA180-1LC, WA180-3, WA180L-3 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader/Parallel Tool Carrier WA180-1, WA180-1LC, WA180-3, WA180L-3, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Komatsu Wheel Loader/Parallel Tool Carrier WA180-1, WA180-1LC, WA180-3, WA180L-3 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: 3,812 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBMW17020 - Wheel Loader WA180-1LC Shop Manual.pdf
CEBM001102 - Wheel Loader WA180-3, WA180L-3 Shop Manual.pdf
CEBM001900 - Parallel Tool Carrier WA180-3 Shop Manual.pdf
SEBM005802 - Wheel Loader WA180-3 Shop Manual.pdf
SEBMU4170105 - Wheel Loader WA180-1 Shop Manual.pdf
CEAM001301 - Wheel Loader WA180-3, WA180L-3 Operation & Maintenance Manual.pdf
CEAM002100 - Parallel Tool Carrier WA180-3 Operation & Maintenance Manual.pdf
CEAMW17021 - Wheel Loader WA180-1LC Operation & Maintenance Manual.pdf
SEAM007401 - Wheel Loader WA180-3 Operation & Maintenance Manual.pdf
SEAMU4170103 - Wheel Loader WA180-1 Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM001301 - Wheel Loader WA180-3, WA180L-3 Operation & Maintenance Manual...2
INTRODUCTION...5
1. FORWARD...6
2. SAFETY INFORMATION...7
3. INTRODUCTION...8
3.1 INTENDED USE...8
3.2 FEATURES...8
3.3 BREAKING IN A NEW MACHINE...8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
4.1 MACHINE SERIAL NO. PLATE POSITION...9
4.2 ENGINE SERIAL NO. PLATE POSITION...9
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
5. CONTENTS...10
SAFETY...15
6. GENERAL PRECAUTIONS...16
7. PRECAUTIONS DURING OPERATION...22
7.1 BEFORE STARTING ENGINE...22
7.2 AFTER STARTING ENGINE...25
7.3 TRANSPORTATION...34
7.4 BATTERY...35
7.5 TOWING...38
8. PRECAUTIONS FOR MAINTENANCE...39
8.1 BEFORE CARRYING OUT MAINTENANCE...39
8.2 DURING MAINTENANCE...44
8.3 TIRES...49
9. POSITION FOR ATTACHING SAFETY LABELS...51
9.1 POSITION FOR ATTACHING SAFETY LABELS...51
OPERATION...56
10. GENERAL VIEW...57
10.1 GENERAL VIEW OF MACHINE...57
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...58
11. EXPLANATION OF COMPONENTS...60
11.1 METER, LAMPS...60
11.2 SWITCHES...64
11.3 CONTROL LEVERS, PEDAL...70
11.4 CAP WITH LOCK...74
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...74
11.5 SAFETY BAR...74
11.6 TOWING PIN...75
11.7 GREASE PUMP CLAMP AND RUBBER RING...75
11.8 BACKUP ALARM...75
11.9 FUSE...76
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT...76
11.10 SLOW BLOW FUSE...77
11.11 STORAGE PLACE FOR THIS MANUAL...78
11.12 AUXILIARY POWER SOURCE...78
11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB...78
12. CHECK BEFORE STARTING ENGINE...79
12.1 WALK AROUND CHECK...79
12.2 CHECK BEFORE STARTING...82
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...82
12.2.2 CHECK FUEL LEVEL, ADD FUEL...82
12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...83
12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...83
12.2.5 CHECK DUST INDICATOR...84
12.2.6 CHECK ELECTRICAL WIRING...84
12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...85
12.2.8 CHECK EFFECT OF PARKING BRAKE...85
12.2.9 CHECK EFFECT OF WHEEL BRAKES...86
12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...86
12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...86
12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...86
12.2.13 CHECK OPERATIONS OF GAUGES...86
12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...86
12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...86
12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...86
12.3 ADJUSTMENT BEFORE OPERATION...87
12.3.1 OPERATOR'S SEAT...87
12.3.2 ADJUST SEAT BELT...89
12.3.3 ADJUST REAR VEIW MIRRORS...90
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...91
12.5 STARTING ENGINE...92
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...92
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...93
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...93
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...93
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...94
12.7 MOVING MACHINE OFF...95
12.8 CHANGING GEAR SPEED...97
12.9 CHANGING DIRECTION...97
12.10 TURNING...98
12.11 STOPPING MACHINE...99
12.12 OPERATION OF WORK EQUIPMENT...100
12.13 WORK POSSIBLE USING WHEEL LOADER...101
12.13.1 DIGGING OPERATIONS WITH ROCK PILES...101
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...102
12.13.3 LEVELING OPERATION...103
12.13.4 PUSHING OPERATIONS...103
12.13.5 LOAD AND CARRY OPERATIONS...103
12.13.6 LOADING OPERATIONS...104
12.14 PRECAUTIONS FOR OPERATION...105
12.14.1 PERMISSIBLE WATER DEPTH...105
12.14.2 IF WHEEL BRAKE DOES NOT WORK...105
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...105
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE...106
12.15 ADJUSTING WORK EQUIPMENT POSTURE...107
12.15.1 ADJUSTING BOOM KICKOUT...107
12.15.2 ADJUSTING BUCKET POSITIONER...108
12.15.3 BUCKET LEVEL INDICATOR...108
12.16 PARKING MACHINE...109
12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION...110
12.18 STOPPING ENGINE...110
12.19 CHECKS AFTER STOPPING ENGINE...111
12.20 LOCKING...111
REMARKS...111
12.21 HANDLING THE TIRES...112
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES...112
12.21.2 TIRE PRESSURE...112
13. TRANSPORTATION...114
13.1 LOADING, UNLOADING WORK...114
13.2 PRECAUTION FOR LOADING...115
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...115
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...116
13.3.2 WEIGHT LIST...116
13.3.3 LIFTING PROCEDURE...117
14. COLD WEATHER OPERATIONS...118
14.1 PRECAUTIONS FOR LOW TEMPERATURE...118
14.1.1 FUEL AND LUBRICANTS...118
14.1.2 COOLANT...118
14.1.3 BATTERY...119
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...120
14.3 AFTER COLD WEATHER...120
15. LONG TERM STORAGE...121
15.1 BEFORE STORAGE...121
15.2 DURING STORAGE...121
15.3 AFTER STORAGE...121
16. TROUBLESHOOTING...122
16.1 WHEN MACHINE RUNS OUT OF FUEL...122
16.2 TOWING THE MACHINE...123
16.2.1 WHEN ENGINE CAN BE USED...125
16.2.2 WHEN ENGINE CANNOT BE USED...125
16.3 IF BATTERY IS DISCHARGED...126
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...126
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...127
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...128
16.4 OTHER TROUBLE...130
16.4.1 ELECTRICAL SYSTEM...130
16.4.2 CHASSIS...131
16.4.3 ENGINE...134
MAINTENANCE...136
17. GUIDES TO MAINTENANCE...137
18. OUTLINES OF SERVICE...140
18.1 OUTLINE OF OIL, FUEL, COOLANT...140
18.1.1 OIL...140
18.1.2 FUEL...140
18.1.3 COOLANT...141
18.1.4 GREASE...142
18.1.5 STORING OIL AND FUEL...142
18.1.6 FILTERS...142
18.2 OUTLINE OF ELECTRIC SYSTEM...143
19. WEAR PARTS LIST...144
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...145
20.1 ENGINE OIL SPECIFICATIONS...146
20.2 DIESEL FUEL SPECIFICATIONS...147
20.3 COOLANT SPECIFICATIONS...148
21.STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...154
21.1 INTRODUCTION OF NECESSARY TOOLS...154
21.2 TORQUE LIST...155
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...157
23. MAINTENANCE SCHEDULE CHART...161
23.1 MAINTENANCE SCHEDULE CHART...161
24.SERVICE PROCEDURES...165
24.1 INITIAL 250 HOURS SERVICE...165
24.1.1 REPLACE FUEL FILTERS EVERY 500 HOURS SERVICE...165
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE...165
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE...165
24.2 WHEN REQUIRED...166
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...166
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...168
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL...169
24.2.4 CLEAN THE AXLE CASE BREATHER...170
24.2.5 CLEAN RADIATOR FINS...170
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...171
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...172
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...173
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...174
24.2.10 CHECK WINDOW WASHING FLUID...174
24.2.11 ADJUST PARKING BRAKE...175
24.2.12 REPLACE SLOW BLOW FUSE...176
24.2.13 CHECK AIR INTAKE HEATER...176
24.3 CHECK BEFORE STARTING...177
24.4 EVERY 50 HOURS SERVICE...178
24.4.1 CHECK THE TIRE INFLATION PRESSURE...178
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...178
24.5 EVERY 100 HOURS SERVICE...179
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...179
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...180
24.5.3 LUBRICATING...181
24.6 EVERY 250 HOURS SERVICE...182
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...182
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN...183
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...183
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...184
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...185
24.6.6 CHECK AIR INTAKE SYSTEM...185
24.6.7 LUBRICATING...186
24.7 EVERY 500 HOURS SERVICE...187
24.7.1 REPLACE FUEL FILTERS...187
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...189
24.7.3 LUBRICATE...190
24.8 EVERY 1000 HOURS SERVICE...191
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...191
24.8.2 CLEAN TRANSMISSION CASE BREATHER...192
24.8.3 LUBRICATE...193
24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...194
24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE...195
24.8.6 CHECK FAN BELT TENSION...196
24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...196
24.9 EVERY 2000 HOURS SERVICE...197
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...197
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...200
24.9.3 CHANGE AXLE OIL...200
24.9.4 CHECK BRAKE DISC WEAR...201
24.9.5 CHECK ALTERNATOR...201
24.9.6 CHECK STARTER MOTOR...201
24.9.7 CHECK VIBRATION DAMPER...201
24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...201
24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE...202
SPECIFICATIONS...205
25.SPECIFICATIONS...205
OPTIONS, ATTACHMENTS...208
26. AVAILABLE ATTACHMENTS...209
27. HEATER AND AIR CONDITIONING (IF EQUIPPED)...211
27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...211
27.2 COOL BOX COMPARTMENT...212
28.HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...213
28.1 STRUCTURE AND FUNCTION OF E.C.S.S...213
28.2 METHOD OF OPERATING E.C.S.S...214
28.3 PRECAUTIONS WHEN OPERATING E.C.S.S...214
28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...215
CEAM002100 - Parallel Tool Carrier WA180-3 Operation & Maintenance Manual...217
INTRODUCTION...220
1. FORWARD...221
2. SAFETY INFORMATION...222
3. INTRODUCTION...223
3.1 INTENDED USE...223
3.2 FEATURES...223
3.3 BREAKING IN A NEW MACHINE...223
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...224
4.1 MACHINE SERIAL NO. PLATE POSITION...224
4.2 ENGINE SERIAL NO. PLATE POSITION...224
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...224
5. CONTENTS...225
SAFETY...231
6. GENERAL PRECAUTIONS...232
7. PRECAUTIONS DURING OPERATION...238
7.1 BEFORE STARTING ENGINE...238
7.2 AFTER STARTING ENGINE...241
7.3 TRANSPORTATION...250
7.4 BATTERY...251
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
9. POSITION FOR ATTACHING SAFETY LABELS...267
9.1 POSITION FOR ATTACHING SAFETY LABELS...267
OPERATION...273
10. GENERAL VIEW...274
10.1 GENERAL VIEW OF MACHINE...274
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...275
11. EXPLANATION OF COMPONENTS...277
11.1 METER, LAMPS...277
11.2 SWITCHES...281
11.3 CONTROL LEVERS, PEDAL...287
11.4 CAP WITH LOCK...291
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...291
11.5 SAFETY BAR...291
11.6 TOWING PIN...292
11.7 GREASE PUMP CLAMP AND RUBBER RING...292
11.8 BACKUP ALARM...292
11.9 FUSE...293
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT...293
11.10 SLOW BLOW FUSE...294
11.11 STORAGE PLACE FOR THIS MANUAL...295
11.12 AUXILIARY POWER SOURCE...295
11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB...295
12. CHECK BEFORE STARTING ENGINE...296
12.1 WALK AROUND CHECK...296
12.2 CHECK BEFORE STARTING...299
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...299
12.2.2 CHECK FUEL LEVEL, ADD FUEL...299
12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...300
12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...300
12.2.5 CHECK DUST INDICATOR...301
12.2.6 CHECK ELECTRICAL WIRING...301
12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...302
12.2.8 CHECK EFFECT OF PARKING BRAKE...302
12.2.9 CHECK EFFECT OF WHEEL BRAKES...303
12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...303
12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...303
12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...303
12.2.13 CHECK OPERATIONS OF GAUGES...303
12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...303
12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...303
12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...303
12.3 ADJUSTMENT BEFORE OPERATION...304
12.3.1 OPERATOR'S SEAT...304
12.3.2 ADJUST SEAT BELT...306
12.3.3 ADJUST REAR VEIW MIRRORS...307
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...308
12.5 STARTING ENGINE...309
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...309
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...310
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...310
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...310
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...311
12.7 MOVING MACHINE OFF...312
12.8 CHANGING GEAR SPEED...314
12.9 CHANGING DIRECTION...314
12.10 TURNING...315
12.11 STOPPING MACHINE...316
12.12 OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL)...317
12.12.1 LIFT ARM OPERATION (LEVER)...317
12.12.2 BUCKET OPERATION (LEVER)...317
12.13 OPERATION OF WORK EQUIPMENT (WITH FORK TOOL)...318
12.13.1 LIFT ARM OPERATION (LEVER)...318
12.13.2 FORK OPERATION (LEVER)...318
12.14 OPERATION OF WORK EQUIPMENT (WITH MULTI- PURPOSE BUCKET TOOL)...319
12.14.1 LIFT ARM OPERATION (LEVER)...319
12.14.2 BUCKET OPERATION (LEVER)...319
12.14.3 AUXILIARY OPERATION (LEVER)...320
12.14.4 POSITION INDICATOR...320
12.15 OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)...322
12.15.1 LIFT ARM OPERATION (LEVER)...322
12.16 HYDRAULIC QUICK COUPLER...323
12.16.1 COUPLING THE ATTACHMENT...323
12.16.2 UNCOUPLING FROM THE ATTACHMENT...324
12.16.3 ATTACHMENTS REQUIRING HYDRAULIC POWER...325
12.17 WORK POSSIBLE USING PARALLEL TOOL CARRIER...326
12.17.1 DIGGING OPERATIONS WITH ROCK PILES...326
12.17.2 DIGGING OPERATIONS ON LEVEL GROUND...327
12.17.3 LEVELING OPERATION...328
12.17.4 PUSHING OPERATIONS...328
12.17.5 LOAD AND CARRY OPERATIONS...328
12.17.6 LOADING OPERATIONS...329
12.17.7 MULTI-PURPOSE BUCKET...330
12.17.8 PALLET FORKS...335
12.17.9 MATERIAL HANDLING ARM...338
12.18 PRECAUTIONS FOR OPERATION...339
12.18.1 PERMISSIBLE WATER DEPTH...339
12.18.2 IF WHEEL BRAKE DOES NOT WORK...339
12.18.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...339
12.18.4 PRECAUTIONS WHEN DRIVING MACHINE...340
12.19 ADJUSTING BOOM KICK-OUT POSITIONER...341
12.19.1 ADJUSTING BOOM KICK OUT...341
12.19.2 ADJUSTING BUCKET / FORK POSITIONER...342
12.20 PARKING MACHINE...343
12.21 CHECKS AFTER COMPLETION OF ENGINE OPERATION...344
12.22 STOPPING ENGINE...344
12.23 CHECKS AFTER STOPPING ENGINE...345
12.24 LOCKING...345
12.25 HANDLING THE TIRES...346
12.25.1 PRECAUTIONS WHEN HANDLING THE TIRES...346
12.25.2 TIRE PRESSURE...346
13. TRANSPORTATION...348
13.1 LOADING, UNLOADING WORK...348
13.2 PRECAUTION FOR LOADING...349
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...349
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...350
13.3.2 WEIGHT LIST...350
13.3.3 LIFTING PROCEDURE...351
14. COLD WEATHER OPERATIONS...352
14.1 PRECAUTIONS FOR LOW TEMPERATURE...352
14.1.1 FUEL AND LUBRICANTS...352
14.1.2 COOLANT...352
14.1.3 BATTERY...353
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...354
14.3 AFTER COLD WEATHER...354
15. LONG TERM STORAGE...355
15.1 BEFORE STORAGE...355
15.2 DURING STORAGE...355
15.3 AFTER STORAGE...355
16. TROUBLESHOOTING...356
16.1 WHEN MACHINE RUNS OUT OF FUEL...356
16.2 TOWING THE MACHINE...357
16.2.1 WHEN ENGINE CAN BE USED...359
16.2.2 WHEN ENGINE CANNOT BE USED...359
16.3 IF BATTERY IS DISCHARGED...360
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...360
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...361
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...362
16.4 OTHER TROUBLE...364
16.4.1 ELECTRICAL SYSTEM...364
16.4.2 CHASSIS...365
16.4.3 ENGINE...368
MAINTENANCE...371
17. GUIDES TO MAINTENANCE...372
18. OUTLINES OF SERVICE...375
18.1 OUTLINE OF OIL, FUEL, COOLANT...375
18.1.1 OIL...375
18.1.2 FUEL...375
18.1.3 COOLANT...376
18.1.4 GREASE...377
18.1.5 STORING OIL AND FUEL...377
18.1.6 FILTERS...377
18.2 OUTLINE OF ELECTRIC SYSTEM...378
19. WEAR PARTS LIST...379
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...380
20.1 ENGINE OIL SPECIFICATIONS...381
20.2 DIESEL FUEL SPECIFICATIONS...382
20.3 COOLANT SPECIFICATIONS...383
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...389
21.1 INTRODUCTION OF NECESSARY TOOLS...389
21.2 TORQUE LIST...390
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...392
23. MAINTENANCE SCHEDULE CHART...396
23.1 MAINTENANCE SCHEDULE CHART...396
24. SERVICE PROCEDURES...400
24.1 INITIAL 250 HOURS SERVICE...400
24.1.1 REPLACE FUEL FILTERS EVERY 500 HOURS SERVICE...400
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE...400
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE...400
24.2 WHEN REQUIRED...401
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...401
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...403
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL...404
24.2.4 CLEAN THE AXLE CASE BREATHER...405
24.2.5 CLEAN RADIATOR FINS...405
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...406
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...407
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...408
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...409
24.2.10 CHECK WINDOW WASHING FLUID...409
24.2.11 ADJUST PARKING BRAKE...410
24.2.12 REPLACE SLOW BLOW FUSE...411
24.2.13 CHECK AIR INTAKE HEATER...411
24.3 CHECK BEFORE STARTING...412
24.4 EVERY 50 HOURS SERVICE...413
24.4.1 CHECK THE TIRE INFLATION PRESSURE...413
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...413
24.5 EVERY 100 HOURS SERVICE...414
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...414
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...415
24.5.3 LUBRICATING...416
24.6 EVERY 250 HOURS SERVICE...417
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...417
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN...418
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...418
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...419
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...420
24.6.6 CHECK AIR INTAKE SYSTEM...420
24.6.7 LUBRICATING...421
24.7 EVERY 500 HOURS SERVICE...422
24.7.1 REPLACE FUEL FILTERS...422
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...424
24.7.3 LUBRICATE...425
24.8 EVERY 1000 HOURS SERVICE...426
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...426
24.8.2 CLEAN TRANSMISSION CASE BREATHER...427
24.8.3 LUBRICATE...428
24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...429
24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE After the first 1000 hours only thereafter evey 2000 hour intervals...430
24.8.6 CHECK FAN BELT TENSION...431
24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...431
24.9 EVERY 2000 HOURS SERVICE...432
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...432
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...435
24.9.3 CHANGE AXLE OIL...435
24.9.4 CHECK BRAKE DISC WEAR...436
24.9.5 CHECK ALTERNATOR...436
24.9.6 CHECK STARTER MOTOR...436
24.9.7 CHECK VIBRATION DAMPER...436
24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...436
24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE...437
SPECIFICATIONS...439
25. SPECIFICATIONS...440
OPTIONS, ATTACHMENTS...447
26. AVAILABLE ATTACHMENTS...448
27. SELECTING ATTACHMENTS AND TIRES...449
28. HEATER AND AIR CONDITIONING (IF EQUIPPED)...450
28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...450
28.2 COOL BOX COMPARTMENT...451
29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...452
29.1 STRUCTURE AND FUNCTION OF E.C.S.S...452
29.2 METHOD OF OPERATING E.C.S.S...453
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...453
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...454
CEAMW17021 - Wheel Loader WA180-1LC Operation & Maintenance Manual...456
FOREWORD...460
INTRODUCTION...461
SAFETY INFORMATION...461
BREAKING IN THE NEW MACHINE...462
MACHINE AND ENGINE SERIAL NUMBERS...463
QUICK REFERENCE INFORMATION...464
CONTENTS...465
SAFETY PRECAUTIONS -- SECTION 1...474
GENERAL PRECAUTIONS...475
PERSONNEL PRECAUTIONS...475
MACHINE PRECAUTIONS...475
OPERATION...476
BEFORE STARTING...476
START-UP...477
GENERAL OPERATING PRECAUTIONS...477
DRIVING THE MACHINE...478
OPERATING THE ATTACHMENTS...479
PULLING/TOWING...479
SHUTDOWN...480
MAINTENANCE...480
GENERAL MACHINE PRECAUTIONS...480
GENERAL WORK PRECAUTIONS...481
ATTACHMENTS...482
BRAKES...482
CAB/ROPS...482
COOLING...482
ELECTRICAL...483
ENGINE...483
FUEL SYSTEM...484
HYDRAULICS...484
TIRES AND RIMS...484
TURBOCHARGER...484
VITON SEALS...485
SAFETY PRODUCT GRAPHICS AND LOCATIONS...486
OPERATION -- SECTION 2...498
GENERAL VIEW...499
INSTRUMENTS AND CONTROLS...500
CLUSTER GAUGE...500
TORQUE CONVERTER OIL TEMPERATURE GAUGE...500
ENGINE COOLING WATER TEMPERATURE GUAGE...501
FUEL GAUGE...501
VOLTMETER...501
PILOT LAMPS, METERS...502
BRAKE OIL LEVEL PILOT LAMP...502
PARKING BRAKE PILOT LAMP...502
GROUND DRIVEN STEERING NORMAL PILOT LAMP (IF EQUIPPED)...503
GROUND DRIVEN STEERING PILOT LAMP (IF EQUIPPED)...503
TURN SIGNAL PILOT LAMP...503
SPEEDOMETER...503
WORKING PILOT LAMP...504
HIGH BEAM PILOT LAMP...504
SERVICE METER...504
SWITCHES...505
PARKING LAMP AND TRANSMISSION CUT-OFF SELECTOR SWITCH...505
WORKING LAMP AND CLUSTER GAUGE CHECK SWITCH...506
LAMP SWITCH...506
STARTING SWITCH...507
HORN BUTTON...507
ETHER START SWITCH...508
CAB DOME LAMP SWITCH...508
FRONT WIPER SWITCH...508
REAR WIPER SWITCH...508
PEDALS AND LEVERS...509
DIRECTIONAL LEVER...509
SPEED CONTROL LEVER...509
SAFETY LOCK (FOR DIRECTIONAL LEVER)...510
SPEED CONTROL LEVER STOPPER...510
TURN SIGNAL LEVER...510
ACCELERATOR PEDAL...510
BRAKE PEDALS...511
WORK EQUIPMENT CONTROL LEVER...512
WORK EQUIPMENT CONTROL LEVER LOCK...513
PARKING BRAKE LEVER...513
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED...513
FUSE BOX...514
FUSE BOX I...515
FUSE BOX II...515
OPERATOR'S SEAT...516
RIGID TYPE...516
FORWARD-BACKWARD ADJUSTMENT...516
SEAT HEIGHT ADJUSTMENT...516
BACKREST ADJUSTMENT...516
BUCKET TYPE SEAT (OPT)...516
FORWARD-BACKWARD ADJUSTMENT...516
SEAT ANGLE ADJUSTMENT...516
SEAT CUSHION ADJUSTMENT...516
BACKREST ADJUSTMENT...516
SEAT HEIGHT ADJUSTMENT...516
SEARS SEAT...517
FORWARD-BACKWARD ADJUSTMENT...517
SEAT ANGLE ADJUSTMENT...517
WEIGHT ADJUSTMENT...517
BACKREST TILT ADJUSTMENT...517
HEIGHT ADJUSTMENT...517
KAB SEAT...518
WEIGHT ADJUSTMENT...518
HEIGHT ADJUSTMENT...518
BACKREST ANGLE ADJUSTMENT...518
FORE AND AFT ADJUSTMENT...518
HEADREST ADJUSTMENT (IF EQUIPPED)...518
RIGHT SIDE ARMREST...518
SEAT BELT...519
ClGARETTE LIGHTER...520
AIR CLEANER SERVICE INDICATOR...520
FRAME LOCKING BAR...520
DRAWBAR PIN...521
CAB HEATER AND DEFROSTER...522
CONTROL PANEL...522
FAN SPEED SWITCH (1)...522
FOOT / DEFROSTER SELECT LEVER (2)...522
AIR INTAKE SELECTOR LEVER (3)...522
CONTROL PANEL...523
FAN SPEED SWITCH...523
TEMPERATURE CONTROL LEVER...523
AIR INTAKE SELECTOR LEVER...523
METHOD OF OPERATION...524
CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED...525
CONTROL PANEL...525
FAN SPEED SWITCH...525
AIR CONDITIONER SWITCH...525
TEMPERATURE CONTROL LEVER...525
AIR INTAKE SELECTOR LEVER...525
METHOD OF OPERATION...526
PRECAUTIONS FOR USING AIR CONDITIONER...527
HANDLING AIR CONDITIONER IN SEASON...527
HANDLING AIR CONDITIONER IN OFF-SEASONS...527
CHECK BEFORE STARTING...528
WALK-AROUND CHECK...528
CHECK AND REFILL COOLANT...528
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN...529
CHECK FUEL LEVEL AND REFILL FUEL...529
CHECK AIR CLEANER SERVICE INDICATOR...530
CHECK AND REFILL OF OIL IN BRAKE OIL TANK...530
ADDITIONAL CHECKS...531
CHECK ELECTRICAL WIRING...531
DRAIN THE WATER FROM PRIMARY FUEL FILTER/WATER SEPARATOR...531
OPERATING YOUR MACHINE...532
BEFORE STARTING THE ENGINE...532
STARTING ENGINE...533
SPECIAL STARTING...533
COLD WEATHER STARTING...534
CHECKS AFTER STARTING...536
COLD WEATHER WARM-UP PROCEDURE...536
MOVING MACHINE OFF...537
CHANGING GEAR SPEED...538
CHANGING DIRECTION...538
TURNING...539
TO STOP THE MACHINE...540
TO STOP THE ENGINE...541
OPERATIONS AFTER STOPPING ENGINE...541
OPERATIONAL PRECAUTIONS...542
WORKING IN DUSTY LOCATIONS...542
MAXIMUM DEPTH OF WATER...542
IF WHEEL BRAKE DOES NOT WORK...543
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...543
LOWER THE CENTER OF GRAVITY WHEN TURNING...543
BRAKING ON DOWNHILL SLOPES...543
IF ENGINE STOPS...543
POSSIBLE WORK USING LOADER...544
EXCAVATION...544
LEVELING...546
LOAD AND CARRY OPERATIONS...547
LOADING...547
Cross Drive Loading...547
V-Shape Loading...547
PARKING MACHINE...548
PRECAUTIONS WHEN TIRE CHAINS ARE FITTED...548
PROCEDURE FOR MOVING R.H. LADDER...548
PROCEDURE FOR MOVING L.H. LADDER...549
ADJUSTMENT OF WORK EQUIPMENT...550
ADJUSTING BOOM KICKOUT...550
ADJUSTING BUCKET POSITIONER...551
BUCKET LEVEL INDICATOR...551
HANDLING TIRES...552
PRECAUTIONS WHEN HANDLING TIRES...552
PRECAUTIONS WHEN DRIVING MACHINE...552
TIRE PRESSURE...552
TOWING...554
TOWING THE MACHINE...554
WHEN ENGINE CAN BE USED...554
WHEN ENGINE CANNOT BE USED...554
TRANSPORTATION...554
COLD WEATHER OPERATION...555
PREPARATION FOR LOW TEMPERATURE...555
FUEL AND LUBRICANTS...555
COOLANT...555
BATTERY...555
CAUTIONS AFTER COMPLETION OF WORK...555
AFTER COLD WEATHER...556
LONG TERM STORAGE...556
BEFORE STORAGE...556
DURING STORAGE...556
AFTER STORAGE...556
HANDLING OF BAlTERY...557
PRECAUTIONS FOR CHARGING BAlTERY...557
REMOVAL AND INSTALLATION OF BAlTERY...557
STARTING ENGINE WITH BOOSTER CABLES...557
BEFORE CONNECTING BOOSTER CABLES...557
CONNECTING BOOSTER CABLES...558
STARTING ENGINE...558
DISCONNECTING BOOSTER CABLES...558
TROUBLESHOOTING...559
ELECTRICAL SYSTEM...559
ENGINE...559
CHASSIS...560
TRANSMISSION...560
DRIVE AXLES...560
WHEEL BRAKES...560
PARKING BRAKE...560
STEERING...560
EQUIPMENT HYDRAULIC SYSTEM...560
MAINTENANCE -- SECTION 3...562
PERIODIC MAINTENANCE...563
MAINTENANCE GUIDELINES...563
OUTLINES OF SERVICE...564
LUBRICATION WHEN SHIPPED...564
RELATING TO ENGINE...565
ENGINE OIL...565
COOLANT...565
DIESEL FUEL...565
RELATING TO HYDRAULIC SYSTEM...565
RELATING TO ELECTRICAL SYSTEM...565
RELATING TO LUBRICATION...566
BLEEDING AIR...566
BLEEDING AIR FROM HYDRAULIC TANK...566
BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT...567
BLEEDING AIR FROM FUEL SYSTEM...568
WEAR PARTS REPLACEMENT...570
PERIODICAL PART REPLACEMENT...570
LUBRICANTS, FUEL AND COOLANT...571
PROPER SELECTION TABLE...571
ENGINE OIL...572
Normal Operation...572
Arctic Operation...572
AXLE OIL...573
GREASE...573
DIESEL FUEL...573
COOLANT...573
SCHEDULED MAINTENANCE GUIDE...580
OIL FILLER AND LEVEL GAUGE POSITIONS...584
INITIAL 250 HOURS SERVICE ONLY...585
TRANSMISSION OIL FILTER...585
WHEN REQUIRED...585
COOLANT ADDITIVE CONCENTRATION - DCA4...585
AIR CLEANER...585
CHECKING...585
CLEANING OR REPLACING OUTER ELEMENT...586
REPLACING INNER ELEMENT...586
CLEANING OUTER ELEMENT...587
TRANSMISSION OIL...588
RADIATOR CORE...588
WINDSHIELD WASHER TANKS...589
DRIVE AXLE OIL...589
DRIVE AXLE HOUSING BREATHERS...591
LUBRICATING...591
BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED...593
BUCKET TEETH - IF EQUIPPED...593
BUCKET IS EQUIPPED WITH BOLT-ON TEETH...593
BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH...594
PARKING BRAKE...595
INSPECTION...595
ADJUSTMENT...595
AIR CONDITIONER CONDENSER - IF EQUIPPED...596
AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED...596
STEERING...597
HYDRAULIC SYSTEM...597
SERVICE METER...597
CHECK BEFORE STARTING...598
EVERY 50 HOURS SERVICE...598
FUEL TANK...598
TIRES...598
EVERY 100 HOURS SERVICE...598
HYDRAULIC TANK...598
LUBRICATING...599
CAB AIR FILTER - IF EQUIPPED...600
EVERY 250 HOURS SERVICE...601
LUBRICATING...601
WHEEL HUB BOLTS...603
ENGINE OIL PAN AND FILTER...604
BATTERY ELECTROLYTE...605
AIR INTAKE SYSTEM...606
AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED...606
EVERY 500 HOURS SERVICE...607
LUBRICATING...607
FUEL FILTERS...608
GENERAL...608
REPLACEMENT...608
TRANSMISSION OIL FILTER...610
ANTIFREEZE CONCENTRATION...610
AIR DRYER - IF EQUIPPED...610
EVERY 1000 HOURS SERVICE...611
LUBRICATING...611
HYDRAULIC TANK AND FILTER...613
TRANSMISSION CASE BREATHER...614
TRANSMISSION OIL AND STRAINER...614
ENGINE VALVES...615
DRIVE BELT...618
DRIVE BELT, TENSIONER BEARING AND FAN HUB...618
EVERY 2000 HOURS SERVICE...619
DRIVE AXLES...619
HYDRAULIC TANK BREATHER...621
BRAKE DISC...621
VIBRATION DAMPER...621
COOLING SYSTEM...622
SPECIFICATIONS -- SECTION 4...624
GENERAL SPECIFICATIONS...625
STANDARD TIGHTENING TORQUES...630
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...630
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...630
TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS...631
UNIT CONVERSIONS...632
AREA...633
DENSITY (Mass Density)...633
FORCE...634
FORCE PER LENGTH...634
HEAT...634
LENGTH...635
MASS (WEIGHT)...635
POWER...636
PRESSURE...636
TEMPERATURE...636
TEMPERATURE INTERVAL OR TOLERANCE...637
VOLUME...637
TORQUE...638
VELOCITY...638
CEBM001102 - Wheel Loader WA180-3, WA180L-3 Shop Manual...641
CEBM001900 - Parallel Tool Carrier WA180-3 Shop Manual...1223
CEBMW17020 - Wheel Loader WA180-1LC Shop Manual...1856
CONTENTS...1860
10 ENGINE...1878
11 STRUCTURE AND FUNCTION...1878
ENGINE MOUNTING...1879
RADIATOR AND OIL COOLER...1880
FUEL TANK AND PIPING...1881
ENGINE CONTROL...1882
12 TESTING AND ADJUSTING...1884
STANDARD VALUE TABLE...1885
SERVICE TOOL LIST...1887
SAFETY PRECAUTIONS...1888
EXHAUST GAS COLOR...1889
ACCELERATOR PEDAL OPERATING FORCE AND ANGLE...1890
OPERATING FORCE...1890
OPERATING ANGLE...1891
13 DISASSEMBLY AND ASSEMBLY...1894
CRANKING MOTOR...1895
REMOVAL...1895
INSTALLATION...1895
ALTERNATOR...1896
REMOVAL...1896
INSTALLATION...1896
OIL COOLER...1897
REMOVAL...1897
INSTALLATION...1898
WATER PUMP...1899
REMOVAL...1899
INSTALLATION...1900
FUEL INJECTORS...1901
REMOVAL...1901
INSTALLATION...1903
TURBOCHARGER...1905
REMOVAL...1905
INSTALLATION...1907
CYLINDER HEAD...1909
REMOVAL...1909
INSTALLATION...1912
RADIATOR...1915
REMOVAL...1915
INSTALLATION...1918
ENGINE...1922
REMOVAL...1922
INSTALLATION...1929
FUEL TANK...1937
REMOVAL...1937
INSTALLATION...1938
20 POWER TRAIN...1940
21 STRUCTURE AND FUNCTION...1940
GENERAL...1943
HYDRAULIC CIRCUIT FOR POWER TRAIN...1945
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...1946
FORWARD FIRST...1947
TORQUE CONVERTER AND TRANSMISSION PIPING...1949
TORQUE CONVERTER CHARGING PUMP...1950
OUTLINE...1950
SPECIFICATIONS...1950
TORQUE CONVERTER...1951
SPECIFICATIONS...1951
OUTLINE...1952
FLOW OF MOTIVE FORCE...1952
FLOW OF OIL...1952
TORQUE CONVERTER OIL FILTER...1953
OPERATION...1953
TORQUE CONVERTER OIL COOLER...1955
OUTLINE...1955
TRANSMISSION...1956
OUTLINE...1958
CLUTCH SHAFTS...1958
FORWARD AND REVERSE CLUTCHES...1958
FIRST GEAR CLUTCH...1959
SECOND AND THIRD GEAR CLUTCH...1959
OPERATION OF CLUTCH...1960
WHEN ENGAGED...1960
WHEN DISENGAGED...1960
FORWARD FIRST...1961
OPERATION...1962
REVERSE FIRST...1963
OPERATION...1964
TRANSMISSION CONTROL VALVE...1965
MAIN REGULATOR VALVE...1967
FUNCTION...1967
OPERATION...1967
TORQUE CONVERTER OIL OUTLET VALVE...1968
FUNCTION...1968
OPERATION...1968
QUICK RETURN VALVE AND ACCUMULATOR...1969
FUNCTION...1969
Quick Return Valve...1969
Accumulator...1969
OPERATION...1969
When Clutch Is Engaged...1969
Immediately After Gear Shifting...1969
POWER MODULATING FUNCTION...1971
FUNCTION...1971
CLUTCH CUT-OFF VALVE...1975
OPERATION...1975
DRIVE SHAFTS...1977
OUTLINE...1977
AXLES...1979
FRONT...1979
REAR...1980
DIFFERENTIALS...1981
FRONT...1981
REAR...1982
TORQUE PROPORTIONING DIFFERENTIAL...1983
OUTLINE...1983
FUNCTION...1984
OPERATION...1984
FINAL DRIVES...1985
OUTLINE...1985
AXLE MOUNTING...1987
FRONT AXLE...1988
REAR AXLE...1988
TIRES AND WHEELS...1989
THREE PIECE WHEEL...1989
ONE PIECE WHEEL...1990
SPECIFICATIONS...1991
22 TESTING AND ADJUSTING...1992
STANDARD VALUE TABLE...1993
SERVICE TOOL LIST...1995
SAFETY PRECAUTIONS...1995
ENGINE STALL SPEEDS...1997
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES...1999
TRANSMISSION SHIFT LEVERS...2001
TRANSMISSION CONTROL VALVE SPOOLS...2002
TROUBLESHOOTING...2004
PRECAUTIONS...2005
METHOD OF READING TROUBLESHOOTING TABLE...2007
PREVENTING RECURRENCE OF TROUBLE...2009
CHECKS BEFORE TROUBLESHOOTING...2010
TROUBLESHOOTING TABLE...2011
TORQUE CONVERTER AND TRANSMISSION...2011
1. Machine does not move off...2011
2. Machine speed is low, thrust is weak, gradeability falls off...2013
3. Large shock when off or changing gear...2015
4. Large time lag when moving off or changing gear...2016
5. Oil temperature in torque converter is high...2017
23 DISASSEMBLY AND ASSEMBLY...2018
TORQUE CONVERTER CHARGING PUMP...2020
REMOVAL...2020
INSTALLATION...2020
TORQUE CONVERTER TRANSMISSION...2021
REMOVAL...2021
INSTALLATION...2028
TORQUE CONVERTER...2035
DISASSEMBLY...2035
ASSEMBLY...2038
TRANSMISSION...2041
DISASSEMBLY...2041
ASSEMBLY...2048
FORWARD REVERSE CLUTCH PACKS...2059
DISASSEMBLY...2059
ASSEMBLY...2062
FIRST SPEED CLUTCH PACK...2067
DISASSEMBLY...2067
ASSEMBLY...2069
SECOND AND THIRD SPEED CLUTCH PACKS...2072
DISASSEMBLY...2072
ASSEMBLY...2074
TRANSMISSION CONTROL VALVE...2079
REMOVAL...2079
INSTALLATION...2081
DISASSEMBLY...2085
ASSEMBLY...2089
DRIVE SHAFT...2095
DISASSEMBLY...2095
ASSEMBLY...2097
FRONT AXLE...2099
REMOVAL...2099
INSTALLATION...2101
REAR AXLE...2103
REMOVAL...2103
INSTALLATION...2107
DIFFERENTIAL...2112
DISASSEMBLY...2112
ASSEMBLY...2116
AXLE HOUSING...2126
DISASSEMBLY...2126
ASSEMBLY...2132
24 MAINTENANCE STANDARD...2138
TRANSMISSION AND ENGINE MOUNT...2139
TORQUE CONVERTER CHARGING PUMP...2141
TORQUE CONVERTER...2142
TRANSMISSION...2143
TRANSMISSION CLUTCH ASSEMBLY...2145
FORWARD-REVERSE CLUTCH ASSEMBLY...2145
1ST CLUTCH ASSEMBLY...2145
2ND, 3RD CLUTCH ASSEMBLY...2145
TRANSMISSION CONTROL VALVE...2147
AXLE...2149
DIFFERENTIAL...2151
FINAL DRIVE...2153
DRIVE SHAFT...2154
AXLE MOUNT...2155
40 STEERING SYSTEM...2158
41 STRUCTURE AND FUNCTION...2158
GENERAL...2159
HYDRAULIC CIRCUIT FOR STEERING...2160
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...2161
STEERING VALVE...2162
CONNECTION OF HAND PUMP AND SLEEVE...2168
PRIORITY VALVE...2170
STEERING CYLINDER...2173
CENTER HINGE PIN...2174
42 TESTING AND ADJUSTING...2176
STANDARD VALUE TABLE...2177
SERVICE TOOL LIST...2177
STEERING WHEEL PLAY...2178
OPERATING FORCE OF STEERING WHEEL...2179
OPERATING TIME OF STEERING WHEEL...2180
STEERING OIL PRESSURE...2181
TROUBLESHOOTING...2182
TROUBLESHOOTING TABLE...2183
STEERING CIRCUIT...2183
1. Steering wheel does not turn...2183
2. Steering wheel is sluggish...2184
3. Steering wheel moves unsteadily or is subjected to large shock...2185
4. Machine tends to turn naturally in one particular direction when traveling...2185
5. Left and right turning radii are different...2185
43 DISASSEMBLY AND ASSEMBLY...2186
STEERING VALVE...2187
REMOVAL...2187
INSTALLATION...2188
DISASSEMBLY...2189
ASSEMBLY...2192
STEERING RELIEF VALVE...2197
REMOVAL AND DISASSEMBLY...2197
ASSEMBLY AND INSTALLATION...2198
PRIORITY VALVE...2199
