Noticeofrevision
9threvision
Theaffectedpagesareindicatedbytheuseofthe followingmarks.Itisrequestedthatnecessaryactionsmustbetakentothesepagesaccordingtothe listbelow.
Listofrevisedpages
MarkPageRevision number
q 1(09) 2(08) q 3(09) q 4(09) q 5(09) q 6(09) q 7(09) q 8(09) q 9(09) q 10(09)
00-1(01)
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00-11(07) 00-12(07)
00-13(07) 00-14(07) 00-14-1(07) 00-14-2(07) q00-15(09) 00-16
00-17 q00-18(09) 00-19 00-20 00-21 00-22
MarkPageRevision number
2022/10
MarkIndicationActionrequired QPagetobenewlyaddedAdd qPagetobereplacedReplace ()PagetobedeletedDiscard
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10-76(05) 10-77 10-78 10-79 10-80 10-81(06) 10-82(05) 10-83(06) 10-84
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10-85 10-86 10-87 10-88 10-89 10-90 10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112 10-113 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-121 10-122 10-123 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132 10-133 10-134 10-135 10-136
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q30-95(09) q30-96(09)
q30-97(09) q30-98(09) (30-99) (30-100)
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q50-167(09)
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q50-170(09)
q50-171(09)
q50-172(09) q50-173(09)
q50-174(09)
q50-175(09)
Q50-175-1(09)
Q50-175-2(09)
50-176(04)
50-177 50-178
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80-1(01)
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80-4(01) 80-5(01)
80-6(01) 80-7(01)
80-8(01)
80-9(01) 80-10(01)
80-11(01) 80-12(01)
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80-38(01)
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80-40(01)
80-41(01)
80-42(01)
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80-45(01)
80-46(01)
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90-1
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90-41(07)
90-43(07)
90-45(07)
90-47(07) 1(07) 2(07) 3(07) 4(07) 5(07) 6(07) 7(07) 8(07) 9(07) qColophon(09)
00Indexandforeword
Tableofcontents1
00Indexandforeword
Tableofcontents..................................................................................................................................00-2
Forewordandgeneralinformation.....................................................................................................00-15
Safetynotice...................................................................................................................................00-15
Howtoreadtheshopmanual.........................................................................................................00-20
Explanationoftermsformaintenancestandard.............................................................................00-22
Handlingofelectricequipmentandhydrauliccomponent..............................................................00-24
Handlingofconnectorsnewlyusedforengines.............................................................................00-33
Howtoreadelectricwirecode........................................................................................................00-36
Precautionswhencarryingoutoperation........................................................................................00-39
Methodofdisassemblingandconnectingpush-pulltypecoupler...................................................00-42
Standardtighteningtorquetable.....................................................................................................00-45
Conversiontable.............................................................................................................................00-49
01Specification
Specificationandtechnicaldata....................................................................................................01-3
Specificationdimensiondrawing.................................................................................................01-3
Specifications..............................................................................................................................01-4
Weighttable................................................................................................................................01-8
Tableoffuel,coolantandlubricants...........................................................................................01-10
10Structure,functionandmaintenancestandard
Engineandcoolingsystem............................................................................................................10-4
Enginemountandtransmissionmount.......................................................................................10-4
Coolingsystem...........................................................................................................................10-5
Coolingfanpump........................................................................................................................10-6
Coolingfanmotor........................................................................................................................10-14
Powertrain.....................................................................................................................................10-21
Powertrain..................................................................................................................................10-21
Powertrainsystemdiagram.......................................................................................................10-22
Driveshaft...................................................................................................................................10-24
Powertrainpipingdiagram.........................................................................................................10-25
Torqueconverter.........................................................................................................................10-26
Transmission...............................................................................................................................10-34
Transmissioncontrolvalve.........................................................................................................10-52
ECMV..........................................................................................................................................10-56
Mainreliefvalveandtorqueconverterreliefvalve......................................................................10-68
Axle.............................................................................................................................................10-70
Differential...................................................................................................................................10-74
Limitedslipdifferential................................................................................................................10-79
Finaldrive...................................................................................................................................10-86
Steeringsystem.............................................................................................................................10-92
Steeringcomponentlayoutdrawing............................................................................................10-92
Steeringcolumn..........................................................................................................................10-93
Steeringpump.............................................................................................................................10-94
Steeringvalve.............................................................................................................................10-107
Orbit-rollvalve.............................................................................................................................10-124
Stopvalve...................................................................................................................................10-132
Steeringreliefvalve....................................................................................................................10-133
Steeringcylinder.........................................................................................................................10-134
Emergencysteeringmotor..........................................................................................................10-136
Emergencysteeringpump..........................................................................................................10-137
00-2WA470-6R,WA480-6R
Joysticksteeringleverlinkage....................................................................................................10-138
Electricalsteeringlever...............................................................................................................10-139
JoystickEPCvalve.....................................................................................................................10-140
Brakesystem.................................................................................................................................10-142
Brakecomponentlayoutdrawing...............................................................................................10-142
Componentlayoutofbrakecoolingsystem.............................................................................10-142-1
Brakecoolingcontrolsystem...................................................................................................10-142-2
Chargevalve...............................................................................................................................10-143
Brakevalve.................................................................................................................................10-150
Accumulator(forbrake)..............................................................................................................10-155
Slackadjuster.............................................................................................................................10-156
Brake..........................................................................................................................................10-158
Parkingbrakecontrol..................................................................................................................10-163
Parkingbrake..............................................................................................................................10-164
Parkingbrakesolenoidvalve......................................................................................................10-166
Emergencyparkingbrakereleasevalve.....................................................................................10-168
Brakecoolingoilcooler...............................................................................................................10-169
Brakecoolingpumpmotor......................................................................................................10-169-1
Brakecoolingfan....................................................................................................................10-169-2
Undercarriageandframe...............................................................................................................10-170
Axlemountandcenterhingepin................................................................................................10-170
Tires............................................................................................................................................10-174
Hydraulicsystem...........................................................................................................................10-176
Hydrauliccomponentlayoutdrawing..........................................................................................10-176
Workequipmentcontrolleverlinkage.........................................................................................10-179
Hydraulictank.............................................................................................................................10-182
Powertrainpump........................................................................................................................10-184
Workequipmentpump................................................................................................................10-186
Workequipmentcontrolvalve....................................................................................................10-206
CLSS..........................................................................................................................................10-217
Eachfunctionandoperationofeachvalve.................................................................................10-222
PPCvalve...................................................................................................................................10-236
Accumulator(forPPCcircuit).....................................................................................................10-244
Accumulator(forpowertraincircuit)...........................................................................................10-245
Accumulator(forECSS).............................................................................................................10-246
WorkequipmentPPCcut-offsolenoidvalve..............................................................................10-247
Workequipment.............................................................................................................................10-250
Workequipmentlinkage.............................................................................................................10-250
Bucket.........................................................................................................................................10-253
Bucketpositionerandboomkick-out..........................................................................................10-254
Workequipmentcylinder............................................................................................................10-260
Cabanditsattachments................................................................................................................10-261 Cab.............................................................................................................................................10-261
Airconditioner.............................................................................................................................10-262
Electricalsystem............................................................................................................................10-280 Machinemonitorsystem.............................................................................................................10-280 Machinemonitor.........................................................................................................................10-284
Electricalsystem(Transmissioncontrollersystem)....................................................................10-316
Transmissioncontroller...............................................................................................................10-356
Electricalsystem(Workequipmentcontrollersystem)...............................................................10-358
Workequipmentcontroller..........................................................................................................10-364
Electrictransmissioncontrol.......................................................................................................10-366
Kickdownswitchandholdswitch................................................................................................10-370
Loadmetercancelswitchandloadmetersubtotalswitch..........................................................10-370
WA470-6R,WA480-6R00-3 (07)
Multi-functionknob......................................................................................................................10-371
Joysticksteeringknob.................................................................................................................10-372
KOMTRAXsystem......................................................................................................................10-374
Enginestartingcircuit..................................................................................................................10-376
Enginestoppingcircuit................................................................................................................10-378
Preheatingcircuit........................................................................................................................10-379
Enginepowermodeselectorcircuit............................................................................................10-380
Engineoutputderatingfunction..................................................................................................10-381
Automaticwarm-upfunction.......................................................................................................10-381
Parkingbrakecircuit...................................................................................................................10-382
Sensor.........................................................................................................................................10-384
20Standardvaluetable
Standardservicevaluetable..........................................................................................................20-3
Standardvaluetableforengine..................................................................................................20-3
Standardvaluetableforchassis.................................................................................................20-4
30Testingandadjusting
Relatedinformationontestingandadjusting.................................................................................30-4
Toolsfortesting,adjusting,andtroubleshooting........................................................................30-4
Testingenginespeed..................................................................................................................30-9
Engineandcoolingsystem............................................................................................................30-9
Testingexhaustgascolor...........................................................................................................30-11
Testingexhausttemperature......................................................................................................30-13
Adjustingvalveclearance...........................................................................................................30-15
Testingcompressionpressure....................................................................................................30-17
Testingblow-bypressure............................................................................................................30-18
Testingengineoilpressure.........................................................................................................30-19
Testingintakeair(boost)pressure.............................................................................................30-20
Handlingfuelsystemequipment.................................................................................................30-21
Releasingresidualpressureinfuelsystem................................................................................30-21
Testingfuelpressure..................................................................................................................30-22
Testingfuelreturnandleakamount...........................................................................................30-23
Bleedingairfromfuelcircuit........................................................................................................30-26
Testingfuelcircuitforleakage....................................................................................................30-28
Handlingofreducedcylindermodeoperation............................................................................30-29
Handlingofnoinjectioncrankingoperation................................................................................30-29
Handlingofcontrollervoltagecircuit...........................................................................................30-30
Checkofmufflerandmufflerstackforloosenessanddamage..................................................30-31
Checkofmufflerfunction............................................................................................................30-31
Checkofinstalledconditionofcylinderheadandmanifolds......................................................30-32
Checkofenginepipingfordamageandlooseness....................................................................30-32
Testingandadjustingairconditionercompressorbelttension...................................................30-33
Testingandadjustingalternatorbelttension..............................................................................30-34
Powertrain.....................................................................................................................................30-35
Adjustingtransmissionspeedsensor.........................................................................................30-35
Adjustingdirectionalleverlength................................................................................................30-36
Adjustinggearshiftleverlength..................................................................................................30-36
TestingFNRleverandgearshiftlever.......................................................................................30-37
Testingandadjustingpowertrainoilpressure...........................................................................30-38
Procedureforflushingtorqueconverterandtransmissionhydrauliccircuit................................30-52
Methodofmovingmachinewhentransmissionvalveisbroken.................................................30-54
Checkofaxlefinaldriveforoilleakage......................................................................................30-57
Checkofdriveshaftsforlooseness,playanddamage..............................................................30-57