Day: June 16, 2025

---

INSTANT DOWNLOAD

---

Complete service workshop service manual contains service, maintenance, and troubleshooting information for the Porsche Cayenne (955/957/958) 2003-2016. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Porsche Cayenne (955/957/958) 2003-2016 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

FILE LIST (2.1 GB PDF):
Cayenne V8 4.5 L 2004 Service & Repair Manual.pdf
Cayenne Repair Manual 2010-
Cayenne Repair Manual 2004-
Cayenne II (92A) Service & Repair Manual.pdf
Cayenne I (9PA) Service & Repair Manual.pdf

2003-2008 ENGINE Cylinder Head, Valve Drive
2003-2008 ENGINE Cylinder Head, Valve Drive
15 03 21 REMOVING CAMSHAFT HOUSING – AS OF MY 2003, UNTIL MY
2004 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO)
PRELIMINARY WORK
Preliminary work for removing camshaft housing
1. Remove engine. Refer to 10 01 19 Removing and installing V8 4.5 l engine – as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan).
2. Remove intake-air distributor. Refer to 24 46 01 Checking the intake-air distributor for leaks – as of MY2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan).
3. Pull off the cable plug on the camshaft sensor.
4. Turbocharged engine (M48/50): Remove oil feed line from camshaft housing. To do this, unscrew union nut.
5. Turbocharged engine (M48/50): Remove sheetmetal bracket for turbocharger.
6. Unscrew ground connection.
7. Remove cover for camshaft housing. –> 15 91 21 Removing cover for camshaft housing – “Removing”
8. Remove timing case cover. –> 15 33 21 Removing chain case lid – as of MY 2004 (Cayenne TIP,
9. Remove camshafts. –> 150521 Removing camshafts
10. Remove flat-base tappets and put down in accordance with installation position. –> Removing and installing flat-base tappets
REMOVING CAMSHAFT HOUSING
Removing the camshaft housing
…

Porsche Cayenne I (9PA) Servie Repair Manual & Wiring Diagram….2
00. GENERAL….0
0. GENERAL….0
0.SALES CHECK….2
1 Maintenace self- diagnostic….49
01.ENGINE V8 4.5 l….142
1.ENGINE….142
1.CRANKCASE,SUSPENSION….142
2.CRANKSHAFT,PISTONS….358
3.CYLINDER HEAD,VALVE DRIVE….434
4.LUBRICATION….636
5.COOLING….720
02.ENGINE V8 S TYPE AND TURBO….807
02.Engine….807
1.Crankase,suspension….807
2.Crankshaft,pistons….1013
3.Cylinder head,valve drive….1085
4.Cooling….1278
03.Engine V8 4.5 l-Petrol,Exhaust,Electric….1361
2.ENGINE….1361
1.FUEL ACTUATION….1361
2.FUEL SYSTEM,ELECTRONIC INJECTION….1458
3.EXHAUST SYSTEM….1541
4.STARTER,POWER SUPPLY,CRUISE CONTROL….1605
5.IGNITION SYSTEM….1668
04.Engine-Petrol,Exhaust,Electric S TYPE AND TURBO….1700
03.Engine-Petrol,Exhaust,Electric….1700
1.Fuel,actuation….1700
2.Fuel system,Electronic injection….1794
3.Exhaust system….1875
4.Starter,Power supply,Cruise control….1937
5.Ignition system….1997
05.AUTOMATIC TRANSMISSION….2027
3.TRANSMISSION….2027
1.TORQUE CONVERTER….2027
2.AUTOMATIC TRANSMISSION-ACTUATION,ASS,HOUSING….2037
3.AUTOMATIC TRANSMISSION-GEARS,CONTROL….2147
4.FINAL DRIVE,DIFFERENTIAL,DIFFERNTIAL LOCK….2184
06. MANUAL TRANSMISSION….2342
04.MANUAL TRANSMISSION….2342
1.CLUTCH CONTROL….2342
2.ACTUATION,ASS. HOUSING….2378
3.GEARS,SHAFTS,INT. GEARSH…2428
4.FINAL DRIVE,DIFFERENTIAL,DIFFERENTIAL LOCK….2439
07.CHASSIS….2594
4.CHASSIS….2594
1.FRONT WHEEL SUSPENSION,DRIVE SHAFT….2594
2.REAR WHEEL,SUSPENSION DRIVE SHAFTS….2772
3.LEVEL CONTROL….2874
4.ANTI LOCK BRAKE SYSTEM….2957
5.BRAKES BRAKE MECHANICS….2983
6.BRAKES-HYDRAULICS ,REGULATOR,BOOSTER….3130
7.STEERING….3162
08.BODY….3236
5.BODY….3236
1.BODY FRONT….3236
2.BODY CENTER,FRAME ,ROOF….3484
3.BODY REAR….3566
4.LIDS,FLAPS….3618
5.DOOR FRONT,CENTRAL LOCKING SYSTEM….3795
6.DOOR REAR,CENTRAL LOCKING SYSTEM….3929
09.BODY OUTSIDE EQUIPMENT….4044
6.BODY OUTSIDE EQUIPMENT….4044
1.SLIDING ROOF….4044
2.BUMPERS….4167
3.GLAZING,WINDOW CONTROL….4234
4.EXTERIOR EQUIPMENT….4355
5.INTERIOR EQUIPMENT….4582
6.PASSENGER PROTECTION….4725
10.BODY-EQUIPMENT INSIDE….4856
7.BODY-EQUIPMENT INSIDE….4856
1LININGS,INSULATION….4856
2.SEAT,FRAMES….5161
3.SEAT ULPHOSTERIES,COVER….5271
11. Air Conditioning….5421
8 Air Conditioning….5421
80 Heating….5421
82 Auxiliary Heater….5435
85 Ventilation….5517
87 Air Conditioning….5558
88 Auxiliary air-conditioning system….5710
12 Electrical….5786
9 Electrical….5786
90 Instruments,alarm system….5786
91 Radio,telephone, on- board computer, navigation….5833
92 Windshield wiper and washer system….6034
94 Lights,lamp,switches exterior….6114
96 Lihhts, lamp,Switches interior,theft protection….6253
97 Wiring….6360
Porsche Cayenne II (92A) Servie Repair Manual & Wiring Diagram….6766
Porsche Cayenne….6766
General Information….6766
01 – SALES CHECK….6766
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,….6766
CAYENNE (3.0), CAYENNE GTS, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6766
TURBO & CAYENNE TURBO S > TOOLS….6766
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,….6766
CAYENNE (3.0), CAYENNE GTS, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6766
TURBO & CAYENNE TURBO S > TECHNICAL VALUES….6766
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,….6766
CAYENNE (3.0), CAYENNE GTS, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6766
TURBO & CAYENNE TURBO S > INFORMATION > PERFORMING VEHICLE….6766
HANDOVER….6766
WM 010100 SALES CHECK (CAYENNE TIP, CAYENNE TIP (3.0), CAYENNE S,….6768
CAYENNE TURBO & CAYENNE S HYBRID) > SALES CHECK….6768
09 – PORSCHE SYSTEM COMPONENTS….6771
WM 0940IN PORSCHE UNIVERSAL CHARGER (AC) (HIGH-VOLTAGE CHARGING….6771
CABLE) DIAGNOSTICS (FAULT CODES) (CAYENNE S E-HYBRID) > INFORMATION >….6771
GENERAL INFORMATION….6771
WM 0940IN PORSCHE UNIVERSAL CHARGER (AC) (HIGH-VOLTAGE CHARGING….6772
CABLE) DIAGNOSTICS (FAULT CODES) (CAYENNE S E-HYBRID) > FAULT….6772
DESCRIPTION FOR UNIVERSAL CHARGER CONTROL UNIT….6772
WM 0940IN UPDATING SOFTWARE FOR PORSCHE UNIVERSAL CHARGER (AC)….6779
(HIGH-VOLTAGE CHARGING CABLE)/RESETTING PIN (CAYENNE S E-HYBRID) >….6779
TOOLS….6779
WM 0940IN UPDATING SOFTWARE FOR PORSCHE UNIVERSAL CHARGER (AC)….6779
(HIGH-VOLTAGE CHARGING CABLE)/RESETTING PIN (CAYENNE S E-HYBRID) >….6779
GENERAL INFORMATION….6779
WM 0940IN UPDATING SOFTWARE FOR PORSCHE UNIVERSAL CHARGER (AC)….6780
(HIGH-VOLTAGE CHARGING CABLE)/RESETTING PIN (CAYENNE S E-HYBRID) >….6780
UPDATING SOFTWARE/RESETTING PIN….6780
WM 0940Z1 DISASSEMBLING AND ASSEMBLING PORSCHE UNIVERSAL CHARGER….6785
(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) > GENERAL….6785
INFORMATION….6785
WM 0940Z1 DISASSEMBLING AND ASSEMBLING PORSCHE UNIVERSAL CHARGER….6786
(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) >….6786
DISASSEMBLING PORSCHE UNIVERSAL CHARGER (AC)….6786
(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) > ASSEMBLING….6787
PORSCHE UNIVERSAL CHARGER (AC)….6787
WM 090595 PORSCHE CD – SPECIAL TOOL FOR CHECKING NOISE AND….6788
VIBRATIONS (ALL MODELS) > TOOLS….6788
WM 090595 PORSCHE CD – SPECIAL TOOL FOR CHECKING NOISE AND….6789
VIBRATIONS (ALL MODELS) > GENERAL INFORMATION ON CHECKING….6789
FREQUENCY STIMULATION VIA THE SOUND SYSTEM….6789
WM 090595 PORSCHE CD – SPECIAL TOOL FOR CHECKING NOISE AND….6789
VIBRATIONS (ALL MODELS) > PROCEDURE….6789
0X – COMPLETE VEHICLE – GENERAL….6791
WM 0X00IN ELIMINATING NOISE SYMPTOMS – OVERVIEW OF MATERIALS FOR….6791
ELIMINATING DISTURBING NOISES (CAYENNE TIP, CAYENNE MAN, CAYENNE S,….6791
CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S,….6791
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL….6791
INFORMATION > SYMPTOMS….6791
WM 0X00IN ELIMINATING NOISE SYMPTOMS – OVERVIEW OF MATERIALS FOR….6791
ELIMINATING DISTURBING NOISES (CAYENNE TIP, CAYENNE MAN, CAYENNE S,….6791
CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S,….6791
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL….6791
INFORMATION > CAUSES AND REMEDIAL ACTION….6791
WM 0X00IN ELIMINATING NOISE SYMPTOMS – OVERVIEW OF MATERIALS FOR….6791
ELIMINATING DISTURBING NOISES (CAYENNE TIP, CAYENNE MAN, CAYENNE S,….6791
CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S,….6792
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TOOLS AND….6792
MATERIALS….6792
WM 0X00IN OVERVIEW OF A, B AND C MARKETS (CAYENNE TIP, CAYENNE MAN,….6794
CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE….6794
TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) >….6794
INFORMATION > OVERVIEW OF A, B AND C MARKETS….6794
WM 0X00IN TEST DRIVE – MAINTENANCE (CAYENNE TIP, CAYENNE MAN, CAYENNE….6795
S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,….6795
CAYENNE TIP (3.0)) > TEST DRIVE – MAINTENANCE….6795
WM 0X00IN TEST DRIVE – SALES CHECK (CAYENNE TIP, CAYENNE MAN, CAYENNE….6796
S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,….6796
CAYENNE TIP (3.0)) > TEST DRIVE – SALES CHECK….6796
WM 0X01IN ALARM SYSTEM: CHECKING OPERATION OF MONITORING DEVICES….6796
(CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S….6796
E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ALARM….6796
SYSTEM: CHECKING OPERATION OF MONITORING DEVICES….6796
WM 0X01IN CHECKING VEHICLE IDENT. NO. FOR CONFORMITY (CAYENNE,….6797
CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6797
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING VEHICLE IDENT. NO…6797
FOR CONFORMITY….6797
WM 0X01IN CHECKING GLAZING (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,….6799
CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6799
CAYENNE (3.0)) > CHECKING GLAZING….6799
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6799
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6799
DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING LID LOCK AT FRONT AND….6799
REAR….6799
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6799
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6799
DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON REAR LID CLOSING….6799
AID….6799
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6799
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6799
DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON AUTOMATIC REAR….6799
LID….6799
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6800
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6800
DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING SAFETY HOOK FOR FRONT….6800
LID….6800
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6800
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6800
DIESEL, CAYENNE (3.0)) > INFORMATION > DOOR LOCK FUNCTION TEST….6800
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6800
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6800
DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON TANK CAP LOCK….6800
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE….6800
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S….6800
DIESEL, CAYENNE (3.0)) > MAINTENANCE WORK > GREASING DOOR ARRESTER….6800
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6801
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6801
CAYENNE (3.0)) > WARNING NOTE FOR SEAT BELTS….6801
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6801
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6801
CAYENNE (3.0)) > CHECKING PROCEDURE FOR SEAT BELT….6801
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6802
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6802
CAYENNE (3.0)) > CHECKING BELT STRAP….6802
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6805
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6805
CAYENNE (3.0)) > CHECKING AUTOMATIC BELT DEVICE (LOCKING EFFECT)….6805
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6806
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6806
CAYENNE (3.0)) > CHECKING LOOK AND OPERATION OF SEAT-BELT BUCKLE….6806
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6806
CAYENNE (3.0)) > CHECKING SASH GUIDES….6806
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO….6807
S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,….6807
CAYENNE (3.0)) > CHECKING MOUNTING ELEMENTS AND MOUNTING POINTS….6807
WM 0X01IN CHECKING VEHICLE EQUIPMENT FOR COMPLETENESS (CAYENNE,….6807
CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6807
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > VEHICLE EQUIPMENT….6807
WM 0X01IN CHECKING VEHICLE EQUIPMENT FOR COMPLETENESS (CAYENNE,….6808
CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6808
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOL KIT….6808
WM 0X01IN CHECKING VEHICLE EQUIPMENT FOR COMPLETENESS (CAYENNE,….6809
CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE….6809
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DRIVER'S KEY….6809
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE….6809
TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID,….6809
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TOOLS….6809
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE….6809
TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID,….6809
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TECHNICAL VALUES….6809
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE….6810
TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID,….6810

…
Power Distribution….22772
Power Distribution Circuit (1 of 10)….22773
Power Distribution Circuit (2 of 10)….22775
Power Distribution Circuit (3 of 10)….22777
Power Distribution Circuit (4 of 10)….22779
Power Distribution Circuit (5 of 10)….22781
Power Distribution Circuit (6 of 10)….22783
Power Distribution Circuit (7 of 10)….22785
Power Distribution Circuit (8 of 10)….22787
Power Distribution Circuit (9 of 10)….22789
Power Distribution Circuit (10 of 10)….22791
Power Door Locks….22792
Power Door Locks Circuit (1 of 3)….22794
Power Door Locks Circuit (2 of 3)….22795
Power Door Locks Circuit (3 of 3)….22798
Power Mirrors….22798
Power Mirrors Circuit….22800
Power Mirrors Circuit….22799
Power Seats….22800
Driver Power Seat Circuit….22801
Passenger Power Seat Circuit….22803
Rear Seat Heater Circuit….22805
Power Top/Sunroof….22806
Panoramic Roof Circuit….22807
Sunroof Circuit….22809
Power Windows….22810
Power Windows Circuit….22811
Tailgate Power Window Circuit….22813
Radio….22814
….22815
Bose Radio Circuit (2 of 3)….22817
Bose Radio Circuit (3 of 3)….22819
Satellite Radio Circuit….22821
Shift Interlock….22822
Shift Interlock Circuit….22823
Starting/Charging ….22824
….22825
Starting Circuit….22827
Supplemental Restraints (Airbag)….22828
Supplemental Restraints Circuit (1 of 3)….22829
Supplemental Restraints Circuit (2 of 3)….22831
Supplemental Restraints Circuit (3 of 3)….22833
Transmission….22834
A/T Circuit….22835
Transfer Case Circuit, W/ Air Suspension….22837
Transfer Case Circuit, W/O Air Suspension….22839
Trunk, Tailgate & Fuel door….22840
Trunk, Tailgate, Fuel Door Circuit….22841
Warning Systems….22842
….22844
Wiper & Washer Systems….22844
Wiper/Washer Circuit….22845

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP-1055F, with all the workshop service information to maintain, diagnose, repair, and rebuild.

Caterpillar ASPHALT PAVERS AP-1055F Repair Service Manuals
workshop service 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.

UENR5176 – Schematic (AP1055F Asphalt Paver Hydraulic System 396-7346)
UENR5583 – Disassembly and Assembly (AP1055F Asphalt Paver Machine Systems).pdf
UENR5580 – Disassembly and Assembly (AP1055F Asphalt Paver Engine Supplement).pdf
UENR5176 – Schematic (AP1055F Asphalt Paver Hydraulic System 396-7346).pdf
UENR5175 – Schematic AP1055F Asphalt Paver Electrical System (Machine 399-3173-03 399-3174-02 483-3775-01; Engine 417-1240-02; PDM 423-0404-01; Canopy_Lighting 423-0403-01; Product Link 462-0805-01 280-4391-01 For SN RLM1-UP).pdf
UENR3806 – Specifications (AP1055F Asphalt Paver Machine Systems).pdf
UENR3804 – Specifications (AP1055F Asphalt Paver Propel System).pdf
UENR3146 – Systems Operation & Testing and Adjusting (AP1055F Asphalt Paver Machine Systems).pdf
UENR3144 – Systems Operation & Testing and Adjusting (AP1055F Asphalt Paver Propel System).pdf
M0099472 – Testing and Adjusting (AP1055F Asphalt Paver Propel Systems).pdf
M0099472 – Systems Operation (AP1055F Asphalt Paver Propel Systems).pdf

Total Pages: 1,511 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting…
Language: English

AP-1055F ASPHALT PAVER RLM
AP-1055F ASPHALT PAVER TJ5

TABLE OF CONTENTS
M0099472 – Systems Operation (AP1055F Asphalt Paver Propel Systems)……1
General Information (Propel System)……2
Graphic Color Codes……4
Location of Electrical Components (Propel System)……6
Location of Hydraulic Components (Propel System)……9
Operator Controls (Propel System)……13
Piston Pump (Propel)……20
Piston Motor (Propel)……28
Final Drive Planetary……31
Parking Brake……35
Electrical Schematic (Propel System)……37
Hydraulic Schematic (Propel System)……44
M0099472 – Testing and Adjusting (AP1055F Asphalt Paver Propel Systems)……53
Machine Preparation for Troubleshooting……54
Visual Inspection……55
Propel System Troubleshooting……59
Hydraulic Oil Contamination – Test……62
Piston Pump Flow – Test……69
Piston Pump Neutral – Test and Adjust – Left Propel……77
Piston Pump Neutral – Test and Adjust – Right Propel……87
Relief Valve (Charge) – Test and Adjust – Left Pump……97
Relief Valve (Charge) – Test and Adjust – Right Pump……109
Pressure Limiter Valve – Test and Adjust – Left Pump……121
Pressure Limiter Valve – Test and Adjust – Right Pump……137
Seal Leakage for Final Drive Planetary – Test……151
Solenoid (Shift) – Test……158
Rotary Position Sensor (Decelerator Pedal) – Calibrate……163
Steering Wheel – Calibrate……168
Accumulator (Track Tension) – Test and Charge……176
Forward Currents (EDC)- Calibrate……186
Reverse Currents (EDC)- Calibrate……197
UENR3144 – Systems Operation & Testing and Adjusting (AP1055F Asphalt Paver Propel System)……208
General Information (Propel System)……209
Graphic Color Codes……211
Location of Electrical Components (Propel System)……213
Location of Hydraulic Components (Propel System)……216
Operator Controls (Propel System)……220
Piston Pump (Propel)……227
Piston Motor (Propel)……235
Final Drive Planetary……238
Parking Brake……242
Electrical Schematic (Propel System)……244
Hydraulic Schematic (Propel System)……251
Machine Preparation for Troubleshooting……260
Visual Inspection……261
Propel System Troubleshooting……265
Hydraulic Oil Contamination – Test……268
Piston Pump Flow – Test……275
Piston Pump Neutral – Test and Adjust – Left Propel……283
Piston Pump Neutral – Test and Adjust – Right Propel……293
Relief Valve (Charge) – Test and Adjust – Left Pump……303
Relief Valve (Charge) – Test and Adjust – Right Pump……315
Pressure Limiter Valve – Test and Adjust – Left Pump……327
Pressure Limiter Valve – Test and Adjust – Right Pump……343
Seal Leakage for Final Drive Planetary – Test……357
Solenoid (Shift) – Test……364
Rotary Position Sensor (Decelerator Pedal) – Calibrate……369
Track Alignment……374
Steering Wheel – Calibrate……385
Accumulator (Track Tension) – Test and Charge……393
Forward Currents (EDC)- Calibrate……403
Reverse Currents (EDC)- Calibrate……414
UENR3146 – Systems Operation & Testing and Adjusting (AP1055F Asphalt Paver Machine Systems)……425
Graphic Color Codes……426
Cooling Fan Manifold……428
Hydraulic Oil Contamination – Test……432
Piston Pump Flow (Auxiliary) – Test……439
Vibratory Shaft Speed – Calibrate……448
Solenoid Valve (Tamper) – Calibrate……460
Piston Pump Flow (Cooling Fan) – Test……469
Pump Control Valve (Auxiliary) – Test and Adjust……478
Relief Valve (Charge; Auger Conveyor and Drag Conveyor) – Test and Adjust……487
Relief Valve (Main; Auger Conveyor and Drag Conveyor) – Test and Adjust……499
Piston Pump Neutral (Auger Conveyor and Drag Conveyor) – Test and Adjust……521
Piston Motor Case Drain Flow (Auger Conveyor and Drag Conveyor) – Test……552
Conveyor Drive Chain (Auger) – Check and Adjust……562
Conveyor Drive Chain (Drag) – Check and Adjust……568
Conveyor Chain (Drag) – Check and Adjust……573
Conveyor Speed (Auger) – Check……578
Conveyor Speed (Drag) – Check……587
Pressure Reducing Valve – Test and Adjust – Shift Solenoid……597
Tow Point – Calibration……605
Gear Pump (Generator Cooling) Pressure – Test……612
Fan Speed (Ventilation) – Test……619
Insulation – Test……625
Auger Conveyor – Calibrate……628
Sensor (Paddle) – Calibrate – Auger Feed……647
Sensor (Paddle) – Calibrate – Conveyor……656
Drag Conveyor – Calibrate……666
UENR3804 – Specifications (AP1055F Asphalt Paver Propel System)……684
Hydraulic Tank……685
Hydraulic Tank and Mounting……687
Propel Pump and Mounting……689
Hydraulic Oil Filter (Return)……690
Midroller (Mobil-Trac)……691
Accumulator (Track Tension) (Mobil-Trac)……693
Final Drive……694
Track Roller Frame……696
Belt (Mobil-trac System)……705
Pressure Switch (Track Tension)……707
Brake Pump (Manual Release)……709
UENR3806 – Specifications (AP1055F Asphalt Paver Machine Systems)……710
Hydraulic Tank……713
Hydraulic Tank and Mounting……715
Oil Cooler Bypass Valve……717
– Generator……718
Hydraulic Oil Filter (Generator)……720
Hydraulic Oil Filter (Return)……722
Lines (Auxiliary Pump)……723
Lines (Auxiliary Hydraulic)……724
Control Valve (Auxiliary)……726
Counterbalance Valve (Hopper Hoist; Tow Point)……727
Hydraulic Cylinder (Tow Point)……728
Lines (Truck Hitch)……730
Push Roller……731
Hydraulic Cylinder (Hopper Hoist)……733
Lines (Auger Hoist)……734
Hydraulic Cylinder (Auger Hoist)……735
Lines (Screed)……738
Hydraulic Cylinder (Screed Hoist)……739
Blade and Mounting (Track Plow)……741
Apron……742
Hopper……744
Access Door……746
Conveyor Drive (Drag)……748
Footshaft……751
Position Sensor (Paddle)……753
Auger Conveyor – Mounting……754
Transverse Beam……757
Main Frame……758
Extender Lines……760
Thickness Control……762
Power Crown Group……764
Power Sloper Group……766
Slope Lines Group……768
Drop Arm……770
Height Adjuster Group……772
Lines (Tamper)……775
Lines (Hydraulic Fan)……777
Vibratory Lines Group……779
Position Sensor (Sonic)……781
Generator……784
Washdown Group……787
Washdown Group – Ecology……789
Diaphram Pump (Washdown)……790
Walkway……791
Canopy……793
Seat and Mounting……794
Grade Control……795
Window……797
Window – Front……798
Platform……806
Grade Control Mounting……808
Operator Console……812
Steering Column……815
Steering Control……816
Fuel Tank……820
Fuel Lines……822
Flood Lighting……824
Roading Lighting……828
Communication Electronic Control Module (Product Link)……830
Air Lines (Aftercooler)……833
Air Cleaner……835
UENR5175 – Schematic AP1055F Asphalt Paver Electrical System (Machine 399-3173-03 399-3174-02 483-3775-01; Engine 417-1240-02; PDM 423-0404-01; Canopy_Lighting 423-0403-01; Product Link 462-0805-01 280-4391-01 For SN RLM1-UP)……838
Feature……838
Cover Page……840
Information……0
Component Location……0
Machine Electrical System……0
Page 1 of 2……841
Page 2 of 2……842
Power Distribution Module and Electrical Options……843
Engine……844
Connector Location……0
Machine Electrical System……845
Power Distribution Module and Electrical Options……846
Engine……847
Schematics……0
Machine Electrical System……848
Power Distribution Module and Electrical Options……849
Engine……850
Machine Views……0
Machine Electrical System……0
Center Console Rear View……851
Center Console / Battery Comp……852
Engine Interface……853
Fuel Tank / LH Battery Comp……854
Generator / Engine LH Rear View……855
Hydraulic Propel Motors……856
Hydraulic Pumps RH Side……857
Inside RH Rear Frame……858
LH Operator Station……859
Rear Tractor LH View……860
Rear Tractor RH View……861
RH Operator Station……862
RH Rear Below Operator Station……863
Steering View……864
Tractor LH Front View……865
Tractor LH Middle View……866
Tractor LH Rear Side View……867
Tractor RH Front View……868
Tractor RH Rear Side View……869
Power Distribution Module and Electrical Options……0
Optional Cab with Wipers……870
Optional Screed LED Lighting……871
Power Distribution Module – Fuses……872
Power Distribution Module – Relays……873
Product Link PL421……874
Product Link PL522……875
Product Link PL631 / PL641……876
Engine……0
Engine LH View……877
Engine RH View……878
Engine Top View……879
UENR5176 – Schematic (AP1055F Asphalt Paver Hydraulic System 396-7346)……880
Main……881
Features……881
Cover page……883
Tables……0
Components……884
Taps……885
Schematic……886
Machine Views……0
Right Side……887
Right Rear……888
Rear VIew……889
Left Side……890
Front View……891
Collage……892
UENR5580 – Disassembly and Assembly (AP1055F Asphalt Paver Engine Supplement)……922
System Pressure – Release……923
Air Cleaner – Remove and Install……924
Exhaust (Muffler) – Remove and Install……926
Battery – Remove and Install……929
Alternator – Remove and Install……934
Electric Starting Motor – Remove and Install……937
Alternator Belt – Remove and Install……940
Belt Tensioner – Remove and Install……942
Water Separator; Primary Fuel Filter; and Fuel Priming Pump – Remove and Install……944
Fuel Cooler – Remove and Install……946
Fuel Filter (Secondary) and Fuel Filter Base – Remove and Install……947
Fan – Remove and Install……949
Gear Motor (Fan Drive) – Remove and Install……952
Gear Motor (Fan Drive) – Disassemble……955
Gear Motor (Fan Drive) – Assemble……959
Radiator; Hydraulic Oil Cooler; and Fuel Cooler – Remove and Install……963
Radiator; Hydraulic Oil Cooler; and Fuel Cooler – Disassemble……974
Radiator; Hydraulic Oil Cooler; and Fuel Cooler – Assemble……980
Air Aftercooler – Remove and Install……986
Access Cover (Expansion Tank) – Remove and Install……989
Engine – Remove……1002
Engine – Install……1011
UENR5583 – Disassembly and Assembly (AP1055F Asphalt Paver Machine Systems)……1020
System Pressure – Release……1025
Fuel Tank – Remove and Install……1026
Hydraulic Oil Filter (Return) – Remove and Install……1028
Hydraulic Oil Filter (Return) – Disassemble……1030
Hydraulic Oil Filter (Return) – Assemble……1032
Hydraulic Tank – Remove and Install……1034
Gear Pump (Conveyor System Charge) – Remove and Install……1037
Gear Pump (Conveyor System Charge) – Disassemble……1039
Gear Pump (Conveyor System Charge) – Assemble……1045
Hydraulic Oil Filter (Conveyor System Charge) – Remove and Install……1052
Piston Pump (Left Drag Conveyor and Left Auger Conveyor) – Remove and Install……1055
Piston Pump (Right Drag Conveyor and Right Auger Conveyor) – Remove and Install……1057
Piston Pump (Drag Conveyor and Auger Conveyor) – Disassemble……1059
Piston Pump (Drag Conveyor and Auger Conveyor) – Assemble……1069
Piston Motor (Drag Conveyor) – Remove and Install……1078
Piston Motor (Drag Conveyor) – Disassemble……1080
Piston Motor (Drag Conveyor) – Assemble……1085
Chain (Drag Conveyor) – Remove and Install……1090
Final Drive Planetary (Drag Conveyor) – Remove and Install……1093
Final Drive Planetary (Drag Conveyor) – Disassemble……1094
Final Drive Planetary (Drag Conveyor) – Assemble……1100
Drag Conveyor – Remove and Install……1106
Feeder Drive Shaft Group – Remove and Install……1109
Feeder Drive Shaft Group – Disassemble……1113
Feeder Drive Shaft Group – Assemble……1117
Footshaft – Remove and Install……1122
Footshaft – Disassemble……1123
Footshaft – Assemble……1127
Plates (Drag Pans) – Remove and Install……1132
Piston Motor (Auger Conveyor) – Remove and Install……1133
Piston Motor (Auger Conveyor) – Disassemble……1135
Piston Motor (Auger Conveyor) – Assemble……1140
Chain (Auger Conveyor) – Remove and Install……1145
Final Drive Planetary (Auger Conveyor) – Remove and Install……1147
Final Drive Planetary (Auger Conveyor) – Disassemble……1151
Final Drive Planetary (Auger Conveyor) – Assemble……1157
Hydraulic Cylinder (Auger Hoist) – Remove and Install……1164
Auger Conveyor – Remove and Install……1167
Auger – Disassemble……1170
Auger – Assemble……1176
Hydraulic Filter (Suction Return) – Remove and Install……1182
Piston Pump (Right Propel) – Remove and Install……1186
Piston Pump (Left Propel) – Remove and Install……1188
Piston Pump (Propel) – Disassemble……1190
Piston Pump (Propel) – Assemble……1212
Piston Motor (Propel) – Remove and Install……1238
Piston Motor (Propel) – Disassemble……1239
Piston Motor (Propel) – Assemble……1248
Brake Pump and Valve – Remove and Install……1258
Brake Pump and Valve – Disassemble……1259
Brake Pump and Valve – Assemble……1261
Blade (Track Plow) – Remove and Install……1263
Belt – Remove and Install……1265
Belt Tensioner – Remove and Install……1269
Belt Tensioner – Disassemble……1271
Belt Tensioner – Assemble……1275
Hydraulic Cylinder (Belt Tensioner) – Remove and Install……1280
Track Roller Frame (Front) – Remove……1284
Track Roller Frame (Rear) – Remove……1287
Bogie (Front) – Remove and Install……1289
Bogie (Rear) – Remove and Install……1291
Bogie – Disassemble……1293
Bogie – Assemble……1296
Track Roller Frame (Front) – Install……1300
Track Roller Frame (Rear) – Install……1303
Accumulator Charging Valve (Belt Tensioner) – Remove and Install……1305
Accumulator Charging Valve (Belt Tensioner) – Disassemble……1307
Accumulator Charging Valve (Belt Tensioner) – Assemble……1309
Wheel (Final Drive) – Remove and Install……1311
Final Drive Planetary – Remove and Install……1314
Final Drive Planetary – Disassemble……1317
Duo-Cone Conventional Seals – Install……1335
Final Drive Planetary – Assemble……1347
Piston Pump (Auxiliary) – Remove and Install……1365
Piston Pump (Auxiliary) – Disassemble……1367
Piston Pump (Auxiliary) – Assemble……1376
Control Valve (Auxiliary) – Remove and Install……1388
Control Valve (Auxiliary) – Disassemble……1391
Control Valve (Auxiliary) – Assemble……1394
Hydraulic Cylinder (Hopper Hoist) – Remove and Install……1397
Control Valve (Apron) – Remove and Install……1401
Control Valve (Apron) – Disassemble……1403
Control Valve (Apron) – Assemble……1405
Apron – Remove and Install……1407
Hopper – Remove and Install……1410
Seat – Remove and Install……1413
Steering Wheel – Remove and Install……1416
Steering Column – Remove and Install……1418
Steering Control (Force Control) – Remove and Install……1422
Steering Control (Force Control) – Disassemble……1426
Steering Control (Force Control) – Assemble……1430
Operator Platform – Remove and Install……1434
Piston Pump (Tamper Bar) – Remove and Install……1437
Piston Pump (Tamper Bar) – Disassemble……1439
Piston Pump (Tamper Bar) – Assemble……1448
Control Valve (Vibratory) – Remove and Install……1460
Control Valve (Vibratory) – Disassemble……1461
Control Valve (Vibratory) – Assemble……1464
Screed – Remove and Install……1467
Main Frame Extension (Powered) – Remove and Install……1470
Main Frame Extension (Powered) – Disassemble……1472
Main Frame Extension (Powered) – Assemble……1474
Hydraulic Cylinder (Screed Hoist) – Remove and Install……1477
Solenoid Valve (Tow Point) – Remove and Install……1479
Counterbalance Valve (Hopper Hoist; Tow Point) – Remove and Install……1481
Counterbalance Valve (Hopper Hoist; Tow Point) – Disassemble……1483
Counterbalance Valve (Hopper Hoist; Tow Point) – Assemble……1485
Hydraulic Cylinder (Tow Point) – Remove and Install……1487
Tow Arm – Remove and Install……1490
Gear Motor (Ventilation System) – Remove and Install……1493
Gear Motor (Ventilation System) – Disassemble……1497
Gear Motor (Ventilation System) – Assemble……1499
Return Manifold and Oil Cooler Bypass Valve – Remove and Install……1501
Push Roller – Remove and Install……1505
Push Roller – Disassemble……1507
Push Roller – Assemble……1509
Control Valve (Truck Hitch) – Remove and Install……1511
Control Valve (Truck Hitch) – Disassemble……1513
Control Valve (Truck Hitch) – Assemble……1515
Truck Hitch – Remove and Install……1517
Truck Hitch – Disassemble……1519
Truck Hitch – Assemble……1524
Electric Motor (Washdown Pump) – Remove and Install……1529
Piston Pump (Hydraulic Fan) – Remove and Install……1531
Generator and Drive – Remove and Install……1534
Generator – Disassemble……1541
Generator – Assemble……1550
Power Inverter – Remove and Install……1560
Power Inverter – Disassemble……1565
Power Inverter – Assemble……1568

Caterpillar ASPHALT PAVERS AP-1055F Repair Service Manuals (SN Prefix RLM/TJ5)

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA30-5, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Wheel Loader WA30-5 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: 1,051 pages
File Format: PDF
Language: English

SEBM016503 – Wheel Loader WA30-5 avance Shop Manual.pdf
SEAM010700 – Wheel Loader WA20-2, WA30-5, WA40-3, WA50-3 Operation & Maintenance Manual.pdf
SEAM034300 – Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.pdf
SEAM03610102 – Wheel Loader WA20-1 Operation & Maintenance Manual.pdf
TEN00071-00 – Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.pdf

MAIN SECTIONS
SEAM010700 – Wheel Loader WA20-2, WA30-5, WA40-3, WA50-3 Operation & Maintenance Manual…..2
COVER…..2
1. FOREWORD…..3
2. SAFETY INFORMATION…..4
3. INTRODUCTION…..5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..6
5. CONTENTS…..8
SAFETY…..11
6. GENERAL PRECAUTIONS…..12
7. PRECAUTIONS DURING OPERATION…..17
7.1 BEFORE STARTING ENGINE…..17
7.2 OPERATING MACHINE…..19
7.3 TRANSPORTATION…..24
7.4 BATTERY…..25
7.5 TOWING…..26
8. PRECAUTIONS FOR MAINTENACE…..27
8.1 BEFORE CARRYING OUT MAINTENANCE…..27
8.2 DURING MAINTENANCE…..31
8.3 TIRES…..35
9. POSITION FOR ATTACHING SAFETY LABELS…..37
OPERATION…..41
10. GENERAL VIEW…..42
10.1 GENERAL VIEW OF MACHINE…..42
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..43
11. EXPLANATION OF COMPONENTS…..44
11.1 METER, LAMPS…..44
11.2 SWITCHES…..48
11.3 CONTROL LEVERS, PEDALS…..50
11.4 CAP WITH LOCK…..54
11.5 SAFETY BAR…..54
11.6 TILT HOOD…..55
11.7 TOWING PIN…..55
11.8 FUSE…..55
11.9 FUSIBLE LINK…..56
11.10 MANUAL POCKET…..57
11.11 CONNECTORS…..57
12. OPERATION…..58
12.1 CHECK BEFORE STARTING ENGINE…..58
12.2 STARTING ENGINE…..69
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..72
12.4 MOVING MACHINE OFF…..74
12.5 CHANGING DIRECTION…..76
12.6 TURNING…..76
12.7 STOPPING MACHINE…..77
12.8 OPERATION OF WORK EQUIPMENT…..78
12.9 WORK POSSIBLE USING WHEEL LOADER…..79
12.10 PRECAUTIONS FOR OPERATION…..83
12.11 ADJUSTING WORK EQUIPMENT POSTURE…..85
12.12 PARKING MACHINE…..86
12.13 CHECKS AFTER COMPLETIONOF OPERATION…..87
12.14 STOPPING ENGINE…..88
12.15 CHECK AFTER STOPPING ENGINE…..88
12.16 LOCKING…..88
12.17 HANDLING THE TIRES…..89
13. TRANSPORTATION…..92
13.1 LOADING, UNLOADING WORK…..92
13.2 PRECAUTIONS FOR LOADING…..93
13.3 LIFTING MACHINE…..93
13.4 PRECAUTIONS FOR TRANSPORTATION…..96
13.5 REMOVING AND INSTALLATION OF CANOPY…..96
14. COLD WEATHER OPERATION…..98
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..98
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..100
14.3 AFTER COLD WEATHER…..100
15. LONG-TERM STORAGE…..101
15.1 BEFORE STORAGE…..101
15.2 DURING STORAGE…..101
15.3 AFTER STORAGE…..101
16. TROUBLESHOOTING…..102
16.1 WHEN MACHINE RUNS OUT OF FUEL…..102
16.2 TOWING THE MACHINE…..103
16.3 IF BATTERY IS DISCHARGED…..106
16.4 OTHER TROUBLE…..110
MAINTENANCE…..115
17. GUIDES TO MAINTENANCE…..116
18. OUTLINES OF SERVICE…..119
18.1 OUTLINE OF OIL, FUEL, COOLANT…..119
18.2 OUTLINE OF ELECTRIC SYSTEM…..122
19. WEAR PARTS LIST…..123
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..124
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..128
21.1 INTRODUCTION OF NECESSARY TOOLS…..128
21.2 TORQUE LIST…..130
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..131
23. MAINTENANCE SCHEDULE CHART…..138
23.1 MAINTENANCE SCHEDULE CHART…..138
24. SERVICE PROCEDURE…..141
24.1 INITIAL 250 HOURS SERVICE…..141
24.2 WHEN REQUIRED…..142
24.3 CHECK BEFORE STARTING…..156
24.4 EVERY 50 HOURS SERVICE…..162
24.5 EVERY 250 HOURS SERVICE…..163
24.6 EVERY 500 HOURS SERVICE…..168
24.7 EVERY 1000 HOURS SERVICE…..171
24.8 EVERY 2000 HOURS SERVICE…..174
SPECIFICATIONS…..177
25. SPECIFICATIONS…..178
OPTIONS, ATTACHMENTS…..179
26. OPTIONAL PARTS AND ATTACHMENTS…..180
27. SEAT BELT…..181
27.1 FASTENING AND REMOVING BELT…..181
27.2 ADJUST BELT LENGTH…..182
27.3 CHECK SEAT BELT AND MOUNTS…..182
28. EQUIPMENT WITH CAB…..183
28.1 SWITCHES…..183
28.2 REAR WINDOW…..187
28.3 CHECK AND MAINTENANCE…..188
SEAM034300 – Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual…..197
COVER PAGE…..197
1. FOREWORD…..198
2. SAFETY INFORMATION…..199
3. INTRODUCTION…..200
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..201
5. CONTENTS…..202
SAFETY…..205
6. GENERAL PRECAUTIONS…..206
7. PRECAUTIONS DURING OPERATION…..211
7.1 BEFORE STARTING ENGINE…..211
7.2 OPERATING MACHINE…..213
7.3 TRANSPORTATION…..218
7.4 BATTERY…..219
7.5 TOWING…..220
8. PRECAUTIONS FOR MAINTENANCE…..221
8.1 BEFORE CARRYING OUT MAINTENANCE…..221
8.2 DURING MAINTENANCE…..225
8.3 PRECAUTIONS WITH TIRES…..229
9. POSITION FOR ATTACHING SAFETY LABELS…..230
OPERATION…..235
10. GENERAL VIEW…..236
10.1 GENERAL VIEW OF MACHINE…..236
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..237
11. EXPLANATION OF COMPONENTS…..239
11.1 METER, LAMPS…..239
11.2 SWITCHES…..242
11.3 CONTROL LEVERS, PEDALS…..244
11.4 CAP WITH LOCK…..248
11.5 SAFETY BAR…..248
11.6 TILT HOOD…..249
11.7 TOWING PIN…..249
11.8 FUSE…..249
11.9 FUSIBLE LINK…..250
11.10 MANUAL POCKET…..251
11.11 CONNECTORS…..251
12. OPERATION…..252
12.1 CHECK BEFORE STARTING ENGINE…..252
12.2 STARTING ENGINE…..265
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..268
12.4 MOVING MACHINE OFF…..270
12.5 CHANGING DIRECTION…..272
12.6 TURNING…..272
12.7 STOPPING MACHINE…..273
12.8 OPERATION OF WORK EQUIPMENT…..274
12.9 OPERATING FRONT ATTACHMENT SERVICE HYDRAULIC CIRCUIT…..275
12.10 WORK POSSIBLE USING WHEEL LOADER…..277
12.11 PRECAUTIONS FOR OPERATION…..281
12.12 ADJUSTING WORK EQUIPMENT POSTURE…..283
12.13 PARKING MACHINE…..284
12.14 CHECKS AFTER COMPLETION OF OPERATION…..285
12.15 STOPPING ENGINE…..286
12.16 CHECK AFTER STOPPING ENGINE…..286
12.17 LOCKING…..286
12.18 HANDLING THE TIRES…..287
13. TRANSPORTATION…..290
13.1 LOADING, UNLOADING WORK…..290
13.2 PRECAUTIONS FOR LOADING…..291
13.3 LIFTING MACHINE…..291
13.4 PRECAUTIONS FOR TRANSPORTATION…..294
14. COLD WEATHER OPERATION…..295
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..295
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..297
14.3 AFTER COLD WEATHER…..297
15. LONG-TERM STORAGE…..298
15.1 BEFORE STORAGE…..298
15.2 DURING STORAGE…..298
15.3 AFTER STORAGE…..298
16. TROUBLESHOOTING…..299
16.1 WHEN MACHINE RUNS OUT OF FUEL…..299
16.2 TOWING THE MACHINE…..300
16.3 IF BATTERY IS DISCHARGED…..303
16.4 OTHER TROUBLE…..307
MAINTENANCE…..312
17. GUIDES TO MAINTENANCE…..313
18. OUTLINES OF SERVICE…..316
18.1 OUTLINE OF OIL, FUEL, COOLANT…..316
18.2 OUTLINE OF ELECTRIC SYSTEM…..318
19. WEAR PARTS LIST…..319
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..320
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..324
21.1 INTRODUCTION OF NECESSARY TOOLS…..324
21.2 TORQUE LIST…..326
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..327
23. MAINTENANCE SCHEDULE CHART…..328
23.1 MAINTENANCE SCHEDULE CHART…..328
24. SERVICE PROCEDURE…..331
24.1 INITIAL 250 HOURS SERVICE…..331
24.2 WHEN REQUIRED…..332
24.3 CHECK BEFORE STARTING…..345
24.4 EVERY 50 HOURS SERVICE…..351
24.5 EVERY 250 HOURS SERVICE…..352
24.6 EVERY 500 HOURS SERVICE…..357
24.7 EVERY 1000 HOURS SERVICE…..361
24.8 EVERY 2000 HOURS SERVICE…..364
SPECIFICATIONS…..366
25. SPECIFICATIONS…..367
SEAM03610102 – Wheel Loader WA20-1 Operation & Maintenance Manual…..370
COVER…..370
FOREWORD…..371
BREAKING IN YOUR NEW MACHINE…..372
CONTENTS…..373
SAFETY HINTS…..374
GENERAL LOCATIONS AND SPECIFICATIONS…..379
INSTRUMENTS AND CONTROLS…..380
CHECK BEFORE STARTING…..390
OPERATING YOUR MACHINE…..394
BUCKET OPERATION…..401
HOW TO USE INCHING PEDAL…..405
TIRE REPLACEMENT…..407
HANDLING THE TIRES…..408
HANDLING OF BATTERY…..409
MACHINE MOVEMENT…..411
COLD WEATHER OPERATION…..412
TRANSPORTATION…..415
PERIODIC MAINTENANCE…..416
PRECAUTIONS FOR MAINTENANCE…..417
PERIODIC REPLACEMENT OF PARTS FOR SAFETY…..421
MAINTENANCE TABLE…..422
OIL FILLER AND LEVEL GAUGE POSITIONS…..425
EVERY 50 HOURS SERVICE…..426
EVERY 250 HOURS SERVICE…..426
EVERY 500 HOURS SERVICE…..433
EVERY 1000 HOURS SERVICE…..437
EVERY 2000 HOURS SERVICE…..440
WHEN REQUIRED…..441
ADJUSTMENT…..446
STORAGE…..448
SERVICE METER…..450
MACHINE AND ENGINE SERIAL NUMBERS…..451
FUEL,COOLANT AND LUBRICANTS…..452
SEBM016503 – Wheel Loader WA30-5 avance Shop Manual…..456
COVER…..456
CONTENTS…..457
01 GENERAL…..480
GENERAL ASSEMBLY DRAWING…..481
SPECIFICATIONS…..483
WEIGHT TABLE…..486
LIST OF LUBRICANT AND WATER…..487
10 STRUCTURE AND FUNCTION…..489
POWER TRAIN…..490
POWER TRAIN SYSTEM…..491
RADIATOROIL COOLER…..493
DAMPER COUPLING…..494
HST PIPING…..495
HST HYDRAULIC SYSTEM DIAGRAM…..496
HST HYDRAULIC CIRCUIT DIAGRAM…..497
MAIN PISTON PUMP…..498
HIGH-PRESSURE RELIEF VALVE…..500
LOW-PRESSURE RELIEF VALVE…..502
WORK EQUIPMENTSTEERING PUMP, HST CHARGE PUMP…..503
CHARGE PUMP OIL FILTER…..504
SPEED RELATED VALVE (DA VALVE)…..505
PISTON MOTOR…..506
DIRECTIONAL SHUTTLE VALVE…..508
SERVO VALVE…..509
INCHING VALVE…..510
TRANSFER…..511
HST CONTROL…..512
DRIVE SHAFT…..513
AXLE…..514
DIFFERENTIAL…..516
FINAL DRIVE…..519
AXLE MOUNT…..521
TIREWHEEL…..522
CENTER HINGE PIN…..523
STEERING PIPING…..524
STEERING COLUMN…..525
PRIORITY VALVE…..526
STEERING VALVE (ORBIT-ROLL)…..530
BRAKE, PARKING BRAKE CONTROL…..538
BRAKE (ALSO USED AS PARKING BRAKE)…..539
WORK EQUIPMENT PIPING…..540
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…..541
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…..542
WORK EQUIPMENT LEVER LINKAGE…..543
HYDRAULIC TANK…..544
HYDRAULIC FILTER…..545
MAIN CONTROL VALVE…..546
WORK EQUIPMENT LINKAGE…..553
BUCKET…..554
BUCKET POSITIONER…..555
PROXIMITY SWITCH…..556
ROPS CANOPY…..557
CENTRAL PANEL (CLUSTER GAUGE)…..558
ENGINE START CIRCUIT…..559
ENGINE STOP CIRUIT…..559
PREHEATING CIRCUIT…..560
PARKING BRAKE CIRCUIT…..561
20 TESTING AND ADJUSTING…..562
STANDARD VALUE TABLE FOR ENGINE…..563
STANDARD VALUE TABLE FOR CHASSIS…..565
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..570
ADJUSTING VALVE CLEARANCE…..571
MEASURING COMPRESSION PRESSURE…..574
TESTING AND ADJUSTING FUEL INJECTION TIMING…..575
BLEEDING AIR FROM FUEL CIRCUIT…..581
TESTING AND ADJUSTING FAN BELT TENSION…..582
TESTING FOR ABNORMALITY IN FUEL LEVEL SENSOR…..584
MEASURING ACCELERATOR PEDAL…..585
MEASURING OPERATING EFFORT, TRAVEL OF DIRECTIONAL LEVER…..587
MEASURING STALL SPEED…..588
MEASURING HST OIL PRESSURE…..589
TESTING AND ADJUSTING STEERING WHEEL…..590
MEASURING OPERATING TIME FOR STEERING WHEEL…..591
MEASURING STEERING PRESSURE…..592
TESTING AND ADJUSTING BRAKE PEDAL…..593
MEASURING OPERATING EFFORT, TRAVEL OF BRAKE PEDAL…..595
MEASURING BRAKE PERFORMANCE…..596
MEASURING PARKING BRAKE PERFORMANCE…..597
MEASURING BRAKE DISC WEAR…..598
TESTING AND ADJUSTING INCHING VALVE LINKAGE…..599
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER…..600
MEASURING TRAVEL OF MAIN CONTROL VALVE SPOOL…..602
MEASURING WORK EQUIPMENT PRESSURE…..603
TESTING AND ADJUSTING BUCKET POSITIONER…..605
TROUBLESHOOTING…..607
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..608
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..609
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..610
CHECKS BEFORE TROUBLESHOOTING…..618
TROUBLESHOOTING OF ELECTRICAL SYSTEM…..619
E-1 ENGINE DOES NOT START…..620
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)…..625
TROUBLESHOOTING…..626
CHECKING MACHINE BEFORE TROUBLESHOOTING…..626
CHECKING HST BEFORE TROUBLESHOOTING…..627
H-1 IMPOSSIBLE TO TRAVEL IN EITHER DIRECTION (FORWARD OR REVERSE)…..629
H-2 IMPOSSIBLE TO TRAVEL IN ONE DIRECTION ONLY (EITHER FORWARD OR REVERSE)…..630
H-3 LACKS SPEED IN BOTH DIRECTIONS (FORWARD AND REVERSE)…..631
H-4 LACKS SPEED IN ONE DIRECTION ONLY (FORWARD OR REVERSE)…..632
H-5 LACKS DRAWBAR PULL IN BOTH DIRECTIONS (FORWARD AND REVERSE)…..632
H-6 LACKS DRAWBAR PULL IN ONE DIRECTION ONLY (FORWARD OR REVERSE)…..633
H-7 ENGINE SPEED IS HIGH WHEN STARTING IN BOTH DIRECTIONS (FORWARD AND REVERSE)…..633
H-8 ENGINE SPEED IS HIGH WHEN STARTING IN ONE DIRECTION ONLY (FORWARD OR REVERSE)…..633
30 DISASSEMBLY AND ASSEMBLY…..634
HOW TO READ THIS MANUAL…..635
PRECAUTIONS WHEN CARRYING OUT OPERATION…..637
SPECIAL TOOLS LIST…..639
FUEL INJECTION PUMP…..640
REMOVAL…..640
INSTALLATION…..641
ENGINE…..642
REMOVAL AND INSTALLATION…..642
RADIATOR…..672
REMOVAL AND INSTALLATION…..672
FUEL TANK…..681
REMOVAL AND INSTALLATION…..681
MAIN PISTON PUMP…..682
REMOVAL…..682
INSTALLATION…..687
DISASSEMBLY AND ASSEMBLY…..691
PISTON MOTOR…..697
REMOVAL…..697
INSTALLATION…..699
DISASSEMBLY…..701
ASSEMBLY…..702
ENGINE AND TRANSFER…..703
REMOVAL AND INSTALLATION…..703
TRANSFER…..731
DISASSEMBLY…..731
ASSEMBLY…..734
DRIVE SHAFT…..738
DISASSEMBLY…..738
ASSEMBLY…..739
FRONT AXLE…..740
REMOVAL…..740
INSTALLATION…..741
REAR AXLE…..742
REMOVAL…..742
INSTALLATION…..745
DIFFERENTIALS…..748
DISASSEMBLY…..748
ASSEMBLY…..751
AXLE HOUSINGS…..762
DISASSEMBLY…..762
ASSEMBLY…..767
CENTER HINGE PIN…..773
REMOVAL…..773
INSTALLATION…..780
STEERING VALVE…..790
REMOVAL AND INSTALLATION…..790
DISASSEMBLY…..791
ASSEMBLY…..794
RELIEF VALVE HOUSING SIDE OF STEERING VALVE…..799
DISASSEMBLY…..799
ASSEMBLY…..800
STEERING CYLINDER…..801
REMOVAL AND INSTALLATION…..801
PARKING BRAKE…..802
REMOVAL…..802
INSTALLATION…..804
HYDRAULIC TANK…..807
REMOVAL AND INSTALLATION…..807
WORK EQUIPMENT VALVE…..808
REMOVAL AND INSTALLATION…..808
DUMP CYLINDER…..809
REMOVAL AND INSTALLATION…..809
LIFT CYLINDER…..810
REMOVAL AND INSTALLATION…..810
HYDRAULIC CYLINDER…..811
DISASSEMBLY…..811
ASSEMBLY…..813
WORK EQUIPMENT…..815
REMOVAL…..815
INSTALLATION…..818
COUNTERWEIGHT…..821
REMOVAL AND INSTALLATION…..821
INSTRUMENTS PANEL…..822
REMOVAL AND INSTALLATION…..822
40 MAINTENANCE STANDARD…..823
TRANSMISSIONENGINE MOUNT…..824
WORK EQUIPMENTSTEERING PUMP, HST CHARGE PUMP…..825
TRANSFER…..826
HST INCHING VALVE…..828
DRIVE SHAFT…..829
DIFFERENTIAL (1/2)…..830
DIFFERENTIAL (2/2)…..831
FINAL DRIVE…..833
AXLE MOUNT…..834
STEERING COLUMN…..835
PRIORITY VALVE…..836
STEERING CYLINDER MOUNT…..837
BRAKE…..838
HYDRAULIC CYLINDER…..839
CENTER HINGE PIN…..841
WORK EQUIPMENT LINKAGE…..842
BUCKET POSITIONER…..844
BUCKET…..845
90 OTHERS…..846
ELECTRICAL CIRCUIT DIAGRAMSERIAL NO. 22005-26000…..847
ELECTRICAL CIRCUIT DIAGRAM (1/2)SERIAL NO. 26001 AND UP…..848
ELECTRICAL CIRCUIT DIAGRAM (2/2)SERIAL NO. 26001 AND UP…..849
BACKHOE…..850
CONTENTS…..851
GENERAL…..852
GENERAL ASSEMBLY DRAWING…..852
SPECIFICATIONS…..853
WEIGHT TABLE…..855
STRUCTURE AND FUNCTION…..856
VALVE CONTROL…..856
HYDRAULIC CIRCUIT DIAGRAM…..857
BACKHOE CONTROL VALVE…..858
CHECK VALVE…..860
WORK EQUIPMENT…..862
ACTUAL ELECTRICAL WIRING DIAGRAM…..863
ELECTRICAL CIRCUIT DIAGRAM…..864
TESTING AND ADJUSTING…..865
ADJUSTING BACKHOE SWING…..865
TEN00071-00 – Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual…..866
COVER…..866
FOREWORD…..867
FOREWORD…..868
SAFETY INFORMATION…..871
INTRODUCTION…..873
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…..873
NECESSARY INFORMATION…..874
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..874
ENGINE SERIAL NO. PLATE AND POSITION…..874
POSITION OF SERVICE METER…..874
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..875
CONTENTS…..876
SAFETY…..879
SAFETY…..880
SAFETY LABELS…..882
LOCATION OF SAFETY LABELS…..883
SAFETY LABELS…..884
GENERAL PRECAUTIONS…..888
SAFETY RULES…..888
IF ABNORMALITIES ARE FOUND…..888
CLOTHING AND PERSONAL PROTECTIVE ITEMS…..888
FIRE EXTINGUISHER AND FIRST AID KIT…..888
SAFETY FEATURES…..888
KEEP MACHINE CLEAN…..889
INSIDE OPERATOR'S COMPARTMENT…..889
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…..889
HANDRAILS AND STEPS…..890
MOUNTING AND DISMOUNTING…..890
NO PEOPLE ON ATTACHMENTS…..890
DO NOT GET CAUGHT IN ARTICULATED PORTION…..891
PREVENTION OF BURNS…..891
FIRE PREVENTION…..892
ACTION IF FIRE OCCURS…..893
WINDOW WASHER LIQUID…..893
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…..893
PRECAUTIONS FOR ATTACHMENTS, OPTIONS…..893
UNAUTHORIZED MODIFICATION…..893
SAFETY AT WORKSITE…..894
WORKING ON LOOSE GROUND…..894
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…..894
ENSURE GOOD VISIBILITY…..895
VENTILATION FOR ENCLOSED AREAS…..895
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…..895
EMERGENCY EXIT FROM OPERATOR'S CAB…..895
BE CAREFUL ABOUT ASBESTOS DUST…..896
PRECAUTIONS FOR OPERATION…..897
STARTING ENGINE…..897
CHECKS BEFORE STARTING ENGINE…..897
PRECAUTIONS WHEN STARTING…..897
PRECAUTIONS IN COLD AREAS…..898
OPERATION…..899
CHECKS BEFORE OPERATION…..899
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE…..899
PRECAUTIONS WHEN TRAVELING…..900
PRECAUTIONS WHEN USING A SMOKE POT…..900
TRAVELING ON SLOPES…..901
PROHIBITED OPERATIONS…..902
PRECAUTIONS WHEN OPERATING…..902
METHODS OF USING BRAKE…..903
OPERATE CAREFULLY ON SNOW…..903
PARKING MACHINE…..904
TRANSPORTATION…..905
LOADING AND UNLOADING…..905
SHIPPING…..905
BATTERY…..906
BATTERY HAZARD PREVENTION…..906
STARTING WITH BOOSTER CABLES…..907
TOWING…..908
WHEN TOWING…..908
PRECAUTIONS FOR MAINTENANCE…..909
WARNING TAG…..909
KEEP WORK PLACE CLEAN AND TIDY…..909
APPOINT LEADER WHEN WORKING WITH OTHERS…..909
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..910
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..911
PROPER TOOLS…..911
PERSONNEL…..912
ATTACHMENTS…..912
WORK UNDER THE MACHINE…..912
NOISE…..912
PRECAUTIONS WHEN USING HAMMER…..913
REPAIR WELDING…..913
REMOVING BATTERY TERMINAL…..913
PRECAUTIONS WITH HIGH-PRESSURE OIL…..913
HANDLING HIGH-PRESSURE HOSES…..914
WASTE MATERIALS…..914
COMPRESSED AIR…..914
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..914
PRECAUTIONS WITH TIRES…..915
HANDLING TIRES…..915
PRECAUTIONS WHEN STORING TIRES…..915
OPERATION…..916
GENERAL VIEW…..917
GENERAL VIEW OF MACHINE…..917
GENERAL VIEW OF CONTROLS AND GAUGES…..918
EXPLANATION OF COMPONENTS…..920
MACHINE MONITOR…..920
SWITCHES…..929
CONTROL LEVERS, PEDALS…..931
CAP WITH LOCK…..935
FRAME LOCK BAR…..936
TILT HOOD…..936
TOWING PIN…..936
FUSE…..937
FUSIBLE LINK…..938
MANUAL POCKET…..938
POWER OUTLET…..938
OPERATION…..939
CHECK BEFORE STARTING ENGINE, ADJUST…..939
STARTING ENGINE…..950
OPERATIONS AND CHECKS AFTER STARTING ENGINE…..953
STOPPING ENGINE…..954
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE…..955
TURNING…..959
OPERATION OF WORK EQUIPMENT…..960
HANDLING FRONT ATTACHMENT SERVICE HYDRAULIC CIRCUIT (IF EQUIPPED)…..961
WORK POSSIBLE USING WHEEL LOADER…..962
PRECAUTIONS FOR OPERATION…..966
ADJUSTING WORK EQUIPMENT POSTURE…..968
PARKING MACHINE…..970
CHECKS AFTER COMPLETION OF OPERATION…..972
LOCKING…..972
HANDLING THE TIRES…..973
TRANSPORTATION…..976
TRANSPORTATION PROCEDURE…..976
LOADING, UNLOADING WORK WITH TRAILERS…..976
LIFTING MACHINE…..979
REMOVAL, INSTALLATION OF CANOPY…..983
COLD WEATHER OPERATION…..985
PRECAUTIONS FOR LOW TEMPERATURE…..985
PRECAUTIONS AFTER COMPLETION OF WORK…..986
AFTER COLD WEATHER…..987
LONG-TERM STORAGE…..988
BEFORE STORAGE…..988
DURING STORAGE…..988
AFTER STORAGE…..988
TROUBLESHOOTING…..989
WHEN MACHINE RUNS OUT OF FUEL…..989
TOWING THE MACHINE…..989
IF BATTERY IS DISCHARGED…..991
OTHER TROUBLE…..994
MAINTENANCE…..999
GUIDES TO MAINTENANCE…..1000
OUTLINES OF SERVICE…..1002
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..1002
OUTLINE OF ELECTRIC SYSTEM…..1004
WEAR PARTS…..1005
WEAR PARTS LIST…..1005
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO …..1006
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…..1006
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..1010
TORQUE LIST…..1010
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1011
MAINTENANCE SCHEDULE CHART…..1012
MAINTENANCE SCHEDULE CHART…..1012
SERVICE PROCEDURE…..1014
INITIAL 250 HOURS SERVICE OR INITIAL 3 MONTHS (ONLY AFTER THE FIRST 250…..1014
WHEN REQUIRED…..1015
REPLACE AIR CLEANER ELEMENT…..1015
CLEAN INSIDE OF COOLING SYSTEM…..1016
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..1018
CLEAN WATER SEPARATOR ELEMENT…..1019
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL…..1020
CHECK AXLE OIL LEVEL, ADD OIL…..1021
CLEAN TRANSFER CASE BREATHER…..1022
CLEAN AXLE CASE BREATHER…..1022
CLEAN AND CHECK RADIATOR FINS…..1023
TURN, REPLACE BOLT-ON CUTTING EDGE…..1023
CHECK PARKING BRAKE…..1024
ADJUST PARKING BRAKE RELEASE LEVER…..1024
CHECK BRAKE PEDAL…..1024
SELECTION AND INSPECTION OF TIRES…..1025
CHECK BEFORE STARTING…..1027
EVERY 50 HOURS SERVICE OR EVERY 1 MONTH…..1028
CLEAN AIR CLEANER DUST CUP…..1028
EVERY 250 HOURS SERVICE OR EVERY 3 MONTHS…..1029
LUBRICATING…..1029
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…..1030
CLEAN AIR CLEANER ELEMENT…..1031
CHECK FAN BELT TENSION, ADJUST…..1032
CHECK BATTERY ELECTROLYTE LEVEL…..1033
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN…..1035
EVERY 500 HOURS SERVICE OR EVERY 6 MONTHS…..1036
LUBRICATE REAR AXLE PIVOT PIN (2 PLACES)…..1036
REPLACE FUEL FILTER CARTRIDGE…..1036
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..1038
EVERY 1000 HOURS SERVICE OR EVERY 1 YEAR…..1039
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE AND HST…..1039
LUBRICATING…..1040
EVERY 2000 HOURS SERVICE OR EVERY 2 YEARS…..1041
CHANGE OIL IN TRANSFER CASE…..1041
CHANGE AXLE OIL…..1042
CHECK ALTERNATOR, STARTING MOTOR…..1042
CHECK ENGINE VALVE CLEARANCE, ADJUST…..1042
SPECIFICATIONS…..1043
SPECIFICATIONS…..1044
ATTACHMENTS, OPTIONS…..1045
HANDLING SEAT BELT…..1046
FASTENING AND REMOVING BELT…..1046
ADJUST BELT LENGTH…..1046
CHECK SEAT BELT AND MOUNTS…..1047
HANDLING SERVICE HYDRAULIC CIRCUIT…..1048
CONNECTING HYDRAULIC CIRCUIT…..1048
ROUTE OF HYDRAULIC CIRCUIT…..1049
INDEX…..1050

Komatsu Wheel Loader WA30 Repair Service Manuals

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete workshop repair service manual with electrical wiring diagrams for Komatsu W120-3 Wheel Loader. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Komatsu W120-3 Wheel Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

SEBM0383C01 – Komatsu W120-3 Wheel Loader Shop Manual.pdf
SERIAL NUMBERS: 50001 and UP

MAIN SECTIONS
CONTENTS
GENERAL
POWER TRAIN
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
STEERING SYSTEM
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
AIR SYSTEM
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
STRUCURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
OTHERS
ELECTRICAL SYSTEM

EXCERPT:
ELECTRICAL SYSTEM
The electrical circuit employed in the W120-3 series tractor is a 24 volts, negative ground system. Electrical energy stored in the batteries is available upon demand to the system components. These components, which include the instruments, headlights, stop and tail lights and starting motor, are dependent upon battery energy until the engine drives the generator at a speed sufficient to carry the electrical load. Above this predetermined speed, electrical energy produced by the AC generator supplies the normal demands of the system. A portion of this energy is sent to the batteries to keep them in a state of full charge.
A regulator controls the output of the generator. By using a regulated control, electrical energy produced by the generator is supplied to the system components on
demand.
Two heavy duty twelve volt batteries, wired in series produce a 24 volts system. A battery is housed in each of the battery boxes located on the rear main frame.
Hinged tops on the battery boxes provide easy access for servicing.
The system may be divided into two circuits; the cranking circuit during engine starting and the charging circuit, supplying current to the remainder of the system when the engine is operating. In addition, the charging circuit replaces electrical energy drained from the batteries.
…
Komatsu W120-3 Wheel Loader Workshop Repair & Service Manual

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manual with Electrical Wiring Diagrams for Komatsu/Dressta TD7H, TD8H, TD9H Crawler Tractor, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu/Dressta TD7H, TD8H, TD9H Crawler Tractor 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: 1,071 pages
File Format: PDF
Language: English

CEBM789H04 – Komatsu_Dressta TD7H, TD8H, TD9H Crawler Tractor Shop Manual.pdf

MAIN SECTIONS
INTRODUCTION — SECTION 1
MISCELLANEOUS — SECTION 2
BRAKES — SECTION 4
STEERING — SECTION 5
COOLING — SECTION 6
DRIVE TRAIN — SECTION 7
DIRECT DRIVE — SECTION 7A
TORQUE CONVERTER — SECTION 7B
TRANSMISSION — SECTION 7C
STEERING DRIVE — SECTION 7E
SPROCKET DRIVE — SECTION 7F
ELECTRICAL — SECTION 8
FRAME — SECTION 9
HYDRAULICS — SECTION 10
PUMPS AND MOTORS — SECTION 10A
VALVES — SECTION 10B
CYLINDERS — SECTION 10C
INSTRUMENTS — SECTION 11
POWER — SECTION 12
SUPERSTRUCTURE — SECTION 13
UNDERCARRIAGE — SECTION 14
TRACK CHAIN — SECTION 15
MOUNTED EQUIPMENT — SECTION 17

Komatsu/Dressta TD7H, TD8H, TD9H Crawler Tractor Repair Service Manuals

---

INSTANT DOWNLOAD

---