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KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL SL NO(D87E-2)P090001 & up (D87P-2)P092001 & up – PDF DOWNLOAD
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KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL
SL NO:(D87E-2)P090001 & up (D87P-2)P092001 & up
PUB NUMBER:CEBM004802
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Description
KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL SL NO(D87E-2)P090001 & up (D87P-2)P092001 & up
KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL SL NO(D87E-2)P090001 & UP (D87P-2)P092001 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL SL NO(D87E-2)P090001 & up (D87P-2)P092001 & up
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE, FUNCTION & MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. This section also gives the judgement standards when inspecting disassembled parts. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating problems to causes are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to follow when removing, installing, disassembling or assembling each component, as well
as precautions to be taken for these operations.
TABLE OF CONTENTS:
KOMATSU BOSS D87E-2 D87P-2 CRAWLER TRACTOR SHOP MANUAL SL NO(D87E-2)P090001 & up (D87P-2)P092001 & up
MAIN MENU....................................................................... 0 COVER........................................................................... 1 CONTENTS........................................................................ 2 00 FOREWORD..................................................................... 9 SAFETY NOTICE............................................................... 10 IMPORTANT SAFETY NOTICE................................................. 10 GENERAL PRECAUTIONS..................................................... 10 PREPARATIONS FOR WORK................................................... 10 PRECAUTIONS DURING WORK............................................. 10 GENERAL..................................................................... 12 GENERAL................................................................. 12 STRUCTURE, FUNCTION & MAINTENANCE STANDARD.............................. 12 TESTING AND ADJUSTING................................................... 12 DISASSEMBLY AND ASSEMBLY................................................ 12 HOW TO READ THE SHOP MANUAL................................................. 13 VOLUMES................................................................. 13 DISTRIBUTION AND UPDATING............................................... 13 FILING METHOD........................................................... 13 REVISED EDITION MARK.................................................... 13 REVISIONS............................................................... 13 SYMBOLS................................................................. 14 HOISTING INSTRUCTIONS....................................................... 15 HOISTING................................................................ 15 WIRE ROPES.............................................................. 15 COATING MATERIALS........................................................... 16 STANDARD TIGHTENING TORQUE.................................................. 17 METRIC FASTENERS........................................................ 17 NUTS AND BOLTS...................................................... 17 HOSE NUTS........................................................... 18 SPLIT FLANGE BOLTS.................................................. 18 FLARED NUTS......................................................... 18 ALTERNATIVE FASTENERS................................................... 19 BOLT IDENTIFICATION CHART........................................... 19 GRADE 5 AND 8 NONPHOSPHATE COATED HARDWARE......................... 20 GRADE 8 PHOSPHATE COATED HARDWARE................................... 21 STANDARD METRIC FASTENERS........................................... 21 HYDRAULIC TUBES AND FITTINGS........................................ 22 HOSE CLAMPS......................................................... 22 SPLIT FLANGE CONNECTIONS............................................ 22 ELECTRIC WIRE CODE.......................................................... 23 CLASSIFICATION BY THICKNESS............................................. 23 CLASSIFICATION BY COLOR AND CODE........................................ 23 CONVERSION TABLES........................................................... 24 METHOD OF USING THE CONVERSION TABLE.................................... 24 01 GENERAL...................................................................... 31 VIEW OF MACHINE............................................................. 32 D87E-2.................................................................. 32 D87P-2.................................................................. 33 DIMENSIONAL DRAWINGS........................................................ 34 D87E-2.................................................................. 34 SEMI U DOZER........................................................ 34 STRAIGHT ANGLE DOZER................................................ 36 D87P-2.................................................................. 38 STRAIGHT DOZER...................................................... 38 SPECIFICATIONS.............................................................. 40 WEIGHT TABLE................................................................ 43 USE OF FUEL, COOLANT AND LUBRICANTS......................................... 44 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................ 44 ABBREVIATIONS....................................................... 45 ENGINE OIL SPECIFICATIONS............................................... 45 NORMAL OPERATION.................................................... 45 ARCTIC OPERATION.................................................... 45 DRIVE TRAIN OIL SPECIFICATIONS.......................................... 45 TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS........... 45 EQUIPMENT SYSTEM OIL SPECIFICATIONS..................................... 46 FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS................... 46 COOLING SYSTEM.......................................................... 46 FUEL SYSTEM............................................................. 46 10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS.................................. 47 ENGINE MOUNT................................................................ 49 ENGINE CONTROL.............................................................. 51 3 LEVER CONTROL DRIVE................................................... 51 1 LEVER DRIVE CONTROL................................................... 52 FUEL LINES.................................................................. 53 RADIATOR, OIL COOLER........................................................ 54 DRIVE TRAIN................................................................. 55 DRIVE SHAFT................................................................. 56 DRIVE TRAIN SCHEMATIC....................................................... 56 3 LEVER CONTROL DRIVE................................................... 56 1 LEVER CONTROL DRIVE................................................... 58 DRIVE TRAIN PIPING DIAGRAM.................................................. 60 3 LEVER CONTROL DRIVE................................................... 60 1 LEVER CONTROL DRIVE................................................... 62 TORQUE CONVERTER MOUNTING................................................... 64 TORQUE CONVERTER............................................................ 66 TRANSMISSION................................................................ 69 CONTROLS................................................................ 69 3 LEVER DRIVE CONTROL............................................... 69 1 LEVER DRIVE CONTROL............................................... 69 MOUNTING................................................................ 70 CROSS SECTION........................................................... 71 GEAR SHIFT OPERATION.................................................... 73 DIRECTIONAL (INPUT) SHAFT............................................... 76 COUNTERSHAFT............................................................ 78 RANGE (OUTPUT) SHAFT.................................................... 80 REVERSE IDLER SHAFT..................................................... 82 PRESSURE REGULATOR VALVE................................................ 83 RANGE SELECTOR VALVE.................................................... 85 RATE OF RISE VALVE...................................................... 87 PILOT CONTROL VALVE..................................................... 90 3 LEVER DRIVE CONTROL............................................... 90 PILOT MANIFOLD.......................................................... 91 3 LEVER DRIVE CONTROL............................................... 91 TASC VALVE.............................................................. 92 1 LEVER DRIVE CONTROL............................................... 92 NEUTRAL START VALVE..................................................... 95 1 LEVER DRIVE CONTROL............................................... 95 PRESSURE REGULATOR VALVE................................................ 97 1 LEVER DRIVE CONTROL............................................... 97 CHARGE AND SCAVENGE PUMP................................................ 98 TWO SPEED STEERING..........................................................100 DRIVE UNIT..............................................................101 3 LEVER DRIVE CONTROL...............................................102 1 LEVER DRIVE CONTROL...............................................103 STEERING VALVE..........................................................104 3 LEVER DRIVE CONTROL...............................................104 1 LEVER DRIVE CONTROL...............................................108 STEERING VALVE MANIFOLD.................................................113 FINAL DRIVE.................................................................114 UNDERCARRIAGE...............................................................118 FRONT IDLER.............................................................120 TOP IDLER...............................................................122 TRACK ROLLER............................................................123 TRACK ADJUSTER..........................................................125 TRACK SPRING............................................................126 PIVOT SHAFT.............................................................128 EQUALIZER BAR...........................................................129 TRACK FRAME GUIDES......................................................130 TRACK CHAIN.............................................................131 LUBRICATED STYLE....................................................131 DRY SEALED STYLE....................................................132 MAIN FRAME..................................................................134 EQUIPMENT HYDRAULICS........................................................136 EQUIPMENT HYDRAULIC SCHEMATIC...........................................136 EQUIPMENT HYDRAULIC DIAGRAM.............................................137 RESERVOIR...............................................................138 PUMP....................................................................140 BLADE LIFT AND RIPPER VALVE BANK........................................142 MAIN RELIEF VALVE...................................................143 ANTI CAVITATION VALVE...............................................143 BLADE LIFT SECTION VALVE............................................144 RIPPER LIFT SECTION VALVE...........................................145 RIPPER PITCH SECTION VALVE..........................................146 BLADE LIFT VALVE BANK...................................................147 MAIN RELIEF VALVE...................................................148 ANTI CAVITATION VALVE...............................................148 BLADE LIFT SECTION VALVE............................................149 BLADE TILT VALVE BANK...................................................150 BLADE TILT SECTION VALVE............................................151 MAIN RELIEF VALVE...................................................151 BLADE PILOT CONTROL VALVE...............................................152 DESCRIPTION.........................................................152 RIPPER PILOT CONTROL VALVE..............................................154 DESCRIPTION.........................................................155 PILOT SUPPLY VALVE......................................................156 QUICK DROP VALVE........................................................158 GIMBAL TUBE AND YOKE....................................................159 BLADE LIFT CYLINDER.....................................................160 BLADE TILT CYLINDER.....................................................162 DOZER MODELS........................................................162 ANGLE MODELS........................................................162 RIPPER LIFT CYLINDER....................................................163 RIPPER PITCH CYLINDER...................................................164 CAB.........................................................................165 ELECTRICAL SYSTEM...........................................................166 SCHEMATIC...............................................................166 3 LEVER DRIVE CONTROL...............................................166 1 LEVER DRIVE CONTROL...............................................168 WIRING..................................................................169 1 LEVER DRIVE CONTROL...............................................169 ELECTRICAL COMPONENTS...................................................171 DESCRIPTION.........................................................171 STARTING AND CHARGING GROUP.........................................171 LIGHTING GROUP......................................................171 INDICATOR GROUP.....................................................171 ACCESSORY GROUP.....................................................171 CRANKING MOTOR......................................................172 ALTERNATOR..........................................................172 MASTER DISCONNECT SWITCH............................................173 MAGNETIC SWITCH.....................................................173 RECTIFIER BOARD.....................................................174 IN LINE DIODE.......................................................174 LEFT AND RIGHT SOLENOID DIODE.......................................174 KEY START SWITCH....................................................175 BRAKE PEDAL SWITCH..................................................175 NEUTRAL START SWITCH................................................175 NEUTRAL SOLENOID SWITCH.............................................175 PREHEATER RELAY SWITCH..............................................176 ENGINE AIR PREHEATER................................................176 PREHEAT SELECT SWITCH...............................................177 BIMETAL SWITCH......................................................177 PREHEAT INDICATOR...................................................178 SOUND ALARM.........................................................178 LIGHT SWITCH........................................................179 WORK LIGHTS.........................................................179 GAUGE CLUSTER.......................................................180 HOURMETER...........................................................181 ENGINE OIL PRESSURE SWITCH..........................................181 FUEL GAUGE..........................................................182 FUEL SENDER.........................................................182 AIR FILTER SWITCH...................................................183 TRANSMISSION OR HYDRAULIC FILTER SWITCH.............................183 PILOT FILTER SWITCH.................................................184 ENGINE OIL PRESSURE GAUGE SENDER....................................184 ENGINE COOLANT TEMPERATURE SENDER...................................185 TORQUE CONVERTER OIL TEMPERATURE SENDER.............................185 ENGINE COOLANT TEMPERATURE SWITCH...................................185 TRANSMISSION OIL TEMPERATURE SENDER.................................186 CLUTCH PRESSURE SWITCH..............................................186 WARNING/CAUTION LAMP................................................187 COOLANT LEVEL RELAY.................................................187 BULB CHECK RELAY....................................................187 COOLANT LEVEL SWITCH................................................188 GEAR INDICATOR SENSOR...............................................188 MAIN CIRCUIT BREAKER................................................189 INDIVIDUAL CIRCUIT BREAKERS.........................................189 TIME DELAY MODULE...................................................190 INSTRUMENT PANEL DIODE BOARD........................................190 BACK UP ALARM.......................................................191 BACK UP ALARM SWITCH................................................191 WARNING HORN........................................................192 WARNING HORN SWITCH.................................................192 WIPER MOTOR.........................................................193 WIPER AND WASHER SWITCH.............................................193 WASHER PUMP.........................................................194 DOME LIGHT..........................................................194 CAB SWITCH PANEL....................................................195 BLOWER MOTOR SWITCH.................................................195 BLADE FLOAT SOLENOID................................................196 A/C MAGNETIC CLUTCH.................................................196 STEERING CONTROLLER.................................................197 GRIP BUTTON MICRO SWITCHES..........................................197 GEAR SPEED INDICATOR................................................198 NEUTRAL SOLENOID....................................................198 LEFT OR RIGHT SOLENOID..............................................199 WIRING HARNESSES........................................................201 FRONT HARNESS.......................................................201 ENGINE HARNESS......................................................202 POD HARNESS.........................................................204 CONTROL TOWER HARNESS...............................................205 REAR HARNESS........................................................206 RIGHT REAR HARNESS..................................................207 INSTRUMENT PANEL HARNESS............................................208 CAB HARNESS.........................................................210 CAB PANEL HARNESS...................................................212 CONTROLLER HARNESS..................................................213 INSTRUMENT HARNESS..................................................214 COMPARTMENT HARNESS.................................................215 COMPARTMENT HARNESS.................................................216 A/C HEATER..................................................................217 A/C HEATER LINES........................................................217 COMPRESSOR MOUNTING.....................................................218 CAB A/C UNIT............................................................219 CAB HEATER UNIT.........................................................220 SPECIAL TORQUE CHART........................................................221 20 TESTING, ADJUSTION AND TROUBLESHOOTING.......................................223 STANDARD VALUE TABLES.......................................................224 ENGINE IN CHASSIS.......................................................224 CHASSIS.................................................................225 STALL SPEEDS........................................................225 LEVER MOVEMENT......................................................225 OPERATING EFFORT....................................................227 DRIVE TRAIN.........................................................230 WORK EQUIPMENT......................................................231 TOOLS FOR TESTING AND ADJUSTING.............................................233 ENGINE......................................................................234 ENGINE SPEED............................................................234 EXHAUST COLOR...............................................................235 MEASURING WITH HANDY SMOKER CHECKER B1..................................235 MEASURING WITH SMOKE METER B2...........................................235 BELT TENSION................................................................236 TORQUE CONVERTER STALL SPEEDS...............................................237 CONVERTER STALL.........................................................237 FULL STALL (CONVERTER AND HYDRAULIC)....................................237 FUEL CONTROL LINKAGE........................................................238 3 LEVER DRIVE CONTROL...................................................238 LEVER TRAVEL........................................................238 LEVER EFFORT........................................................238 THROTTLE ADJUSTMENT.................................................238 FUEL CONTROL LINKAGE........................................................240 1 LEVER DRIVE CONTROL...................................................240 LEVER TRAVEL........................................................240 LEVER EFFORT........................................................240 THROTTLE ADJUSTMENT.................................................240 DRIVE TRAIN LEVERS..........................................................242 3 LEVER DRIVE CONTROL...................................................242 GEAR SHIFT LEVER....................................................242 STEERING LEVERS.....................................................242 TASC VALVE..................................................................243 1 LEVER DRIVE CONTROL...................................................243 GEAR TWIST TRAVEL...................................................243 GEAR TWIST EFFORT...................................................243 FRONT TO REAR LEVER TRAVEL..........................................243 FRONT TO REAR LEVER EFFORT..........................................243 LEFT TO RIGHT LEVER TRAVEL..........................................243 LEFT TO RIGHT LEVER EFFORT..........................................243 BRAKE PEDAL.................................................................244 PEDAL TRAVEL............................................................244 PEDAL OPERATING FORCE...................................................244 ADJUSTMENT..............................................................244 DECELERATOR PEDAL...........................................................245 PEDAL TRAVEL............................................................245 PEDAL OPERATING FORCE...................................................245 SAFETY LOCK LEVER...........................................................246 3 LEVER DRIVE CONTROL...................................................246 1 LEVER DRIVE CONTROL...................................................246 BLADE EQUIPMENT LEVER.......................................................247 RAISE, LOWER AND FLOAT TRAVEL...........................................247 TILT TRAVEL.............................................................247 RAISE, LOWER AND FLOAT EFFORT...........................................247 TILT EFFORT.............................................................247 REAR EQUIPMENT LEVER........................................................248 RAISE AND LOWER TRAVEL..................................................248 TILT IN AND OUT TRAVEL..................................................248 RAISE AND LOWER EFFORT..................................................248 TILT IN AND OUT EFFORT..................................................248 DRIVE TRAIN PRESSURES.......................................................249 TRANSMISSION CLUTCH.....................................................249 PILOT REGULATED PRESSURE................................................249 WORK EQUIPMENT..............................................................250 SYSTEM RELIEF VALVE TEST................................................250 BLADE LIFT SYSTEM (1)...............................................250 BLADE TILT SYSTEM (2)...............................................251 BLADE PILOT SYSTEM (3)..............................................251 ADJUSTING RELIEF VALVE..................................................252 BLADE TILT SYSTEM...................................................252 BLADE LIFT SYSTEM...................................................252 PILOT SYSTEM........................................................252 CYLINDER DRIFT TEST.....................................................253 CYLINDER TIME CYCLE.....................................................254 BLADE LIFT..........................................................254 BLADE TILT..........................................................254 PISTON PACKING TEST.....................................................255 BLADE TILT AND RIPPER CYLINDERS.....................................255 CYLINDER RATE OF TRAVEL.................................................255 DEAD ENGINE LOWER TEST..................................................255 SERVICE DIAGNOSIS...........................................................256 ENGINE COOLING SYSTEM...................................................256 ENGINE OVERHEATING DUE TO RESTRICTED AIR FLOW.......................256 ENGINE OVERHEATING DUE TO POOR CIRCULATION..........................256 INTERNAL LEAKAGE....................................................256 ENGINE RUNS COLD....................................................256 EXTERNAL LEAKAGE....................................................257 DRIVE TRAIN COOLANT SYSTEM..............................................257 DRIVE TRAIN OIL OVER HEATING........................................257 DRIVE TRAIN.............................................................258 CLUTCH PRESSURE LAMP GLOWS RED......................................258 (Shift Lever in Neutral, Engine Running, Oil Warm)..................258 CLUTCH PRESSURE LAMP GLOWS RED......................................258 (Shift Lever in Gear, Engine Running, Oil Warm).....................258 HIGH TORQUE CONVERTER OIL TEMPERATURE...............................258 (Gauge on Dash).....................................................258 LOSS OF POWER UNDER LOAD............................................258 SLOW OR ERRATIC TRANSMISSION CLUTCH ENGAGEMENT......................258 TRANSMISSION SHAFT LEVER JUMPS OUT OF GEAR..........................258 DRIVE TRAIN PRESSURES...................................................259 TORQUE CONVERTER STALL SPEED............................................260 TRANSMISSION CLUTCH RESULTS.............................................261 TORQUE CONVERTER........................................................261 LOSS OF FLUID FROM TORQUE CONVERTER.................................261 TORQUE CONVERTER OVERHEATING........................................261 LOSS OF POWER.......................................................261 GRINDING OR SCRAPING NOISE INSIDE CONVERTER HOUSING.................261 FINAL DRIVE.............................................................262 FINAL DRIVE OVERHEATING.............................................262 NOISE...............................................................262 LUBRICANT LEAKING...................................................262 FINAL DRIVE LUBRICANT LEVEL TO HIGH.................................262 EXCESSIVE WEAR ON SPROCKETS.........................................262 EQUIPMENT HYDRAULIC SYSTEM..............................................263 NOISY OPERATION, OIL FOAMING........................................263 BLADE LIFT CIRCUIT WEAK AND/OR SLOW.................................263 (Cylinder Droop)....................................................263 BLADE TILT CIRCUIT WEAK AND/OR SLOW.................................263 BLADE LIFT RIPPER CIRCUITS WEAK AND/OR SLOW.........................263 ALL CIRCUITS WEAK AND/OR SLOW.......................................263 ONE BLADE LIFT OR TILT OR RIPPER CIRCUIT SLOW AND/OR NO MOVEMENT....263 RIPPER PITCH OR LIFT CYLINDERS DROP.................................263 MOMENTARY DROP WHEN ACTUATED FROM HOLD..............................263 OIL OVER HEATING....................................................264 SHORT LIFE OF PUMP..................................................264 EQUIPMENT SYSTEM RESULTS................................................264 UNDERCARRIAGE...........................................................265 TRACK CHAIN COMES OFF DURING OPERATION..............................265 MACHINE CREEPS TO ONE SIDE..........................................265 TRACK CHAIN LOOSE...................................................265 EXCESSIVE OR UNEVEN WEAR OF TRACK AND COMPONENTS....................265 LUBRICANT LEAKAGE...................................................265 FRONT IDLER DOES NOT ROTATE.........................................265 TOP IDLERS DO NOT ROTATE............................................266 TRACK IDLERS DO NOT ROTATE..........................................266 MACHINE LOSES POWER.................................................266 TRACK SHOES BOLTS BREAK.............................................266 30 DISASSEMBLY AND ASSEMBLY.....................................................267 METHOD OF USING MANUAL......................................................269 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................273 SPECIAL TOOL LIST...........................................................276 CRANKCASE GUARD.............................................................285 REMOVAL.................................................................285 INSTALLATION............................................................285 TRANSMISSION GUARD..........................................................286 REMOVAL.................................................................286 INSTALLATION............................................................286 ENGINE HOOD.................................................................287 REMOVAL.................................................................287 INSTALLATION............................................................287 ROPS........................................................................288 REMOVAL.................................................................288 INSTALLATION............................................................288 CAB.........................................................................289 REMOVAL.................................................................289 INSTALLATION............................................................289 OPERATOR’S SEAT.............................................................290 REMOVAL.................................................................290 INSTALLATION............................................................290 OPERATOR’S COMPARTMENT......................................................291 REMOVAL.................................................................291 INSTALLATION............................................................291 FUEL TANK...................................................................292 REMOVAL.................................................................292 INSTALLATION............................................................292 RADIATOR....................................................................293 REMOVAL.................................................................293 INSTALLATION............................................................294 DISASSEMBLY.............................................................295 ASSEMBLY................................................................296 ENGINE......................................................................297 REMOVAL.................................................................297 INSTALLATION............................................................297 TORQUE CONVERTER............................................................298 REMOVAL.................................................................298 INSTALLATION............................................................298 DISASSEMBLY.............................................................300 ASSEMBLY................................................................302 CHARGE AND SCAVENGE PUMP....................................................305 REMOVAL.................................................................305 INSTALLATION............................................................305 DISASSEMBLY.............................................................307 ASSEMBLY................................................................307 SCAVENGE PUMP AND DRIVE.....................................................309 REMOVAL.................................................................309 INSTALLATION............................................................309 DRIVE SHAFT.................................................................310 SERVICE.................................................................310 TRANSMISSION................................................................311 REMOVAL.................................................................311 INSTALLATION............................................................311 COMPLETE ASSEMBLY.......................................................312 DISASSEMBLY.........................................................313 ASSEMBLY............................................................316 INPUT (DIRECTIONAL) CLUTCH SHAFT........................................320 DISASSEMBLY.........................................................321 ASSEMBLY............................................................323 COUNTERSHAFT............................................................327 DISASSEMBLY.........................................................327 ASSEMBLY............................................................328 OUTPUT (RANGE) SHAFT....................................................329 DISASSEMBLY.........................................................330 ASSEMBLY............................................................335 REVERSE IDLER SHAFT.....................................................341 SERVICE.............................................................341 MAIN REGULATOR VALVE....................................................342 DISASSEMBLY.........................................................343 ASSEMBLY............................................................346 RANGE SELECTOR VALVE....................................................350 DISASSEMBLY.........................................................350 ASSEMBLY............................................................353 RATE OF RISE VALVE......................................................356 DISASSEMBLY.........................................................357 ASSEMBLY............................................................360 PILOT CONTROL VALVE AND MANIFOLD........................................363 3 LEVER DRIVE CONTROL...............................................363 TASC VALVE..............................................................369 1 LEVER DRIVE CONTROL...............................................369 NEUTRAL START VALVE.........................................................388 1 LEVER DRIVE CONTROL...................................................388 REMOVAL.............................................................388 INSTALLATION........................................................388 DISASSEMBLY.........................................................388 STEERING CONTROLLER.........................................................390 1 LEVER DRIVE CONTROL...................................................390 REMOVAL.............................................................390 INSTALLATION........................................................390 SERVICE.............................................................390 REGULATOR VALVE.............................................................391 1 LEVER DRIVE CONTROL...................................................391 REMOVAL.............................................................391 INSTALLATION........................................................391 SERVICE.............................................................392 STEERING DRIVE..............................................................393 REMOVAL.................................................................393 INSTALLATION............................................................394 STEERING UNIT...........................................................395 DISASSEMBLY.........................................................395 ASSEMBLY............................................................411 STEERING VALVE..........................................................430 3 LEVER DRIVE CONTROL...............................................430 1 LEVER DRIVE CONTROL...............................................454 STEERING MANIFOLD.......................................................469 FINAL DRIVE AND SPROCKET....................................................471 SPROCKET................................................................471 REMOVAL.............................................................471 INSTALLATION........................................................471 FINAL DRIVE.............................................................472 REMOVAL.............................................................472 INSTALLATION........................................................472 DISASSEMBLY.........................................................474 ASSEMBLY............................................................479 EQUIPMENT PUMP..............................................................484 REMOVAL.................................................................484 INSTALLATION............................................................484 EQUIPMENT VALVES............................................................485 BLADE LIFT VALVE BANK...................................................485 REMOVAL.............................................................485 INSTALLATION........................................................485 DISASSEMBLY.........................................................486 ASSEMBLY............................................................486 BLADE LIFT AND RIPPER VALVE BANK........................................495 REMOVAL.............................................................495 INSTALLATION........................................................495 DISASSEMBLY.............................................................496 ASSEMBLY............................................................496 BLADE TILT VALVE BANK...................................................506 REMOVAL.............................................................506 INSTALLATION........................................................506 BLADE PILOT VALVE.......................................................507 REMOVAL.............................................................507 INSTALLATION........................................................507 DISASSEMBLY.........................................................509 ASSEMBLY............................................................510 PLUNGER CAPSULE.....................................................511 METERING CAPSULE....................................................514 RIPPER PILOT VALVE......................................................515 REMOVAL.............................................................515 INSTALLATION........................................................515 DISASSEMBLY.........................................................517 ASSEMBLY............................................................518 PLUNGER CAPSULE.....................................................519 METERING CAPSULE....................................................520 PILOT SUPPLY VALVE......................................................521 REMOVAL.............................................................521 INSTALLATION........................................................521 DISASSEMBLY.........................................................523 ASSEMBLY............................................................524 QUICK DROP VALVE........................................................526 REMOVAL.............................................................526 INSTALLATION........................................................526 DISASSEMBLY.........................................................528 ASSEMBLY............................................................529 EQUIPMENT CYLINDERS.........................................................530 BLADE LIFT..............................................................530 REMOVAL.............................................................530 INSTALLATION........................................................530 DISASSEMBLY.........................................................532 ASSEMBLY............................................................533 DOZER TILT..............................................................535 REMOVAL.............................................................535 INSTALLATION........................................................535 DISASSEMBLY.........................................................537 ASSEMBLY............................................................538 ANGLE TILT..............................................................540 REMOVAL.............................................................540 INSTALLATION........................................................540 DISASSEMBLY.........................................................542 ASSEMBLY............................................................543 RIPPER LIFT.............................................................545 REMOVAL.............................................................545 INSTALLATION........................................................545 DISASSEMBLY.........................................................547 ASSEMBLY............................................................548 RIPPER PITCH............................................................550 REMOVAL.............................................................550 INSTALLATION........................................................550 DISASSEMBLY.........................................................552 ASSEMBLY............................................................553 UNDERCARRIAGE...............................................................555 WEAR LIMITS.............................................................556 SPECIFICATIONS......................................................556 GENERAL.............................................................557 TRACK SHOE GROUSER HEIGHT...........................................557 LINK HEIGHT.........................................................557 BUSHING OUTSIDE DIAMETER............................................557 INTERNAL PIN AND BUSHING WEAR (PITCH)...............................558 FRONT IDLER FLANGE HEIGHT...........................................558 TRACK ROLLER ROLLING DIAMETER.......................................558 TOP IDLER ROLLING DIAMETER..........................................558 FRONT IDLER.............................................................559 REMOVAL.............................................................559 INSTALLATION........................................................559 DISASSEMBLY.........................................................561 ASSEMBLY............................................................562 CLEARANCE LIMITS....................................................564 TRACK ADJUSTER..........................................................566 REMOVAL.............................................................566 INSTALLATION........................................................566 DISASSEMBLY.........................................................567 ASSEMBLY............................................................567 TRACK ROLLER............................................................568 REMOVAL.............................................................568 INSTALLATION........................................................568 DISASSEMBLY.........................................................570 ASSEMBLY............................................................571 ROLLER CLEARANCES...................................................573 TOP IDLER...............................................................574 REMOVAL.............................................................574 INSTALLATION........................................................574 DISASSEMBLY.........................................................576 ASSEMBLY............................................................580 TRACK FRAME.............................................................585 REMOVAL.............................................................585 INSTALLATION........................................................587 TRACK FAME GUIDE........................................................589 SERVICE.............................................................590 EQUALIZER BAR...........................................................591 SERVICE.............................................................592 PIVOT SHAFT.............................................................594 REMOVAL.............................................................594 INSTALLATION........................................................595 RECOIL SPRING...........................................................596 REMOVAL.............................................................596 INSTALLATION........................................................597 TRACK FRAME ALIGNMENT...................................................599 METAL TYPE FACE SEALS...................................................601 SEAL INSPECTION.....................................................601 SEAL INSTALLATION.......................................................602 TRACK CHAIN.............................................................604 MAINTENANCE.........................................................605 REMOVAL.............................................................605 INSTALLATION........................................................606 COMPLETE CHAIN REBUILD..............................................606 SINGLE JOINT REBUILD................................................609 90 OTHER........................................................................613 DRIVE TRAIN SCHEMATIC......................................................615 3 LEVER DRIVE CONTROL...................................................615 1 LEVER DRIVE CONTROL...................................................617 TORQUE CONVERTER MOUNTING...................................................619 DIRECTIONAL (INPUT) SHAFT...................................................621 COUNTERSHAFT................................................................623 RANGE (OUTPUT) SHAFT........................................................625 RATE OF RISE VALVE..........................................................627 TWO SPEED STEERING..........................................................629 3 LEVER CONTROL.........................................................613 1 LEVER CONTROL.........................................................633 FINAL DRIVE.................................................................633 MAIN FRAME..................................................................635 EQUIPMENT HYDRAULICS .......................................................636 EQUIPMENT HYDRAULIC SCHEMATIC...........................................636 EQUIPMENT HYDRAULIC DIAGRAM.............................................637 PUMP....................................................................639 BLADE PILOT CONTROL VALVE...............................................641 RIPPER PILOT CONTROL VALVE..............................................642 BLADE LIFT CYLINDER.....................................................643 CAB.........................................................................645 ELECTRICAL WIRING SCHEMATIC.................................................647 3 LEVER CONTROL.........................................................647 1 LEVER CONTROL.........................................................648 WIRING......................................................................649 1 LEVER CONTROL.........................................................649 WIRING HARNESS..............................................................651 FRONT HARNESS...........................................................651 ENGINE HARNESS..........................................................653 POD HARNESS.............................................................654 CONTROL TOWER HARNESS...................................................655 REAR HARNESS............................................................656 RIGHT REAR HARNESS......................................................657 INSTRUMENT PANEL HARNESS................................................659 CAB HARNESS.............................................................661 CAB PANEL HARNESS.......................................................662 CONTROLLER HARNESS......................................................663 INSTRUMENT HARNESS......................................................664 COMPARTMENT HARNESS.....................................................665 CONTROL TOWER HARNESS...................................................666 A/C HEATER..................................................................667 A/C HEATER LINES........................................................667 COMPRESSOR MOUNTING.....................................................668
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
