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Komatsu D275A-5 Crawler Bulldozer Shop Manual SEBM026307 – PDF DOWNLOAD
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Komatsu D275A-5 Crawler Bulldozer Shop Manual
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D275A-5 25001 and up
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Description
Komatsu D275A-5 Crawler Bulldozer Shop Manual SEBM026307
FILE DETAILS:
Komatsu D275A-5 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D275A-5
Serial Number: 25001 and up
Book Code: SEBM026307
Language: English
Pages: 985
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D275A-5 Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. 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 chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D275A-5 Crawler Bulldozer Shop Manual
COVER.................................................................................................................................... 1 CONTENTS................................................................................................................................. 2 01 GENERAL............................................................................................................................... 27 SPECIFICATION DRAWING................................................................................................................ 28 SPECIFICATIONS....................................................................................................................... 29 WEIGHT TABLE......................................................................................................................... 35 TABLE OF FUEL,COOLANT AND LUBRICANT.................................................................................................. 37 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD........................................................................................... 38 POWER TRAIN.......................................................................................................................... 40 OVERALL DRAWING OF POWER TRAIN UNIT.................................................................................................. 42 DAMPER, UNIVERSAL JOINT.............................................................................................................. 45 TORQUE CONVERTER, PTO................................................................................................................ 47 TORQUE CONVERTER..................................................................................................................... 50 SCAVENGING PUMP...................................................................................................................... 53 TRANSMISSION CONTROL................................................................................................................. 54 TRANSMISSION......................................................................................................................... 55 TRANSMISSION ECMV.................................................................................................................... 68 MAIN RELIEF VALVE AND TORQUE CONVERTER VALVE......................................................................................... 73 POWER TRAIN PUMP,STEERING LUBRICATION PUMP........................................................................................... 76 LUBRICATION RELIEF VALVE............................................................................................................. 77 STEERING, BRAKE CONTROL.............................................................................................................. 78 BEVEL GEAR SHAFT,STEERING CLUTCH AND BRAKE........................................................................................... 80 STEERING CONTROL VALVE............................................................................................................... 89 STEERING CLUTCH ECMV................................................................................................................. 91 STEERING BRAKE ECMV.................................................................................................................. 92 PARKING BRAKE VALVE.................................................................................................................. 99 SUDDEN BRAKE PREVENTION VALVE .......................................................................................................100 FINAL DRIVE..........................................................................................................................101 SPROCKET.............................................................................................................................106 TRACK FRAME..........................................................................................................................108 RECOIL SPRING........................................................................................................................110 IDLER................................................................................................................................112 TRACK ROLLER.........................................................................................................................114 CARRIER ROLLER.......................................................................................................................116 TRACK ROLLER BOGIE...................................................................................................................118 TRACK SHOE...........................................................................................................................119 MAIN FRAME...........................................................................................................................121 SUSPENSION...........................................................................................................................123 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM..............................................................................................126 PPC CONTROL PIPING DIAGRAM...........................................................................................................129 WORK EQUIPMENT CONTROL...............................................................................................................130 WORK EQUIPMENT PUMP..................................................................................................................132 COOLING FAN PUMP.....................................................................................................................148 COOLING FAN MOTOR....................................................................................................................156 HYDRAULIC TANK.......................................................................................................................161 ACCUMULATOR..........................................................................................................................163 PPC LOCK VALVE.......................................................................................................................164 PPC VALVE (FOR BLADE LIFT,BLADE TILT)................................................................................................165 PPC VALVE (FOR RIPPER)...............................................................................................................172 HYDRAULIC CYLINDER...................................................................................................................177 PISTON VALVE.........................................................................................................................180 QUICK DROP VALVE.....................................................................................................................181 PIN PULLER SWITCH....................................................................................................................182 PIN PULLER SOLENOID VALVE............................................................................................................183 BLADE CONTROL KNOB...................................................................................................................185 PITCH SELECTOR SOLENOID VALVE........................................................................................................186 CONTROL VALVE........................................................................................................................187 OPERATION OF CONTROL VALVE...........................................................................................................195 SELF-REDUCING PRESSURE VALVE.........................................................................................................212 CYLINDER STAY........................................................................................................................219 BLADE................................................................................................................................220 RIPPER EQUIPMENT.....................................................................................................................225 CAB MOUNT............................................................................................................................227 CAB..................................................................................................................................228 AIR CONDITIONER......................................................................................................................230 ENGINE CONTROL.......................................................................................................................231 ENGINE CONTROL SYSTEM................................................................................................................232 DECELERATION POTENTIOMETER...........................................................................................................233 CRI ENGINE CONTROL SYSTEM............................................................................................................234 MONITOR SYSTEM.......................................................................................................................236 MONITOR PANEL........................................................................................................................238 SENSORS..............................................................................................................................242 MODE SELECTION SYSTEM (FOR SSC SPECIFICATION)........................................................................................246 ELECTRICAL EQUIPMENT.................................................................................................................250 PALM COMMAND CONTROL SYSTEM..........................................................................................................253 20 TESTING AND ADJUSTING.................................................................................................................255 STANDARD VALUE TABLE FOR ENGINE......................................................................................................256 STANDARD VALUE TABLE FOR CHASSIS.....................................................................................................257 TESTING AND ADJUSTING................................................................................................................263 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................265 MEASURING ENGINE SPEED...........................................................................................................267 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...................................................................................270 MEASURING EXHAUST TEMPERATURE....................................................................................................272 MEASURING EXHAUST GAS COLOR......................................................................................................273 ADJUSTING VALVE CLEARANCE........................................................................................................275 MEASURING COMPRESSION PRESSURE...................................................................................................276 MEASURING BLOW-BY PRESSURE.......................................................................................................277 MEASURING ENGINE OIL PRESSURE....................................................................................................278 HANDLING OF FUEL SYSTEM DEVICES..................................................................................................279 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM.....................................................................................279 MEASURING FUEL PRESSURE..........................................................................................................280 BLEEDING AIR FROM FUEL CIRCUIT...................................................................................................281 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE...........................................................................................283 TESTING AND ADJUSTING ALTERNATOR BELT TENSION....................................................................................284 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................284 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL................................................................................285 MEASURING POWER TRAIN OIL PRESSURE...............................................................................................287 ADJUSTING TRANSMISSION SPEED SENSOR..............................................................................................296 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE.......................................................................................297 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER ...................................................................................298 ADJUSTING PCCS LEVER CONSOLE POSITION............................................................................................300 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE.............................................................................301 ADJUSTING CLEARANCE OF IDLER.....................................................................................................304 INSPECTING WEAR OF SPROCKET......................................................................................................304 TESTING AND ADJUSTING TRACK SHOE TENSION.........................................................................................305 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE................................................................................306 TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE..............................................................................310 MEASURING PPC VALVE OUTPUT PRESSURE..............................................................................................311 ADJUSTING PLAY OF PPC VALVE......................................................................................................313 MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE....................................................................314 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER....................................................................315 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER............................................................................316 RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER.........................................................................317 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER........................................................................................317 ADJUSTING RIPPER LEVER POSITION..................................................................................................318 ADJUSTING SAFETY LOCK LEVER......................................................................................................319 MEASURING FAN MOTOR SPEED........................................................................................................320 MEASURING FAN CIRCUIT OIL PRESSURE...............................................................................................320 CHANGING ROTATION DIRECTION OF FAN MOTOR.........................................................................................321 BLEEDING AIR FROM FAN PUMP.......................................................................................................322 ADJUSTING BLADE..................................................................................................................323 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)........................................................................................325 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................................................371 ADJUSTMENT METHOD OF REPLACED CONTROLLER.........................................................................................371 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM.........................................................................373 HANDLING OF OPTIONAL DEVICES.....................................................................................................375 PM CLINIC SERVICE................................................................................................................376 UNDERCARRIAGE TROUBLESHOOTING REPORT.............................................................................................383 TROUBLESHOOTING......................................................................................................................385 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................................................386 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................387 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ................................................................................388 CHECKS BEFORE TROUBLESHOOTING....................................................................................................396 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING.................................................................................397 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM......................................................400 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT).............................................................................411 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT).........................................................................413 CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)...................................................................415 CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT).......................................................................417 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................419 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)........................................................................441 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................444 TROUBLE CODE TABLE...........................................................................................................445 ERROR CODE [1500LO] (TRANSMISSION CLUTCH: SEE THE LIST (LO)).................................................................446 ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1))......................................................................447 ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH))......................................................................448 ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1))......................................................................449 ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST (LH))......................................................................450 ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST (L1))..........................................................................451 ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST (LH))..........................................................................452 ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST (L1))..........................................................................453 ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST (LH))..........................................................................454 ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST (L1))..........................................................................455 ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST (LH))..........................................................................456 ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST (L1))........................................................................457 ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST (LH))........................................................................458 ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST (L1)).........................................................................459 ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST (LH)).........................................................................460 ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1)).........................................................................461 ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH)).........................................................................462 ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1))..........................................................................463 ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH))..........................................................................464 ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))...........................................................................465 ERROR CODE [AD00L2] (COMMON RAIL: SEE THE LIST (L2)).........................................................................465 ERROR CODE [AD00MA] (COMMON RAIL: DEFECTIVE FUNCTION (MA))...................................................................466 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP: SEE THE LIST (L3))....................................................................466 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))..............................................................469 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))..............................................................469 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING (KA))..............................................470 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))........................................................471 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING (KA))..............................................472 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT (KB))...............................................473 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))...................................................474 ERROR CODE [ADAZKB] (NO.1,2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))...........................................................475 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))...................................................477 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))...................................................478 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))...................................................479 ERROR CODE [ADDZKB] (NO.4,5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))...........................................................480 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))........................................................482 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))........................................................483 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))................................................................484 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))........................................................................484 ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)).................................................................485 ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))..........................................................................485 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))...........................................................................486 ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))......................................................................487 ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB))......................................................................488 ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))...............................................................489 ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))...............................................................491 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))................................................................492 ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))................................................................494 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT CIRCUIT (KB))..........................................496 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))..........................................498 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))...........................................500 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))................................................501 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))................502 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)........................504 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))..........................505 ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))................................506 ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER SNET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))...............................508 ERROR CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))......................................................509 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))...............................511 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ))...................................513 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA)).......................................514 ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))......................................515 ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))...............................................517 ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT))....................................................518 ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))....................519 ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK))...........................521 ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))..............................523 ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))....................................524 ERROR CODE [DB3SKR] (STEERING CONTROLLER SNET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))...................................526 ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))....................................................................527 ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA))....................................................................528 ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB))....................................................................530 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA))..................................................................532 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))..................................................................534 ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))...............................................................536 ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))...............................................................538 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6))........................................................540 ERROR CODE [DDN4LD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD))....................................................542 ERROR CODE [DDN5LD] (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO TABLE (LD))..................................................543 ERROR CODE [DDN6LD] (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD))....................................................544 ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)).................................................................545 ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)).................................................................547 ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA))..................................................................549 ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB))..................................................................551 ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))...............................................................553 ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)).........................................................555 ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)).............................................................557 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).......558 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6))..................................559 ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))......................................560 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).............................561 ERROR CODE [DH21KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))............................................562 ERROR CODE [DH21KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))............................................563 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))...............................................564 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)).........................................566 ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))...................................................568 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX))..........................................570 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))...........................................................572 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))...........................................................574 ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).....................................575 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ))..........................................575 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))...............................................................576 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))...........................................................577 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))...........................................................579 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))................................................................580 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))................................................................582 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))................................583 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)).....................................583 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))..........................................................584 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))....................................................585 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB))....................................................587 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))....................................................588 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB))....................................................590 ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))................................................................591 ERROR CODE [DK60KB] (ACCELERATION SENSOR: DISCONNECTION (KB))................................................................592 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)).................................................................593 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)).................................................................594 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR: SEE TABLE (LC)).................................................................595 ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA))...................................................597 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR: SEE TABLE (LC))..................................................................598 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)).....................................................................599 ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA)).......................................................600 ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB)).......................................................601 ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))......................................................602 ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))......................................................603 ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))....................................................604 ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB))....................................................605 ERROR CODE [DWN5KA] (FAN PUMP SOLENOID: DISCONNECTION (KA))..................................................................606 ERROR CODE [DWN5KB] (FAN PUMP SOLENOID: SHORT CIRCUIT (KB))..................................................................607 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))....................................................................608 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))....................................................................609 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))....................................................................610 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))....................................................................611 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))....................................................................612 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))....................................................................613 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))................................................................614 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................615 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))................................................................616 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................617 ERROR CODE [DXH9KA] (RIGHT CLUTCH ECMV: DISCONNECTION (KA))..................................................................618 ERROR CODE [DXH9KB] (RIGHT CLUTCH ECMV: SHORT CIRCUIT (KB))..................................................................619 ERROR CODE [DXHAKA] (LEFT CLUTCH ECMV: DISCONNECTION (KA))...................................................................620 ERROR CODE [DXHAKB] (LEFT CLUTCH ECMV: SHORT CIRCUIT (KB))...................................................................621 ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA))...................................................................622 ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))...................................................................623 ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))....................................................................624 ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))....................................................................625 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................................626 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................627 E-1 THE ENGINE DOES NOT START................................................................................................628 E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION).............................................................630 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE..........................................................................632 E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON..........................................633 E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT..................634 E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH.......................................................635 E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES..................................................................636 E-8 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES........................................................638 E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON.............................................641 E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)....643 E-11 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...........................................................644 E-12 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.............................................................645 E-13 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..........................................................646 E-14 INDICATION OF THE FUEL GAUGE IS ABNORMAL................................................................................647 E-15 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.................................................................648 E-16 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL..................................................................648 E-17 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT......................................................................649 E-18 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP........................................................................650 E-19 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED......................................................................651 E-20 THE ALARM BUZZER CANNOT BE CANCELLED....................................................................................652 E-21 THE OPERATOR MODE CANNOT BE OPERATED....................................................................................653 E-22 THE SERVICE MODE CANNOT BE OPERATED.....................................................................................654 E-23 THE BACK-UP ALARM DOES NOT SOUND........................................................................................656 E-24 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON...........................657 E-25 THE AIR CONDITIONER DOES NOT OPERATE....................................................................................661 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)......................................................................666 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................667 H-1 NO TRAVEL POWER (NO DRAWBAR PULL)........................................................................................668 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)..............................................................................670 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.................................................................................671 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE..............................................................672 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE..............................................673 H-6 STEERING IS NOT POSSIBLE (MACHINE DOES NOT TURN TO RIGHT OR LEFT)........................................................674 H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE....................................................................................674 H-8 STEERING OVERRUN OCCURS..................................................................................................675 H-9 BRAKE DOES NOT WORK......................................................................................................675 H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE.................................................................................676 H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW......................................................................................677 H-12 WORK EQUIPMENT DOES NOT MOVE............................................................................................678 H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER.................................................................................678 H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER.................................................................................679 H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER................................................................................679 H-16 RIPPER TILE SPEED IS SLOW OR LACKS POWER................................................................................680 H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT.................................................................................680 H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT.................................................................................681 H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT................................................................................681 H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE)..............................................682 H-21 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)................................................................682 H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP................................................................682 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)........................................................................................683 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................684 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................688 S-2 ENGINE DOES NOT START ...................................................................................................689 a) ENGINE DOES NOT TURN..................................................................................................689 b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT...........................................................................690 c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................................691 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).....................................................................692 S-4 ENGINE STOPS DURING OPERATIONS...........................................................................................693 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................694 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....................................................................................695 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...........................................................................696 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..................................................................697 S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................698 S-10 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................699 S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)..................................................700 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..............................................................701 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....................................................................................702 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................................703 S-15 ABNORMAL NOISE IS MADE..................................................................................................704 S-16 VIBRATION IS EXCESSIVE..................................................................................................705 30 DISASSEMBLY AND ASSEMBLY..............................................................................................................706 HOW TO READ THIS MANUAL..............................................................................................................709 REMOVAL AND INSTALLATION OF ASSEMBLIES...........................................................................................709 SPECIAL TOOLS....................................................................................................................709 REMOVAL OF PARTS.................................................................................................................709 INSTALLATION OF PARTS............................................................................................................709 SKETCHES OF SPECIAL TOOLS........................................................................................................709 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...........................................................................................710 SPECIAL TOOLS....................................................................................................................710 DISASSEMBLY......................................................................................................................710 ASSEMBLY.........................................................................................................................710 SKETCHES OF SPECIAL TOOLS........................................................................................................710 PRECAUTIONS WHEN CARRYING OUT OPERATION..............................................................................................711 SPECIAL TOOL LIST....................................................................................................................713 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY................................................................................725 SPECIAL TOOLS....................................................................................................................725 REMOVAL..........................................................................................................................725 INSTALLATION.....................................................................................................................727 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY...................................................................................729 REMOVAL..........................................................................................................................729 INSTALLATION.....................................................................................................................732 REMOVAL AND INSTALLATION OF NOZZLE TIP...............................................................................................735 SPECIAL TOOLS....................................................................................................................735 REMOVAL..........................................................................................................................735 INSTALLATION.....................................................................................................................736 SKETCH OF SPECIAL TOOL...........................................................................................................737 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL........................................................................................738 SPECIAL TOOLS....................................................................................................................738 REMOVAL..........................................................................................................................738 INSTALLATION.....................................................................................................................738 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL.........................................................................................740 SPECIAL TOOLS....................................................................................................................740 REMOVAL..........................................................................................................................740 INSTALLATION.....................................................................................................................740 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...................................................................................742 SPECIAL TOOL.....................................................................................................................742 REMOVAL..........................................................................................................................742 INSTALLATION.....................................................................................................................747 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.......................................................................................751 REMOVAL..........................................................................................................................751 INSTALLATION.....................................................................................................................752 REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY...................................................................................753 REMOVAL..........................................................................................................................753 INSTALLATION.....................................................................................................................755 REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY....................................................................................756 REMOVAL..........................................................................................................................756 INSTALLATION.....................................................................................................................757 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY............................................................................758 REMOVAL..........................................................................................................................758 INSTALLATION.....................................................................................................................759 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY..................................................................................760 REMOVAL..........................................................................................................................760 INSTALLATION.....................................................................................................................762 REMOVAL AND INSTALLATION OF ENGINE...................................................................................................763 SPECIAL TOOLS....................................................................................................................763 REMOVAL..........................................................................................................................763 INSTALLATION.....................................................................................................................767 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY..........................................................................................769 SPECIAL TOOLS....................................................................................................................769 REMOVAL..........................................................................................................................769 INSTALLATION.....................................................................................................................772 DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY..........................................................................................773 SPECIAL TOOLS....................................................................................................................773 DISASSEMBLY......................................................................................................................774 ASSEMBLY.........................................................................................................................776 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY................................................................................778 REMOVAL..........................................................................................................................778 INSTALLATION.....................................................................................................................782 DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................................783 DISCONNECTION....................................................................................................................783 CONNECTION.......................................................................................................................788 CONNECTION DIAGRAM OF CENTRALIZED OIL PRESSURE PICK-UP HOSES.....................................................................790 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY.............................................................................................792 DISASSEMBLY......................................................................................................................792 ASSEMBLY.........................................................................................................................795 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY................................................................................799 DISASSEMBLY......................................................................................................................799 ASSEMBLY.........................................................................................................................802 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY...........................................................................806 SPECIAL TOOLS....................................................................................................................806 DISASSEMBLY......................................................................................................................806 ASSEMBLY.........................................................................................................................814 DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY...................................................................................825 SPECIAL TOOLS....................................................................................................................825 DISASSEMBLY......................................................................................................................825 ASSEMBLY.........................................................................................................................831 REMOVAL AND INSTALLATION OF SCAVENGING PUMP..........................................................................................843 REMOVAL..........................................................................................................................843 INSTALLATION.....................................................................................................................843 REMOVAL AND INSTALLATION OF WORK EQUIPMENT PUMP ASSEMBLY.............................................................................844 REMOVAL..........................................................................................................................844 INSTALLATION.....................................................................................................................845 REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY........................................................................................846 REMOVAL..........................................................................................................................846 INSTALLATION.....................................................................................................................847 REMOVAL AND INSTALLATION POWER TRAIN AND STEERING LUBRICATING OIL PUMP ASSEMBLY......................................................848 REMOVAL..........................................................................................................................848 INSTALLATION.....................................................................................................................849 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY.....................................................................................850 SPECIAL TOOLS....................................................................................................................850 REMOVAL..........................................................................................................................850 INSTALLATION.....................................................................................................................851 SKETCH OF SPECIAL TOOL...........................................................................................................852 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY.....................................................................................853 SPECIAL TOOLS....................................................................................................................853 DISASSEMBLY......................................................................................................................853 ASSEMBLY.........................................................................................................................858 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY.....................................................................................866 SPECIAL TOOLS....................................................................................................................866 REMOVAL..........................................................................................................................866 INSTALLATION.....................................................................................................................869 SKETCH OF SPECIAL TOOL...........................................................................................................870 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY...........................................................................................871 REMOVAL..........................................................................................................................871 INSTALLATION.....................................................................................................................871 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...........................................................................................872 SPECIAL TOOLS....................................................................................................................872 DISASSEMBLY......................................................................................................................872 ASSEMBLY.........................................................................................................................873 SKETCH OF SPECIAL TOOL...........................................................................................................875 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY...................................................................................876 SPECIAL TOOLS....................................................................................................................876 REMOVAL..........................................................................................................................876 INSTALLATION.....................................................................................................................879 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY...................................................................................880 SPECIAL TOOLS....................................................................................................................880 DISASSEMBLY......................................................................................................................880 ASSEMBLY.........................................................................................................................880 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY....................................................................................882 SPECIAL TOOLS....................................................................................................................882 REMOVAL..........................................................................................................................882 INSTALLATION.....................................................................................................................883 SKETCH OF SPECIAL TOOL...........................................................................................................884 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY....................................................................................885 SPECIAL TOOLS....................................................................................................................885 DISASSEMBLY......................................................................................................................885 ASSEMBLY.........................................................................................................................886 SKETCH OF SPECIAL TOOL...........................................................................................................888 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY..................................................................................889 REMOVAL..........................................................................................................................889 INSTALLATION.....................................................................................................................889 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY..................................................................................890 SPECIAL TOOLS....................................................................................................................890 DISASSEMBLY......................................................................................................................890 ASSEMBLY.........................................................................................................................891 SKETCH OF SPECIAL TOOL...........................................................................................................893 REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY.......................................................................................894 SPECIAL TOOLS....................................................................................................................894 REMOVAL..........................................................................................................................894 INSTALLATION.....................................................................................................................896 SKETCH OF SPECIAL TOOL...........................................................................................................899 REMOVAL AND INSTALLATION OF 2ND, 3RD AND 4TH BOGIE ASSEMBLY..........................................................................900 SPECIAL TOOLS....................................................................................................................900 REMOVAL..........................................................................................................................900 INSTALLATION.....................................................................................................................902 SKETCH OF SPECIAL TOOL...........................................................................................................906 DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY...........................................................................................908 SPECIAL TOOLS....................................................................................................................908 DISASSEMBLY......................................................................................................................908 ASSEMBLY.........................................................................................................................908 SKETCH OF SPECIAL TOOL...........................................................................................................911 EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY.........................................................................................912 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY.......................................................................................912 EXPANDING TRACK SHOE ASSEMBLY (NORMAL)...........................................................................................912 EXPANDING TRACK SHOE ASSEMBLY....................................................................................................913 INSTALLATION.....................................................................................................................914 WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY..........................................................................915 SPECIAL TOOLS....................................................................................................................915 WHOLE DISASSEMBLY................................................................................................................916 WHOLE ASSEMBLY...................................................................................................................918 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS....................................................................................929 DISASSEMBLY OF 1 LINK IN THE FIELD...............................................................................................930 ASSEMBLY OF 1 LINK IN THE FIELD..................................................................................................931 DISASSEMBLY OF MASTER LINK.......................................................................................................932 ASSEMBLY OF MASTER LINK..........................................................................................................933 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY.....................................................................................935 SPECIAL TOOLS....................................................................................................................935 REMOVAL..........................................................................................................................935 INSTALLATION.....................................................................................................................935 REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY...................................................................................936 SPECIAL TOOLS....................................................................................................................936 REMOVAL..........................................................................................................................936 INSTALLATION.....................................................................................................................937 SKETCH OF SPECIAL TOOL...........................................................................................................939 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING....................................................................................940 SPECIAL TOOLS....................................................................................................................940 DISASSEMBLY......................................................................................................................940 ASSEMBLY.........................................................................................................................940 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................942 REMOVAL..........................................................................................................................942 INSTALLATION.....................................................................................................................944 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................946 ASSEMBLY.........................................................................................................................946 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..............................................................................947 SPECIAL TOOLS....................................................................................................................947 DISASSEMBLY......................................................................................................................947 ASSEMBLY.........................................................................................................................950 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY...........................................................................................954 REMOVAL..........................................................................................................................954 INSTALLATION.....................................................................................................................955 DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY..........................................................................................956 DISASSEMBLY......................................................................................................................956 ASSEMBLY.........................................................................................................................958 REMOVAL AND INSTALLATION OF ROPS GUARD...............................................................................................960 REMOVAL..........................................................................................................................960 INSTALLATION.....................................................................................................................960 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................................................................................961 REMOVAL..........................................................................................................................961 INSTALLATION.....................................................................................................................962 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY.....................................................................................963 SPECIAL TOOLS....................................................................................................................963 REMOVAL..........................................................................................................................963 INSTALLATION.....................................................................................................................966 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY.........................................................................968 REMOVAL..........................................................................................................................968 INSTALLATION.....................................................................................................................968 REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY.............................................................................969 REMOVAL..........................................................................................................................969 INSTALLATION.....................................................................................................................969 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY...............................................................................970 REMOVAL..........................................................................................................................970 INSTALLATION.....................................................................................................................970 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.....................................................................................971 REMOVAL..........................................................................................................................971 INSTALLATION.....................................................................................................................972 REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY.......................................................................................973 REMOVAL..........................................................................................................................973 INSTALLATION.....................................................................................................................973 REMOVAL AND INSTALLATION OF FAN MOTOR................................................................................................974 REMOVAL..........................................................................................................................974 INSTALLATION.....................................................................................................................974 90 OTHERS................................................................................................................................975 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................976 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (SINGLE TILT SPEC)..........................................................................978 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILT SPEC)............................................................................979 DIAGRAM FOR ELECTRICAL CIRCUIT (1/4).................................................................................................980 DIAGRAM FOR ELECTRICAL CIRCUIT (2/4).................................................................................................981 DIAGRAM FOR ELECTRICAL CIRCUIT (3/4).................................................................................................982 DIAGRAM FOR ELECTRICAL CIRCUIT (4/4).................................................................................................983 DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER....................................................................................984 ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB...............................................................................................985
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