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KOMATSU D275A-5 SHOP MANUAL SEBM026313 – PDF DOWNLOAD
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Description
KOMATSU D275A-5 SHOP MANUAL SEBM026313 – PDF DOWNLOAD
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KOMATSU D275A-5 SHOP MANUAL SEBM026313 – PDF DOWNLOAD
Language : English
Pages : 1064
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D275A-5 SHOP MANUAL SEBM026313 – PDF DOWNLOAD
COVER.................................................................................................................................... 1 CONTENTS................................................................................................................................. 2 LIST OF REVISED PAGES.................................................................................................................... 3 01 GENERAL............................................................................................................................... 27 SPECIFICATION DRAWING................................................................................................................ 28 SPECIFICATIONS....................................................................................................................... 29 WEIGHT TABLE......................................................................................................................... 35 TABLE OF FUEL,COOLANT AND LUBRICANT.................................................................................................. 37 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......................................................................................... 39 POWER TRAIN.......................................................................................................................... 42 OVERALL DRAWING OF POWER TRAIN UNIT.................................................................................................. 45 DAMPER, UNIVERSAL JOINT.............................................................................................................. 48 TORQUE CONVERTER, PTO................................................................................................................ 51 TORQUE CONVERTER..................................................................................................................... 54 SCAVENGING PUMP...................................................................................................................... 57 TRANSMISSION CONTROL................................................................................................................. 59 TRANSMISSION......................................................................................................................... 60 TRANSMISSION ECMV.................................................................................................................... 74 MAIN RELIEF VALVE AND TORQUE CONVERTER VALVE......................................................................................... 80 POWER TRAIN PUMP,STEERING LUBRICATION PUMP........................................................................................... 83 LUBRICATION RELIEF VALVE............................................................................................................. 84 STEERING, BRAKE CONTROL.............................................................................................................. 86 BEVEL GEAR SHAFT,STEERING CLUTCH AND BRAKE........................................................................................... 88 STEERING CONTROL VALVE............................................................................................................... 98 STEERING CLUTCH ECMV................................................................................................................. 101 STEERING BRAKE ECMV.................................................................................................................. 102 PARKING BRAKE VALVE.................................................................................................................. 109 SUDDEN BRAKE PREVENTION VALVE ....................................................................................................... 110 FINAL DRIVE.......................................................................................................................... 111 SPROCKET............................................................................................................................. 116 TRACK FRAME.......................................................................................................................... 118 RECOIL SPRING........................................................................................................................ 120 IDLER................................................................................................................................ 122 TRACK ROLLER......................................................................................................................... 124 CARRIER ROLLER....................................................................................................................... 126 TRACK ROLLER BOGIE................................................................................................................... 128 TRACK SHOE........................................................................................................................... 130 MAIN FRAME........................................................................................................................... 132 SUSPENSION........................................................................................................................... 134 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.............................................................................................. 137 PPC CONTROL PIPING DIAGRAM........................................................................................................... 140 WORK EQUIPMENT CONTROL............................................................................................................... 142 WORK EQUIPMENT PUMP.................................................................................................................. 144 COOLING FAN PUMP..................................................................................................................... 160 COOLING FAN MOTOR.................................................................................................................... 168 HYDRAULIC TANK....................................................................................................................... 174 ACCUMULATOR.......................................................................................................................... 178 PPC LOCK VALVE....................................................................................................................... 179 PPC VALVE (FOR BLADE LIFT,BLADE TILT)................................................................................................ 181 PPC VALVE (FOR RIPPER)............................................................................................................... 188 HYDRAULIC CYLINDER................................................................................................................... 194 PISTON VALVE......................................................................................................................... 197 QUICK DROP VALVE..................................................................................................................... 198 PIN PULLER SWITCH.................................................................................................................... 199 PIN PULLER SOLENOID VALVE............................................................................................................ 200 BLADE CONTROL KNOB................................................................................................................... 202 PITCH SELECTOR SOLENOID VALVE........................................................................................................ 203 CONTROL VALVE........................................................................................................................ 204 OPERATION OF CONTROL VALVE........................................................................................................... 212 SELF-REDUCING PRESSURE VALVE......................................................................................................... 229 CYLINDER STAY........................................................................................................................ 236 BLADE................................................................................................................................ 238 RIPPER EQUIPMENT..................................................................................................................... 244 CAB MOUNT............................................................................................................................ 248 CAB.................................................................................................................................. 249 AIR CONDITIONER...................................................................................................................... 251 ENGINE CONTROL....................................................................................................................... 252 ENGINE CONTROL SYSTEM................................................................................................................ 253 DECELERATION POTENTIOMETER........................................................................................................... 254 CRI ENGINE CONTROL SYSTEM............................................................................................................ 256 MONITOR SYSTEM....................................................................................................................... 258 MONITOR PANEL........................................................................................................................ 260 SENSORS.............................................................................................................................. 264 MODE SELECTION SYSTEM (FOR SSC SPECIFICATION)........................................................................................ 268 ELECTRICAL EQUIPMENT................................................................................................................. 272 PALM COMMAND CONTROL SYSTEM.......................................................................................................... 275 20 TESTING AND ADJUSTING................................................................................................................. 277 STANDARD VALUE TABLE FOR ENGINE...................................................................................................... 278 STANDARD VALUE TABLE FOR CHASSIS..................................................................................................... 279 TESTING AND ADJUSTING................................................................................................................ 285 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................ 287 MEASURING ENGINE SPEED........................................................................................................... 289 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................................... 292 MEASURING EXHAUST TEMPERATURE.................................................................................................... 294 MEASURING EXHAUST GAS COLOR...................................................................................................... 295 ADJUSTING VALVE CLEARANCE........................................................................................................ 297 MEASURING COMPRESSION PRESSURE................................................................................................... 298 MEASURING BLOW-BY PRESSURE....................................................................................................... 299 MEASURING ENGINE OIL PRESSURE.................................................................................................... 300 HANDLING OF FUEL SYSTEM DEVICES.................................................................................................. 301 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM..................................................................................... 301 MEASURING FUEL PRESSURE.......................................................................................................... 302 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................... 303 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE........................................................................................... 305 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................... 306 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................... 306 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL................................................................................ 307 MEASURING POWER TRAIN OIL PRESSURE............................................................................................... 309 ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................. 318 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE....................................................................................... 319 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER ................................................................................... 320 ADJUSTING PCCS LEVER CONSOLE POSITION............................................................................................ 322 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE............................................................................. 323 ADJUSTING CLEARANCE OF IDLER..................................................................................................... 326 INSPECTING WEAR OF SPROCKET...................................................................................................... 326 TESTING AND ADJUSTING TRACK SHOE TENSION......................................................................................... 327 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE................................................................................ 328 TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE.............................................................................. 332 MEASURING PPC VALVE OUTPUT PRESSURE.............................................................................................. 333 ADJUSTING PLAY OF PPC VALVE...................................................................................................... 335 MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE.................................................................... 336 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER.................................................................... 337 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER............................................................................ 338 RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER......................................................................... 339 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER........................................................................................ 339 ADJUSTING RIPPER LEVER POSITION.................................................................................................. 340 ADJUSTING SAFETY LOCK LEVER...................................................................................................... 341 MEASURING FAN MOTOR SPEED........................................................................................................ 342 MEASURING FAN CIRCUIT OIL PRESSURE............................................................................................... 342 CHANGING ROTATION DIRECTION OF FAN MOTOR......................................................................................... 343 BLEEDING AIR FROM FAN PUMP....................................................................................................... 345 ADJUSTING BLADE.................................................................................................................. 346 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)........................................................................................ 348 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................................................ 394 ADJUSTMENT METHOD OF REPLACED CONTROLLER......................................................................................... 394 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM......................................................................... 396 HANDLING OF OPTIONAL DEVICES..................................................................................................... 398 PM CLINIC SERVICE................................................................................................................ 399 UNDERCARRIAGE TROUBLESHOOTING REPORT............................................................................................. 407 TROUBLESHOOTING...................................................................................................................... 409 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................... 410 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................ 411 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ................................................................................ 412 CHECKS BEFORE TROUBLESHOOTING.................................................................................................... 420 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING................................................................................. 422 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...................................................... 425 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)............................................................................. 436 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)......................................................................... 438 CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)................................................................... 440 CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)....................................................................... 442 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................... 444 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)........................................................................ 467 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................ 471 TROUBLE CODE TABLE........................................................................................................... 472 ERROR CODE [1500LO] (TRANSMISSION CLUTCH: SEE THE LIST (LO))................................................................. 473 ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1))...................................................................... 474 ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH))...................................................................... 475 ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1))...................................................................... 476 ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST (LH))...................................................................... 477 ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST (L1)).......................................................................... 478 ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST (LH)).......................................................................... 479 ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST (L1)).......................................................................... 480 ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST (LH)).......................................................................... 481 ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST (L1)).......................................................................... 482 ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST (LH)).......................................................................... 483 ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST (L1))........................................................................ 484 ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST (LH))........................................................................ 485 ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST (L1))......................................................................... 486 ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST (LH))......................................................................... 487 ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1))......................................................................... 488 ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH))......................................................................... 489 ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1)).......................................................................... 490 ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH)).......................................................................... 491 ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))........................................................................... 492 ERROR CODE [AD00L2] (COMMON RAIL: SEE THE LIST (L2))......................................................................... 492 ERROR CODE [AD00MA] (COMMON RAIL: DEFECTIVE FUNCTION (MA))................................................................... 493 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP: SEE THE LIST (L3)).................................................................... 493 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA)).............................................................. 496 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB)).............................................................. 496 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING (KA)).............................................. 497 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))........................................................ 498 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING (KA)).............................................. 499 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT (KB))............................................... 500 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................... 501 ERROR CODE [ADAZKB] (NO.1,2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))........................................................... 502 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................... 504 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................... 505 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................... 506 ERROR CODE [ADDZKB] (NO.4,5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))........................................................... 507 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))........................................................ 509 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))........................................................ 510 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))................................................................ 511 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))........................................................................ 511 ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK))................................................................. 512 ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS)).......................................................................... 512 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))........................................................................... 513 ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))...................................................................... 514 ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB))...................................................................... 515 ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))............................................................... 516 ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))............................................................... 518 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))................................................................ 519 ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))................................................................ 521 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT CIRCUIT (KB)).......................................... 523 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)).......................................... 525 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))........................................... 527 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))................................................ 528 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))................ 529 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)........................ 531 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)).......................... 532 ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))................................ 533 ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER SNET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))............................... 535 ERROR CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))...................................................... 536 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))............................... 538 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ))................................... 540 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA))....................................... 541 ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))...................................... 542 ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))............................................... 544 ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)).................................................... 545 ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)).................... 546 ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK))........................... 548 ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)).............................. 550 ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)).................................... 551 ERROR CODE [DB3SKR] (STEERING CONTROLLER SNET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))................................... 553 ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)).................................................................... 554 ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)).................................................................... 555 ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)).................................................................... 557 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)).................................................................. 559 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)).................................................................. 561 ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))............................................................... 563 ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))............................................................... 565 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6))........................................................ 567 ERROR CODE [DDN4LD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)).................................................... 569 ERROR CODE [DDN5LD] (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO TABLE (LD)).................................................. 570 ERROR CODE [DDN6LD] (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD)).................................................... 571 ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA))................................................................. 572 ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))................................................................. 574 ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)).................................................................. 576 ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)).................................................................. 578 ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))............................................................... 580 ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))......................................................... 582 ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))............................................................. 584 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))....... 585 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6)).................................. 586 ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))...................................... 587 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............................. 588 ERROR CODE [DH21KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))............................................ 589 ERROR CODE [DH21KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))............................................ 590 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))............................................... 591 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))......................................... 593 ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))................................................... 595 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX)).......................................... 597 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))........................................................... 599 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))........................................................... 601 ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))..................................... 602 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)).......................................... 602 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))............................................................... 603 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))........................................................... 604 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))........................................................... 606 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))................................................................ 607 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))................................................................ 609 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))................................ 610 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ))..................................... 610 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)).......................................................... 611 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)).................................................... 612 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)).................................................... 614 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)).................................................... 615 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)).................................................... 617 ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))................................................................ 618 ERROR CODE [DK60KB] (ACCELERATION SENSOR: DISCONNECTION (KB))................................................................ 619 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA))................................................................. 620 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))................................................................. 621 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR: SEE TABLE (LC))................................................................. 622 ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA))................................................... 624 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR: SEE TABLE (LC)).................................................................. 625 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))..................................................................... 626 ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA))....................................................... 627 ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB))....................................................... 628 ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))...................................................... 629 ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))...................................................... 630 ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)).................................................... 631 ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)).................................................... 632 ERROR CODE [DWN5KA] (FAN PUMP SOLENOID: DISCONNECTION (KA)).................................................................. 633 ERROR CODE [DWN5KB] (FAN PUMP SOLENOID: SHORT CIRCUIT (KB)).................................................................. 634 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)).................................................................... 635 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)).................................................................... 636 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)).................................................................... 637 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)).................................................................... 638 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)).................................................................... 639 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)).................................................................... 640 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))................................................................ 641 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................ 642 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))................................................................ 643 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................ 644 ERROR CODE [DXH9KA] (RIGHT CLUTCH ECMV: DISCONNECTION (KA)).................................................................. 645 ERROR CODE [DXH9KB] (RIGHT CLUTCH ECMV: SHORT CIRCUIT (KB)).................................................................. 646 ERROR CODE [DXHAKA] (LEFT CLUTCH ECMV: DISCONNECTION (KA))................................................................... 647 ERROR CODE [DXHAKB] (LEFT CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................... 648 ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA))................................................................... 649 ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))................................................................... 650 ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA)).................................................................... 651 ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)).................................................................... 652 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................... 653 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................ 654 E-1 THE ENGINE DOES NOT START................................................................................................ 655 E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION)............................................................. 657 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.......................................................................... 659 E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.......................................... 660 E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.................. 661 E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH....................................................... 662 E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES.................................................................. 663 E-8 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES........................................................ 665 E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON............................................. 668 E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE).... 670 E-11 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY........................................................... 671 E-12 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL............................................................. 672 E-13 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.......................................................... 673 E-14 INDICATION OF THE FUEL GAUGE IS ABNORMAL................................................................................ 674 E-15 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL................................................................. 675 E-16 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.................................................................. 675 E-17 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT...................................................................... 676 E-18 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP........................................................................ 677 E-19 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED...................................................................... 678 E-20 THE ALARM BUZZER CANNOT BE CANCELLED.................................................................................... 679 E-21 THE OPERATOR MODE CANNOT BE OPERATED.................................................................................... 680 E-22 THE SERVICE MODE CANNOT BE OPERATED..................................................................................... 681 E-23 THE BACK-UP ALARM DOES NOT SOUND........................................................................................ 683 E-24 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON........................... 684 E-25 THE AIR CONDITIONER DOES NOT OPERATE.................................................................................... 688 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...................................................................... 693 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................ 694 H-1 NO TRAVEL POWER (NO DRAWBAR PULL)........................................................................................ 695 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED).............................................................................. 697 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE................................................................................. 698 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE.............................................................. 699 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE.............................................. 700 H-6 STEERING IS NOT POSSIBLE (MACHINE DOES NOT TURN TO RIGHT OR LEFT)........................................................ 701 H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE.................................................................................... 701 H-8 STEERING OVERRUN OCCURS.................................................................................................. 702 H-9 BRAKE DOES NOT WORK...................................................................................................... 702 H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE................................................................................. 703 H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW...................................................................................... 704 H-12 WORK EQUIPMENT DOES NOT MOVE............................................................................................ 705 H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER................................................................................. 705 H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER................................................................................. 706 H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER................................................................................ 706 H-16 RIPPER TILE SPEED IS SLOW OR LACKS POWER................................................................................ 707 H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT................................................................................. 707 H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT................................................................................. 708 H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT................................................................................ 708 H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE).............................................. 709 H-21 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)................................................................ 709 H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP................................................................ 709 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)........................................................................................ 711 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................... 712 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................ 716 S-2 ENGINE DOES NOT START ................................................................................................... 717 a) ENGINE DOES NOT TURN.................................................................................................. 717 b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT........................................................................... 718 c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................................ 719 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................... 720 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................... 721 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................ 722 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................... 723 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................... 724 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................. 725 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................... 726 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................... 727 S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).................................................. 728 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................................. 729 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).................................................................................... 730 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................................ 731 S-15 ABNORMAL NOISE IS MADE.................................................................................................. 732 S-16 VIBRATION IS EXCESSIVE.................................................................................................. 733 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................. 735 HOW TO READ THIS MANUAL.............................................................................................................. 739 REMOVAL AND INSTALLATION OF ASSEMBLIES........................................................................................... 739 SPECIAL TOOLS.................................................................................................................... 739 REMOVAL OF PARTS................................................................................................................. 739 INSTALLATION OF PARTS............................................................................................................ 739 SKETCHES OF SPECIAL TOOLS........................................................................................................ 739 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES........................................................................................... 740 SPECIAL TOOLS.................................................................................................................... 740 DISASSEMBLY...................................................................................................................... 740 ASSEMBLY......................................................................................................................... 740 SKETCHES OF SPECIAL TOOLS........................................................................................................ 740 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................. 741 SPECIAL TOOL LIST.................................................................................................................... 743 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY................................................................................ 755 SPECIAL TOOLS.................................................................................................................... 755 REMOVAL.......................................................................................................................... 755 INSTALLATION..................................................................................................................... 757 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY................................................................................... 759 REMOVAL.......................................................................................................................... 759 INSTALLATION..................................................................................................................... 762 REMOVAL AND INSTALLATION OF NOZZLE TIP............................................................................................... 765 SPECIAL TOOLS.................................................................................................................... 765 REMOVAL.......................................................................................................................... 765 INSTALLATION..................................................................................................................... 766 SKETCH OF SPECIAL TOOL........................................................................................................... 767 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL........................................................................................ 768 SPECIAL TOOLS.................................................................................................................... 768 REMOVAL.......................................................................................................................... 768 INSTALLATION..................................................................................................................... 768 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL......................................................................................... 770 SPECIAL TOOLS.................................................................................................................... 770 REMOVAL.......................................................................................................................... 770 INSTALLATION..................................................................................................................... 770 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................... 772 SPECIAL TOOL..................................................................................................................... 772 REMOVAL.......................................................................................................................... 772 INSTALLATION..................................................................................................................... 777 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY....................................................................................... 781 REMOVAL.......................................................................................................................... 781 INSTALLATION..................................................................................................................... 782 REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY................................................................................... 783 REMOVAL.......................................................................................................................... 783 INSTALLATION..................................................................................................................... 785 REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY.................................................................................... 786 REMOVAL.......................................................................................................................... 786 INSTALLATION..................................................................................................................... 787 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY............................................................................ 788 REMOVAL.......................................................................................................................... 788 INSTALLATION..................................................................................................................... 789 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY.................................................................................. 790 REMOVAL.......................................................................................................................... 790 INSTALLATION..................................................................................................................... 792 REMOVAL AND INSTALLATION OF ENGINE................................................................................................... 793 SPECIAL TOOLS.................................................................................................................... 793 REMOVAL.......................................................................................................................... 793 INSTALLATION..................................................................................................................... 797 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY.......................................................................................... 799 SPECIAL TOOLS.................................................................................................................... 799 REMOVAL.......................................................................................................................... 799 INSTALLATION..................................................................................................................... 802 DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY.......................................................................................... 803 SPECIAL TOOLS.................................................................................................................... 803 DISASSEMBLY...................................................................................................................... 804 ASSEMBLY......................................................................................................................... 806 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY................................................................................ 808 REMOVAL.......................................................................................................................... 808 INSTALLATION..................................................................................................................... 812 DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................................ 813 DISCONNECTION.................................................................................................................... 813 CONNECTION....................................................................................................................... 818 CONNECTION DIAGRAM OF CENTRALIZED OIL PRESSURE PICK-UP HOSES..................................................................... 820 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY............................................................................................. 822 DISASSEMBLY...................................................................................................................... 822 ASSEMBLY......................................................................................................................... 825 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY................................................................................ 829 DISASSEMBLY...................................................................................................................... 829 ASSEMBLY......................................................................................................................... 832 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY........................................................................... 836 SPECIAL TOOLS.................................................................................................................... 836 DISASSEMBLY...................................................................................................................... 836 ASSEMBLY......................................................................................................................... 844 DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY................................................................................... 855 SPECIAL TOOLS.................................................................................................................... 855 DISASSEMBLY...................................................................................................................... 855 ASSEMBLY......................................................................................................................... 861 REMOVAL AND INSTALLATION OF SCAVENGING PUMP.......................................................................................... 873 REMOVAL.......................................................................................................................... 873 INSTALLATION..................................................................................................................... 873 REMOVAL AND INSTALLATION OF WORK EQUIPMENT PUMP ASSEMBLY............................................................................. 874 REMOVAL.......................................................................................................................... 874 INSTALLATION..................................................................................................................... 875 REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY........................................................................................ 876 REMOVAL.......................................................................................................................... 876 INSTALLATION..................................................................................................................... 877 REMOVAL AND INSTALLATION POWER TRAIN AND STEERING LUBRICATING OIL PUMP ASSEMBLY...................................................... 878 REMOVAL.......................................................................................................................... 878 INSTALLATION..................................................................................................................... 879 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY..................................................................................... 880 SPECIAL TOOLS.................................................................................................................... 880 REMOVAL.......................................................................................................................... 880 INSTALLATION..................................................................................................................... 881 SKETCH OF SPECIAL TOOL........................................................................................................... 882 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..................................................................................... 883 SPECIAL TOOLS.................................................................................................................... 883 DISASSEMBLY...................................................................................................................... 883 ASSEMBLY......................................................................................................................... 888 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY..................................................................................... 896 SPECIAL TOOLS.................................................................................................................... 896 REMOVAL.......................................................................................................................... 896 INSTALLATION..................................................................................................................... 899 SKETCH OF SPECIAL TOOL........................................................................................................... 900 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY........................................................................................... 901 REMOVAL.......................................................................................................................... 901 INSTALLATION..................................................................................................................... 901 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY........................................................................................... 902 SPECIAL TOOLS.................................................................................................................... 902 DISASSEMBLY...................................................................................................................... 902 ASSEMBLY......................................................................................................................... 903 SKETCH OF SPECIAL TOOL........................................................................................................... 905 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY................................................................................... 906 SPECIAL TOOLS.................................................................................................................... 906 REMOVAL.......................................................................................................................... 907 INSTALLATION..................................................................................................................... 916 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................................................................................... 922 SPECIAL TOOLS.................................................................................................................... 922 DISASSEMBLY...................................................................................................................... 922 ASSEMBLY......................................................................................................................... 922 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.................................................................................... 924 SPECIAL TOOLS.................................................................................................................... 924 REMOVAL.......................................................................................................................... 924 INSTALLATION..................................................................................................................... 925 SKETCH OF SPECIAL TOOL........................................................................................................... 926 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.................................................................................... 927 SPECIAL TOOLS.................................................................................................................... 927 DISASSEMBLY...................................................................................................................... 927 ASSEMBLY......................................................................................................................... 928 SKETCH OF SPECIAL TOOL........................................................................................................... 930 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.................................................................................. 931 REMOVAL.......................................................................................................................... 931 INSTALLATION..................................................................................................................... 931 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................................. 932 SPECIAL TOOLS.................................................................................................................... 932 DISASSEMBLY...................................................................................................................... 932 ASSEMBLY......................................................................................................................... 933 SKETCH OF SPECIAL TOOL........................................................................................................... 935 REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY....................................................................................... 936 SPECIAL TOOLS.................................................................................................................... 936 REMOVAL.......................................................................................................................... 936 INSTALLATION..................................................................................................................... 938 SKETCH OF SPECIAL TOOL........................................................................................................... 941 REMOVAL AND INSTALLATION OF 2ND, 3RD AND 4TH BOGIE ASSEMBLY.......................................................................... 942 SPECIAL TOOLS.................................................................................................................... 942 REMOVAL.......................................................................................................................... 942 INSTALLATION..................................................................................................................... 944 SKETCH OF SPECIAL TOOL........................................................................................................... 948 DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY........................................................................................... 950 SPECIAL TOOLS.................................................................................................................... 950 DISASSEMBLY...................................................................................................................... 950 ASSEMBLY......................................................................................................................... 950 SKETCH OF SPECIAL TOOL........................................................................................................... 953 EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY......................................................................................... 954 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY....................................................................................... 954 EXPANDING TRACK SHOE ASSEMBLY (NORMAL)........................................................................................... 954 EXPANDING TRACK SHOE ASSEMBLY.................................................................................................... 955 INSTALLATION..................................................................................................................... 956 WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY.......................................................................... 957 SPECIAL TOOLS.................................................................................................................... 957 WHOLE DISASSEMBLY................................................................................................................ 958 WHOLE ASSEMBLY................................................................................................................... 960 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS.................................................................................... 971 DISASSEMBLY OF 1 LINK IN THE FIELD............................................................................................... 972 ASSEMBLY OF 1 LINK IN THE FIELD.................................................................................................. 973 DISASSEMBLY OF MASTER LINK....................................................................................................... 974 ASSEMBLY OF MASTER LINK.......................................................................................................... 975 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY..................................................................................... 977 SPECIAL TOOLS.................................................................................................................... 977 REMOVAL.......................................................................................................................... 977 INSTALLATION..................................................................................................................... 977 REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY................................................................................... 978 SPECIAL TOOLS.................................................................................................................... 978 REMOVAL.......................................................................................................................... 978 INSTALLATION..................................................................................................................... 979 SKETCH OF SPECIAL TOOL........................................................................................................... 981 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING.................................................................................... 982 SPECIAL TOOLS.................................................................................................................... 982 DISASSEMBLY...................................................................................................................... 982 ASSEMBLY......................................................................................................................... 982 OPEN AND CLOSE FRONT UNDER GUARD..................................................................................................... 984 Open............................................................................................................................. 984 Close............................................................................................................................ 986 OPEN AND CLOSE REAR UNDER GUARD...................................................................................................... 988 Open............................................................................................................................. 988 Close............................................................................................................................ 990 REMOVE AND INSTALL FRONT UNDER GUARD ASSEMBLY........................................................................................ 992 Removal.......................................................................................................................... 992 Installation..................................................................................................................... 997 REMOVE AND INSTALL REAR UNDER GUARD ASSEMBLY.........................................................................................1002 Removal..........................................................................................................................1002 Installation.....................................................................................................................1008 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................1014 REMOVAL..........................................................................................................................1014 INSTALLATION.....................................................................................................................1016 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................1018 ASSEMBLY.........................................................................................................................1018 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..............................................................................1019 SPECIAL TOOLS....................................................................................................................1019 DISASSEMBLY......................................................................................................................1019 ASSEMBLY.........................................................................................................................1022 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY...........................................................................................1026 INSTALLATION.....................................................................................................................1027 DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY..........................................................................................1028 DISASSEMBLY......................................................................................................................1028 ASSEMBLY.........................................................................................................................1030 REMOVAL AND INSTALLATION OF ROPS GUARD...............................................................................................1032 REMOVAL..........................................................................................................................1032 INSTALLATION.....................................................................................................................1032 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................................................................................1033 REMOVAL..........................................................................................................................1033 INSTALLATION.....................................................................................................................1034 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY.....................................................................................1035 SPECIAL TOOLS....................................................................................................................1035 REMOVAL..........................................................................................................................1035 INSTALLATION.....................................................................................................................1038 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY.........................................................................1040 REMOVAL..........................................................................................................................1040 INSTALLATION.....................................................................................................................1040 REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY.............................................................................1041 REMOVAL..........................................................................................................................1041 INSTALLATION.....................................................................................................................1041 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY...............................................................................1042 REMOVAL..........................................................................................................................1042 INSTALLATION.....................................................................................................................1042 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.....................................................................................1043 REMOVAL..........................................................................................................................1043 INSTALLATION.....................................................................................................................1044 REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY.......................................................................................1045 REMOVAL..........................................................................................................................1045 INSTALLATION.....................................................................................................................1045 REMOVAL AND INSTALLATION OF FAN MOTOR................................................................................................1046 REMOVAL..........................................................................................................................1046 INSTALLATION.....................................................................................................................1046 90 OTHERS................................................................................................................................1047 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................1048 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (SINGLE TILT SPEC)..........................................................................1051 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILT SPEC)............................................................................1053 DIAGRAM FOR ELECTRICAL CIRCUIT (1/4).................................................................................................1055 DIAGRAM FOR ELECTRICAL CIRCUIT (2/4).................................................................................................1057 DIAGRAM FOR ELECTRICAL CIRCUIT (3/4).................................................................................................1059 DIAGRAM FOR ELECTRICAL CIRCUIT (4/4).................................................................................................1061 DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER....................................................................................1063 ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB...............................................................................................1064
DESCRIPTION:
KOMATSU D275A-5 SHOP MANUAL SEBM026313 – PDF DOWNLOAD
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
S.S 28/12/24
