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Komatsu D275AX-5 Crawler Bulldozer Shop Manual SEBM025511 – PDF DOWNLOAD
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Komatsu D275AX-5 Crawler Bulldozer Shop Manual
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D275AX-5 20001 and up
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Description
Komatsu D275AX-5 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D275AX-5 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D275AX-5
Serial Number: 20001 and up
Book Code: SEBM025511
Language: English
Pages: 1061
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D275AX-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 D275AX-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 HYDRAULIC PIPING OF POWER TRAIN...................................................................................................................... 44 DAMPER, UNIVERSAL JOINT.............................................................................................................................. 45 TORQUE CONVERTER, PTO................................................................................................................................ 47 TORQUE CONVERTER..................................................................................................................................... 51 TORQUE CONVERTER VALVE............................................................................................................................... 55 TORQUE CONVERTER VALVE............................................................................................................................... 58 SCAVENGING PUMP...................................................................................................................................... 66 TRANSMISSION CONTROL................................................................................................................................. 67 TRANSMISSION......................................................................................................................................... 68 TRANSMISSION ECMV.................................................................................................................................... 80 MAIN RELIEF VALVE.................................................................................................................................... 85 POWER TRAIN PUMP, STEERING LUBRICATION PUMP.......................................................................................................... 88 LUBRICATION RELIEF VALVE............................................................................................................................. 89 HSS SYSTEM........................................................................................................................................... 91 HSS PUMP............................................................................................................................................. 93 HSS MOTOR............................................................................................................................................ 109 PPC, HSS CHARGE FILTER............................................................................................................................... 118 HSS CHARGE FILTER BYPASS............................................................................................................................. 119 HSS OIL COOLER BYPASS VALVE.......................................................................................................................... 120 STEERING, BRAKE CONTROL.............................................................................................................................. 122 BEVEL GEAR SHAFT, HSS, BRAKE......................................................................................................................... 124 BRAKE VALVE.......................................................................................................................................... 137 BRAKE ECMV........................................................................................................................................... 138 PARKING BRAKE VALVE.................................................................................................................................. 144 SUDDEN BRAKE PREVENTION VALVE........................................................................................................................ 145 FINAL DRIVE.......................................................................................................................................... 146 SPROCKET............................................................................................................................................. 151 TRACK FRAME.......................................................................................................................................... 153 RECOIL SPRING........................................................................................................................................ 155 IDLER................................................................................................................................................ 157 TRACK ROLLER......................................................................................................................................... 159 CARRIER ROLLER....................................................................................................................................... 161 TRACK ROLLER BOGIE................................................................................................................................... 163 TRACK SHOE........................................................................................................................................... 164 MAIN FRAME........................................................................................................................................... 166 SUSPENSION........................................................................................................................................... 168 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.............................................................................................................. 171 PPC CONTROL PIPING DIAGRAM........................................................................................................................... 175 WORK EQUIPMENT CONTROL............................................................................................................................... 176 WORK EQUIPMENT PUMP.................................................................................................................................. 178 COOLING FAN PUMP..................................................................................................................................... 194 COOLING FAN MOTOR.................................................................................................................................... 202 HYDRAULIC TANK....................................................................................................................................... 207 ACCUMULATOR.......................................................................................................................................... 209 PPC LOCK VALVE....................................................................................................................................... 210 PPC VALVE............................................................................................................................................ 211 PPC VALVE............................................................................................................................................ 218 HYDRAULIC CYLINDER................................................................................................................................... 223 PISTON VALVE......................................................................................................................................... 226 QUICK DROP VALVE..................................................................................................................................... 227 PIN PULLER SWITCH.................................................................................................................................... 228 PIN PULLER SOLENOID VALVE............................................................................................................................ 229 BLADE CONTROL KNOB................................................................................................................................... 231 PITCH,DUAL TILT SOLENOID VALVE....................................................................................................................... 232 CONTROL VALVE........................................................................................................................................ 233 DUAL TILT SPECIFICATION.............................................................................................................................. 237 OPERATION OF CONTROL VALVE........................................................................................................................... 241 SELF-REDUCING PRESSURE VALVE......................................................................................................................... 258 CYLINDER STAY........................................................................................................................................ 265 BLADE................................................................................................................................................ 266 RIPPER EQUIPMENT..................................................................................................................................... 271 CAB MOUNT............................................................................................................................................ 273 CAB.................................................................................................................................................. 274 AIR CONDITIONER...................................................................................................................................... 276 ENGINE CONTROL....................................................................................................................................... 277 ENGINE CONTROL SYSTEM................................................................................................................................ 278 DECELERATION POTENTIOMETER........................................................................................................................... 279 CRI ENGINE CONTROL SYSTEM............................................................................................................................ 280 MONITOR SYSTEM....................................................................................................................................... 282 MONITOR PANEL........................................................................................................................................ 284 SENSORS.............................................................................................................................................. 288 MODE SELECTION SYSTEM................................................................................................................................ 292 SENSORS.............................................................................................................................................. 295 ELECTRICAL EQUIPMENT................................................................................................................................. 298 PALM COMMAND CONTROL SYSTEM.......................................................................................................................... 301 20 TESTING AND ADJUSTING................................................................................................................................. 303 STANDARD VALUE TABLE FOR ENGINE...................................................................................................................... 304 STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................... 305 TESTING AND ADJUSTING................................................................................................................................ 311 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................................ 313 MEASURING ENGINE SPEED........................................................................................................................... 315 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................................................... 318 MEASURING EXHAUST TEMPERATURE.................................................................................................................... 320 MEASURING EXHAUST GAS COLOR...................................................................................................................... 322 ADJUSTING VALVE CLEARANCE........................................................................................................................ 323 MEASURING COMPRESSION PRESSURE................................................................................................................... 324 MEASURING BLOW-BY PRESSURE....................................................................................................................... 325 MEASURING ENGINE OIL PRESSURE.................................................................................................................... 326 HANDLING OF FUEL SYSTEM DEVICES.................................................................................................................. 327 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM..................................................................................................... 327 MEASURING FUEL PRESSURE.......................................................................................................................... 328 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................... 329 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE........................................................................................................... 331 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................... 332 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................................... 332 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL................................................................................................ 333 MEASURING POWER TRAIN OIL PRESSURE............................................................................................................... 335 TESTING AND ADJUSTING HSS OIL PRESSURE........................................................................................................... 344 ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................................. 349 BLEEDING AIR FROM HSS PUMP....................................................................................................................... 350 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE....................................................................................................... 350 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER.................................................................................................... 351 ADJUSTING PCCS LEVER CONSOLE POSITION............................................................................................................ 354 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE............................................................................................. 355 ADJUSTING CLEARANCE OF IDLER..................................................................................................................... 358 INSPECTING WEAR OF SPROCKET...................................................................................................................... 358 TESTING AND ADJUSTING TRACK SHOE TENSION......................................................................................................... 359 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE................................................................................................ 360 TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE.............................................................................................. 364 MEASURING PPC VALVE OUTPUT PRESSURE.............................................................................................................. 365 ADJUSTING PLAY OF PPC VALVE...................................................................................................................... 367 MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE.................................................................................... 368 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER.................................................................................... 369 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER............................................................................................ 370 RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER......................................................................................... 371 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER........................................................................................................ 371 ADJUSTING RIPPER LEVER POSITION.................................................................................................................. 372 ADJUSTING SAFETY LOCK LEVER...................................................................................................................... 373 MEASURING FAN MOTOR SPEED........................................................................................................................ 374 MEASURING FAN CIRCUIT OIL PRESSURE............................................................................................................... 375 CHANGING ROTATION DIRECTION OF FAN MOTOR......................................................................................................... 376 BLEEDING AIR FROM FAN PUMP....................................................................................................................... 376 ADJUSTING BLADE.................................................................................................................................. 377 TESTING AND ADJUSTING OPERATOR'S CAB............................................................................................................. 379 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)........................................................................................................ 380 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER............................................................................................ 426 ADJUSTMENT METHOD OF REPLACED CONTROLLER......................................................................................................... 426 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM......................................................................................... 428 HANDLING OF OPTIONAL DEVICES..................................................................................................................... 430 PM CLINIC SERVICE................................................................................................................................ 431 UNDERCARRIAGE TROUBLESHOOTING REPORT............................................................................................................. 438 TROUBLESHOOTING...................................................................................................................................... 440 POINTS TO REMEMBER WHEN TROUBLESHOOTING ......................................................................................................... 441 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................ 442 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................. 443 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................... 451 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING................................................................................................. 452 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...................................................................... 455 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)............................................................................................. 466 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)......................................................................................... 468 CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)................................................................................... 470 CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)....................................................................................... 472 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................... 474 T-BRANCH BOX AND T-BRANCH TABLE.................................................................................................................. 496 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)........................................................................................ 498 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................................ 502 TROUBLE CODE TABLE........................................................................................................................... 503 ERROR CODE [1500LO] (TRANSMISSION CLUTCH:SEE THE LIST.(L1)).................................................................................. 504 ERROR CODE [15SAL1] (FORWARD CLUTCH:SEE THE LIST.(L1))....................................................................................... 505 ERROR CODE [15SALH] (FORWARD CLUTCH:SEE THE LIST.(LH))....................................................................................... 506 ERROR CODE [15SBL1] (REVERSE CLUTCH:SEE THE LIST.(L1))....................................................................................... 507 ERROR CODE [15SBLH] (REVERSE CLUTCH:SEE THE LIST.(LH))....................................................................................... 508 ERROR CODE [15SEL1] (1ST CLUTCH:SEE THE LIST.(L1))........................................................................................... 509 ERROR CODE [15SELH] (1ST CLUTCH:SEE THE LIST.(LH))........................................................................................... 510 ERROR CODE [15SFL1] (2ND CLUTCH:SEE THE LIST.(L1))........................................................................................... 511 ERROR CODE [15SFLH] (2ND CLUTCH:SEE THE LIST.(LH))........................................................................................... 512 ERROR CODE [15SGL1] (3RD CLUTCH:SEE THE LIST.(L1))........................................................................................... 513 ERROR CODE [15SGLH] (3RD CLUTCH:SEE THE LIST.(LH))........................................................................................... 514 ERROR CODE [1800MW] (POWER TRAIN CLUTCH:SLIP (MW))........................................................................................... 515 ERROR CODE [2301L1] (RIGHT BRAKE:SEE THE LIST.(L1)).......................................................................................... 516 ERROR CODE [2301LH] (RIGHT BRAKE:SEE THE LIST.(LH)).......................................................................................... 517 ERROR CODE [2302L1] (LEFT BRAKE:SEE THE LIST.(L1))........................................................................................... 518 ERROR CODE [2302LH] (LEFT BRAKE:SEE THE LIST.(LH))........................................................................................... 519 ERROR CODE [AB00MA] (ALTERNATOR:MALFUNCTION (MA))............................................................................................ 520 ERROR CODE [AD00L2] (COMMON RAIL:SEE THE LIST.(L2)).......................................................................................... 520 ERROR CODE [AD00MA] (COMMON RAIL:DEFECTIVE FUNCTION (MA)).................................................................................... 521 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP:SEE THE LIST.(L3))..................................................................................... 521 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP:DEFECTIVE FUNCTION (MA))............................................................................... 524 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP:FUNCTION REDUCTION (MB))............................................................................... 524 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1:DISCONNECTION IN WIRING (KA))............................................................... 525 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1:SHORT CIRCUIT (KB))......................................................................... 526 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN WIRING (KA))............................................................... 527 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN SHORT (KB))................................................................ 528 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA)).................................................................... 529 ERROR CODE [ADAZKB] (NO.1,2 AND 3 INJECTOR SOLENOIDS:SHORT (KB))............................................................................. 530 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA)).................................................................... 532 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA)).................................................................... 533 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA)).................................................................... 534 ERROR CODE [ADDZKB] (NO.4,5 AND 6 INJECTOR SOLENOIDS:SHORT (KB))............................................................................. 535 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID:DISCONNECTION (KA))......................................................................... 537 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID:DISCONNECTION (KA))......................................................................... 538 ERROR CODE [B@BAZG] (ENGINE OIL:OIL PRESSURE REDUCTION (ZG))................................................................................. 539 ERROR CODE [B@BCNS] (RADIATOR COOLANT:OVERHEAT (NS))......................................................................................... 539 ERROR CODE [B@BCZK] (RADIATOR COOLANT:LEVEL REDUCTION (ZK)).................................................................................. 540 ERROR CODE [B@CENS] (POWER TRAN OIL:OVERHEAT (NS))........................................................................................... 540 ERROR CODE [B@CHZG] (HSS CHARGE OIL:OIL PRESSURE REDUCTION (ZG))............................................................................. 541 ERROR CODE [B@HANS] (HYDRAULIC OIL:OVERHEAT (NS))............................................................................................ 541 ERROR CODE [D110KA] (BATTERY RELAY:DISCONNECTION (KA))....................................................................................... 542 ERROR CODE [D110KB] (BATTERY RELAY:SHORT CIRCUIT (KB))....................................................................................... 543 ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY:DISCONNECTION (KA))................................................................................ 544 ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY:SHORT CIRCUIT (KB))................................................................................ 546 ERROR CODE [D161KA] (BACK-UP ALARM RELAY:DISCONNECTION (KA))................................................................................. 547 ERROR CODE [D161KB] (BACK-UP ALARM RELAY:SHORT CIRCUIT (KB))................................................................................. 549 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY:SHORT CIRCUIT (KB))........................................................... 551 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR))........................................................... 553 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION (INPUT) (KK)).......................................................... 555 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER (KT))................................................................. 556 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY:SOURCE VOLTAGE REDUCTION (INPUT) (KK))............................... 557 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:SOURCE VOLTAGE REDUCTION (INPUT) (KK))...................................... 559 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INCONSISTENCY (KQ))........................................... 560 ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))..... 561 ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER SNET COMMUNICATION:DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)).... 563 ERROR CODE [DB20KT] (ENGINE CONTROLLER:ABNORMALITY IN CONTROLLER (KT))....................................................................... 564 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY:SOURCE VOLTAGE REDUCTION (INPUT) (KK)).............................................. 566 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT:TYPE SELECT SIGNAL INCONSISTENCY (KQ)).................................................... 568 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:MALFUNCTION (MA))........................................................ 569 ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))........... 570 ERROR CODE [DB30KK] (STEERING CONTROLLER:SOURCE VOLTAGE REDUCTION (INPUT) (KK)).............................................................. 572 ERROR CODE [DB30KT] (STEERING CONTROLLER:ABNORMALITY IN CONTROLLER (KT))..................................................................... 573 ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY:SOURCE VOLTAGE REDUCTION (INPUT) (KK))................................... 574 ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY:SOURCE VOLTAGE REDUCTION (INPUT) (KK)).......................................... 576 ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INCONSISTENCY (KQ))............................................... 578 ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))......... 579 ERROR CODE [DB3SKR] (STEERING CONTROLLER SNET COMMUNICATION:DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))........ 581 ERROR CODE [DD11KB] (STARTING SWITCH:SHORT CIRCUIT (KB))..................................................................................... 582 ERROR CODE [DD12KA] (SHIFT UP SWITCH:DISCONNECTION (KA))..................................................................................... 583 ERROR CODE [DD12KB] (SHIFT UP SWITCH:SHORT CIRCUIT (KB))..................................................................................... 585 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH:DISCONNECTION (KA))................................................................................... 587 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH:SHORT CIRCUIT (KB))................................................................................... 589 ERROR CODE [DD14KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))................................................................................ 591 ERROR CODE [DD14KB] (PARKING LEVER SWITCH:SHORT CIRCUIT (KB))................................................................................ 593 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH:REFER TO TABLE (L6).......................................................................... 595 ERROR CODE [DDN4LD] (RIPPER LIFT UP PRESSURE SWITCH:REFER TO TABLE (LD)...................................................................... 597 ERROR CODE [DDN5LD] (RIPPER LIFT DOWN PRESSURE SWITCH:REFER TO TABLE (LD).................................................................... 598 ERROR CODE [DDN6LD] (RIPPER TILT IN PRESSURE SWITCH:REFER TO TABLE (LD)...................................................................... 599 ERROR CODE [DDN7KA] (BLADE PITCH SWITCH:DISCONNECTION (KA)................................................................................... 600 ERROR CODE [DDN7KB] (BLADE PITCH SWITCH:SHORT CIRCUIT (KB)................................................................................... 602 ERROR CODE [DDN9KA] (BLADE TILT SWITCH:DISCONNECTION (KA).................................................................................... 604 ERROR CODE [DDN9KB] (BLADE TILT SWITCH:SHORT CIRCUIT (KB).................................................................................... 606 ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))................................................................................ 608 ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH:SHORT CIRCUIT (KB)).......................................................................... 610 ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH:SEE TABLE (L4)).............................................................................. 612 ERROR CODE [DGE2KX] (ENGINE COOLANT TEMPERATURE SENSOR (FOR HIGH TEMPERATURE):INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))...................... 613 ERROR CODE [DGE3L6] (ENGINE COOLANT TEMPERATURE SENSOR (FOR LOW TEMPERATURE):SEE TABLE (L6))................................................. 614 ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))....................................................... 615 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).............................................. 616 ERROR CODE [DH21KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:DISCONNECTION (KA))............................................................. 617 ERROR CODE [DH21KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:SHORT CIRCUIT (KB))............................................................. 618 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE (KX))................................................................ 619 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE (KX)).......................................................... 621 ERROR CODE [DHH3KA] (HSS PUMP OIL PRESSURE SENSOR A:DISCONNECTION (KA))...................................................................... 623 ERROR CODE [DHH3KB] (HSS PUMP OIL PRESSURE SENSOR A:SHORT CIRCUIT (KB))...................................................................... 624 ERROR CODE [DHH4KA] (HSS PUMP OIL PRESSURE SENSOR B:DISCONNECTION (KA))...................................................................... 625 ERROR CODE [DHH4KB] (HSS PUMP OIL PRESSURE SENSOR B:SHORT CIRCUIT (KB))...................................................................... 626 ERROR CODE [DK10KX] (FUEL CONTROL DIAL:INPUT IS OUT OF NORMAL RANGE (KX)).................................................................... 627 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER:INPUT IS OUT OF NORMAL RANGE (KX))........................................................... 629 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1:DISCONNECTION (KA))............................................................................ 631 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1:SHORT CIRCUIT (KB))............................................................................ 633 ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))...................................................... 634 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1:DISCONNECTION OR SHORT CIRCUIT (KZ))........................................................... 634 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1:SEE TABLE (L8))................................................................................ 635 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2:DISCONNECTION (KA))............................................................................ 636 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2:SHORT CIRCUIT (KB))............................................................................ 638 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER:DISCONNECTION (KA))................................................................................. 639 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER:SHORT CIRCUIT (KB))................................................................................. 641 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))................................................. 642 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER:DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 642 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER:SEE TABLE (L8))........................................................................... 643 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1:DISCONNECTION (KA))..................................................................... 644 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1:SHORT CIRCUIT (KB))..................................................................... 646 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2:DISCONNECTION (KA))..................................................................... 647 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2:SHORT CIRCUIT (KB))..................................................................... 649 ERROR CODE [DK60KA] (ACCELERATION SENSOR:DISCONNECTION (KA))................................................................................. 650 ERROR CODE [DK60KB] (ACCELERATION SENSOR:SHORT CIRCUIT (KB))................................................................................. 651 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR:DISCONNECTION (KA)).................................................................................. 652 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR:SHORT CIRCUIT (KB)).................................................................................. 653 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR:SEE TABLE (LC)).................................................................................. 654 ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR:DISCONNECTION (KA)).................................................................... 656 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR:SEE TABLE (LC))................................................................................... 657 ERROR CODE [DV00KB] (CAUTION BUZZER:SHORT CIRCUIT (KB))...................................................................................... 658 ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID:DISCONNECTION (KA))........................................................................ 659 ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID:SHORT CIRCUIT (KB))........................................................................ 660 ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID:DISCONNECTION (KA))....................................................................... 661 ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID:SHORT CIRCUIT (KB))....................................................................... 662 ERROR CODE [DWN1KA] (HSS PUMP SOLENOID LEFT:DISCONNECTION (KA)).............................................................................. 663 ERROR CODE [DWN1KB] (HSS PUMP SOLENOID LEFT:SHORT CIRCUIT (KB)).............................................................................. 664 ERROR CODE [DWN2KA] (HSS PUMP SOLENOID RIGHT:DISCONNECTION (KA))............................................................................. 665 ERROR CODE [DWN2KB] (HSS PUMP SOLENOID RIGHT:SHORT CIRCUIT (KB))............................................................................. 666 ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID:DISCONNECTION (KA))..................................................................... 667 ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID:SHORT CIRCUIT (KB))..................................................................... 668 ERROR CODE [DWN4KA] (HSS FREE SOLENOID:DISCONNECTION (KA))................................................................................... 669 ERROR CODE [DWN4KB] (HSS FREE SOLENOID:SHORT CIRCUIT (KB))................................................................................... 670 ERROR CODE [DWN5KA] (FAN PUMP SOLENOID:DISCONNECTION (KA))................................................................................... 671 ERROR CODE [DWN5KB] (FAN PUMP SOLENOID:SHORT CIRCUIT (KB))................................................................................... 672 ERROR CODE [DXH1KA] (LOCK-UP SOLENOID:DISCONNECTION (KA)).................................................................................... 673 ERROR CODE [DXH1KB] (LOCK-UP SOLENOID:SHORT CIRCUIT (KB)).................................................................................... 674 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV:DISCONNECTION (KA))..................................................................................... 675 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV:SHORT CIRCUIT (KB))..................................................................................... 676 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV:DISCONNECTION (KA))..................................................................................... 677 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV:SHORT CIRCUIT (KB))..................................................................................... 678 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV:DISCONNECTION (KA))..................................................................................... 679 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV:SHORT CIRCUIT (KB))..................................................................................... 680 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV:DISCONNECTION (KA))................................................................................. 681 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV:SHORT CIRCUIT (KB))................................................................................. 682 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV:DISCONNECTION (KA))................................................................................. 683 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV:SHORT CIRCUIT (KB))................................................................................. 684 ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV:DISCONNECTION (KA)).................................................................................... 685 ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV:SHORT CIRCUIT (KB)).................................................................................... 686 ERROR CODE [DXHCKA] (LEFT BRAKE ECMV:DISCONNECTION (KA))..................................................................................... 687 ERROR CODE [DXHCKB] (LEFT BRAKE ECMV:SHORT CIRCUIT (KB))..................................................................................... 688 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................................... 689 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................................ 690 E-1 THE ENGINE DOES NOT START................................................................................................................ 691 E-2 THE PREHEATER DOES NOT OPERATE.(MANUAL PREHEATING FUNCTION).............................................................................. 693 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.......................................................................................... 695 E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.......................................................... 696 E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.................................. 697 E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH....................................................................... 698 E-7 WHILE THE ENGINE IS OPERATING,ANY CAUTION ITEM FLASHES................................................................................... 699 E-8 WHILE THE ENGINE IS OPERATING,THE EMERGENCY WARNING ITEM FLASHES......................................................................... 701 E-9 WHILE THE PREHEATER IS OPERATING,THE PREHEATING PILOT LAMP DOES NOT COME ON.............................................................. 705 E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE).................... 707 E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON................................... 707 E-12 THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY......................................................................... 708 E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL............................................................................. 709 E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.......................................................................... 710 E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL................................................................................................ 711 E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL................................................................................. 712 E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.................................................................................. 712 E-18 THE SWITCH MODULE CANNOT BE OPERATED.................................................................................................... 713 E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT...................................................................................... 714 E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP........................................................................................ 715 E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED...................................................................................... 716 E-22 PIVOT TURN IS NOT POSSIBLE OR IS NOT RELEASED........................................................................................... 717 E-23 THE ALARM BUZZER CANNOT BE CANCELLED.................................................................................................... 718 E-24 THE OPERATOR MODE CANNOT BE OPERATED.................................................................................................... 719 E-25 THE SERVICE MODE CANNOT BE OPERATED..................................................................................................... 720 E-26 THE BACK-UP ALARM DOES NOT SOUND........................................................................................................ 722 E-27 THE NIGHT LIGHT,THE HEADLAMP,THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON............................................. 723 E-28 THE AIR CONDITIONER DOES NOT OPERATE.................................................................................................... 727 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)..................................................................................... 732 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................................................ 733 H-1 NO TRAVEL POWER (NO DRAWBAR PULL)........................................................................................................ 734 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED).............................................................................................. 735 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE................................................................................................. 736 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE.............................................................................. 737 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE.............................................................. 738 H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)................................................................................. 739 H-7 STEERING SPEED OR POWER IS LOW........................................................................................................... 739 H-8 BRAKE DOES NOT WORK...................................................................................................................... 740 H-9 TORQUE CONVERTER DOES NOT LOCK-UP........................................................................................................ 740 H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE................................................................................................. 741 H-11 ABNORMAL SOUND AROUND HSS PUMP OR HSS MOTOR............................................................................................. 742 H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW...................................................................................................... 743 H-13 WORK EQUIPMENT DOES NOT MOVE............................................................................................................ 744 H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER................................................................................................. 744 H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER................................................................................................. 745 H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER................................................................................................ 745 H-17 RIPPER TILE SPEED IS SLOW OR LACKS POWER................................................................................................ 746 H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT................................................................................................. 746 H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT................................................................................................. 747 H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT................................................................................................ 747 H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE).............................................................. 748 H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)................................................................................ 748 H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP................................................................................ 748 TROUBLESHOOTING OF ENGINE SYSTEMS (S-MODE)....................................................................................................... 749 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................... 750 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................ 754 S-2 ENGINE DOES NOT START.................................................................................................................... 755 a) ENGINE DOES NOT TURN.................................................................................................................. 755 b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT........................................................................................... 756 c) ENGINE SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................................................. 757 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................................... 758 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................... 759 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................................ 760 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................................... 761 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................................... 762 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................. 763 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................... 764 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................... 765 S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).................................................................. 766 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................................................. 767 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).................................................................................................... 768 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................................... 769 S-15 ABNORMAL NOISE IS MADE.................................................................................................................. 770 S-16 VIBRATION IS EXCESSIVE.................................................................................................................. 771 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................. 772 HOW TO READ THIS MANUAL.............................................................................................................................. 775 REMOVAL AND INSTALLATION OF ASSEMBLIES........................................................................................................... 775 SPECIAL TOOLS.................................................................................................................................... 775 REMOVAL OF PARTS................................................................................................................................. 775 INSTALLATION OF PARTS............................................................................................................................ 775 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 775 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES........................................................................................................... 776 SPECIAL TOOLS.................................................................................................................................... 776 DISASSEMBLY...................................................................................................................................... 776 ASSEMBLY......................................................................................................................................... 776 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 776 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................. 777 SPECIAL TOOL LIST.................................................................................................................................... 779 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY................................................................................................ 791 SPECIAL TOOLS.................................................................................................................................... 791 REMOVAL.......................................................................................................................................... 791 INSTALLATION..................................................................................................................................... 793 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY................................................................................................... 795 REMOVAL.......................................................................................................................................... 795 INSTALLATION..................................................................................................................................... 798 REMOVAL AND INSTALLATION OF NOZZLE TIP............................................................................................................... 801 SPECIAL TOOLS.................................................................................................................................... 801 REMOVAL.......................................................................................................................................... 801 INSTALLATION..................................................................................................................................... 802 SKETCH OF SPECIAL TOOL........................................................................................................................... 803 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL........................................................................................................ 804 SPECIAL TOOLS.................................................................................................................................... 804 REMOVAL.......................................................................................................................................... 804 INSTALLATION..................................................................................................................................... 804 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL......................................................................................................... 806 SPECIAL TOOLS.................................................................................................................................... 806 REMOVAL.......................................................................................................................................... 806 INSTALLATION..................................................................................................................................... 806 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................................... 808 SPECIAL TOOL..................................................................................................................................... 808 REMOVAL.......................................................................................................................................... 808 INSTALLATION..................................................................................................................................... 813 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY....................................................................................................... 817 REMOVAL.......................................................................................................................................... 817 INSTALLATION..................................................................................................................................... 818 REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY................................................................................................... 819 REMOVAL.......................................................................................................................................... 819 INSTALLATION..................................................................................................................................... 821 REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY.................................................................................................... 822 REMOVAL.......................................................................................................................................... 822 INSTALLATION..................................................................................................................................... 823 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY............................................................................................ 824 REMOVAL.......................................................................................................................................... 824 INSTALLATION..................................................................................................................................... 825 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY.................................................................................................. 826 REMOVAL.......................................................................................................................................... 826 INSTALLATION..................................................................................................................................... 828 REMOVAL AND INSTALLATION OF ENGINE................................................................................................................... 829 SPECIAL TOOLS.................................................................................................................................... 829 REMOVAL.......................................................................................................................................... 829 INSTALLATION..................................................................................................................................... 833 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY.......................................................................................................... 835 SPECIAL TOOLS.................................................................................................................................... 835 REMOVAL.......................................................................................................................................... 835 INSTALLATION..................................................................................................................................... 838 DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY.......................................................................................................... 839 SPECIAL TOOLS.................................................................................................................................... 839 DISASSEMBLY...................................................................................................................................... 840 ASSEMBLY......................................................................................................................................... 842 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY................................................................................................ 844 REMOVAL.......................................................................................................................................... 844 INSTALLATION..................................................................................................................................... 848 DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................................................ 849 DISCONNECTION.................................................................................................................................... 849 CONNECTION....................................................................................................................................... 856 CONNECTION DIAGRAM OF CENTRALIZED OIL PRESSURE PICK-UP HOSES..................................................................................... 858 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY............................................................................................................. 861 DISASSEMBLY...................................................................................................................................... 861 ASSEMBLY......................................................................................................................................... 864 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY................................................................................................ 868 DISASSEMBLY...................................................................................................................................... 868 ASSEMBLY......................................................................................................................................... 872 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY........................................................................................... 878 SPECIAL TOOLS.................................................................................................................................... 878 DISASSEMBLY...................................................................................................................................... 878 ASSEMBLY......................................................................................................................................... 886 DISASSEMBLY AND ASSEMBLY OF HSS CASE ASSEMBLY........................................................................................................ 897 SPECIAL TOOLS.................................................................................................................................... 897 DISASSEMBLY...................................................................................................................................... 897 ASSEMBLY......................................................................................................................................... 905 REMOVAL AND INSTALLATION OF SCAVENGING PUMP.......................................................................................................... 917 REMOVAL.......................................................................................................................................... 917 INSTALLATION..................................................................................................................................... 917 REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY........................................................................................................ 918 REMOVAL.......................................................................................................................................... 918 INSTALLATION..................................................................................................................................... 919 REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND HSS CHARGE PUMP ASSEMBLY.............................................................................. 920 REMOVAL.......................................................................................................................................... 920 INSTALLATION..................................................................................................................................... 921 REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY........................................................................................................ 922 REMOVAL.......................................................................................................................................... 922 INSTALLATION..................................................................................................................................... 923 REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY............................................................................ 924 REMOVAL.......................................................................................................................................... 924 INSTALLATION..................................................................................................................................... 925 REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY....................................................................................................... 926 REMOVAL.......................................................................................................................................... 926 INSTALLATION..................................................................................................................................... 926 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY..................................................................................................... 927 SPECIAL TOOLS.................................................................................................................................... 927 REMOVAL.......................................................................................................................................... 927 INSTALLATION..................................................................................................................................... 928 SKETCH OF SPECIAL TOOL........................................................................................................................... 929 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..................................................................................................... 930 SPECIAL TOOLS.................................................................................................................................... 930 DISASSEMBLY...................................................................................................................................... 930 ASSEMBLY......................................................................................................................................... 935 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY..................................................................................................... 943 SPECIAL TOOL..................................................................................................................................... 943 REMOVAL.......................................................................................................................................... 943 INSTALLATION..................................................................................................................................... 946 SKETCH OF SPECIAL TOOL........................................................................................................................... 947 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY........................................................................................................... 948 REMOVAL.......................................................................................................................................... 948 INSTALLATION..................................................................................................................................... 948 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY........................................................................................................... 949 SPECIAL TOOLS.................................................................................................................................... 949 DISASSEMBLY...................................................................................................................................... 949 ASSEMBLY......................................................................................................................................... 950 SKETCH OF SPECIAL TOOL........................................................................................................................... 952 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY................................................................................................... 953 SPECIAL TOOLS.................................................................................................................................... 953 REMOVAL.......................................................................................................................................... 953 INSTALLATION..................................................................................................................................... 956 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................................................................................................... 957 SPECIAL TOOLS.................................................................................................................................... 957 DISASSEMBLY...................................................................................................................................... 957 ASSEMBLY......................................................................................................................................... 957 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.................................................................................................... 959 SPECIAL TOOLS.................................................................................................................................... 959 REMOVAL.......................................................................................................................................... 959 INSTALLATION..................................................................................................................................... 960 SKETCH OF SPECIAL TOOL........................................................................................................................... 961 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.................................................................................................... 962 SPECIAL TOOLS.................................................................................................................................... 962 DISASSEMBLY...................................................................................................................................... 962 ASSEMBLY......................................................................................................................................... 963 SKETCH OF SPECIAL TOOL........................................................................................................................... 965 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.................................................................................................. 966 REMOVAL.......................................................................................................................................... 966 INSTALLATION..................................................................................................................................... 966 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................................................. 967 SPECIAL TOOLS.................................................................................................................................... 967 DISASSEMBLY...................................................................................................................................... 967 ASSEMBLY......................................................................................................................................... 968 SKETCH OF SPECIAL TOOL........................................................................................................................... 970 REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY....................................................................................................... 971 SPECIAL TOOLS.................................................................................................................................... 971 REMOVAL.......................................................................................................................................... 971 INSTALLATION..................................................................................................................................... 973 SKETCH OF SPECIAL TOOL........................................................................................................................... 976 REMOVAL AND INSTALLATION OF 2ND,3RD AND 4TH BOGIE ASSEMBLY........................................................................................... 977 SPECIAL TOOLS.................................................................................................................................... 977 REMOVAL.......................................................................................................................................... 977 INSTALLATION..................................................................................................................................... 979 SKETCH OF SPECIAL TOOL........................................................................................................................... 983 DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY........................................................................................................... 985 SPECIAL TOOLS.................................................................................................................................... 985 DISASSEMBLY...................................................................................................................................... 985 ASSEMBLY......................................................................................................................................... 985 SKETCH OF SPECIAL TOOL........................................................................................................................... 988 EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY......................................................................................................... 989 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY....................................................................................................... 989 EXPANDING TRACK SHOE ASSEMBLY (NORMAL)........................................................................................................... 989 EXPANDING TRACK SHOE ASSEMBLY.................................................................................................................... 990 INSTALLATION..................................................................................................................................... 991 WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY.......................................................................................... 992 SPECIAL TOOLS.................................................................................................................................... 992 WHOLE DISASSEMBLY................................................................................................................................ 993 WHOLE ASSEMBLY................................................................................................................................... 995 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS....................................................................................................1007 DISASSEMBLY OF 1 LINK IN THE FIELD...............................................................................................................1008 ASSEMBLY OF 1 LINK IN THE FIELD..................................................................................................................1009 DISASSEMBLY OF MASTER LINK.......................................................................................................................1011 ASSEMBLY OF MASTER LINK..........................................................................................................................1012 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY.....................................................................................................1014 SPECIAL TOOLS....................................................................................................................................1014 REMOVAL..........................................................................................................................................1014 INSTALLATION.....................................................................................................................................1014 REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY...................................................................................................1015 SPECIAL TOOLS....................................................................................................................................1015 REMOVAL..........................................................................................................................................1015 INSTALLATION.....................................................................................................................................1016 SKETCH OF SPECIAL TOOL...........................................................................................................................1018 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING....................................................................................................1019 SPECIAL TOOLS....................................................................................................................................1019 DISASSEMBLY......................................................................................................................................1019 ASSEMBLY.........................................................................................................................................1019 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................................1021 REMOVAL..........................................................................................................................................1021 INSTALLATION.....................................................................................................................................1023 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................................1025 ASSEMBLY.........................................................................................................................................1025 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..............................................................................................1026 SPECIAL TOOLS....................................................................................................................................1026 DISASSEMBLY......................................................................................................................................1026 ASSEMBLY.........................................................................................................................................1029 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY...........................................................................................................1033 REMOVAL..........................................................................................................................................1033 INSTALLATION.....................................................................................................................................1034 DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY..........................................................................................................1035 DISASSEMBLY......................................................................................................................................1035 ASSEMBLY.........................................................................................................................................1037 REMOVAL AND INSTALLATION OF ROPS GUARD...............................................................................................................1039 REMOVAL..........................................................................................................................................1039 INSTALLATION.....................................................................................................................................1039 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................................................................................................1040 REMOVAL..........................................................................................................................................1040 INSTALLATION.....................................................................................................................................1041 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY.....................................................................................................1042 SPECIAL TOOLS....................................................................................................................................1042 REMOVAL..........................................................................................................................................1042 INSTALLATION.....................................................................................................................................1045 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY.........................................................................................1047 REMOVAL..........................................................................................................................................1047 INSTALLATION.....................................................................................................................................1047 REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY.............................................................................................1048 REMOVAL..........................................................................................................................................1048 INSTALLATION.....................................................................................................................................1048 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY...............................................................................................1049 REMOVAL..........................................................................................................................................1049 INSTALLATION.....................................................................................................................................1049 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.....................................................................................................1050 REMOVAL..........................................................................................................................................1050 INSTALLATION.....................................................................................................................................1051 REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY.......................................................................................................1052 REMOVAL..........................................................................................................................................1052 INSTALLATION.....................................................................................................................................1052 REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY (SERIAL NO. 20001-20030)..............................................................................1053 REMOVAL..........................................................................................................................................1053 INSTALLATION.....................................................................................................................................1053 REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY (SERIAL NO. 20031 AND UP).............................................................................1054 REMOVAL..........................................................................................................................................1054 INSTALLATION.....................................................................................................................................1054 90 OTHERS................................................................................................................................................1055 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................1056 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................1057 DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER....................................................................................................1058 ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB...............................................................................................................1059 DIAGRAM FOR ELECTRICAL CIRCUIT (A1 SIZE).............................................................................................................1060 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)...................................................................................................1061
KOMATSU D275AX-5 CRAWLER BULLDOZER SHOP MANUAL SEBM025511 – PDF DOWNLOAD:
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