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KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL (SEBM035005) – PDF DOWNLOAD
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- KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM035005
- SERIAL NUMBER:
D31EX-21 50501 and up
D31PX-21 50501 and up
D37EX-21 5501 and up
D37PX-21 5501 and up
D39EX-21 1501 and up
D39PX-21 1501 and up
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Description
KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL (SEBM035005)
KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL (SEBM035005) – PDF DOWNLOAD:
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KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL (SEBM035005)
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information. - 01. Specification
This section explains the specifications of the machine. - 10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. - 20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. - 30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. - 40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. - 50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. - 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU D31EX,PX-21 D37EX,PX-21 D39EX,PX-21 SERVICE REPAIR MANUAL (SEBM035005)
COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 37 SPECIFICATION DRAWING.................................................................................................................... 38 SPECIFICATIONS........................................................................................................................... 40 WEIGHT TABLE............................................................................................................................. 48 TABLE OF FUEL, COOLANT AND LUBRICANTS.................................................................................................... 52 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD.............................................................................................. 54 COOLING SYSTEM........................................................................................................................... 55 ENGINE CONTROL........................................................................................................................... 56 POWER TRAIN.............................................................................................................................. 57 POWER TRAIN SYSTEM....................................................................................................................... 58 DAMPER .................................................................................................................................. 59 HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM.............................................................................................. 60 STEERING, BRAKE CONTROL.................................................................................................................. 61 SOLENOID VALVE........................................................................................................................... 63 TOWING VALVE............................................................................................................................. 65 FINAL DRIVE.............................................................................................................................. 66 HST PUMP................................................................................................................................. 69 SAFETY-SUCTION VALVE..................................................................................................................... 76 CHARGE SAFETY VALVE...................................................................................................................... 79 CHARGE PUMP.............................................................................................................................. 81 TOWING VALVE............................................................................................................................. 82 HST MOTOR................................................................................................................................ 83 ELECTRIC LEVER (FOR STEERING)............................................................................................................ 95 FRAME ASSEMBLY........................................................................................................................... 98 TRACK FRAME, RECOIL SPRING............................................................................................................... 99 IDLER....................................................................................................................................101 TRACK ROLLER.............................................................................................................................105 CARRIER ROLLER...........................................................................................................................109 SPROCKET.................................................................................................................................111 TRACK SHOE...............................................................................................................................115 ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT....................................................................................120 WORK EQUIPMENT CONTROL...................................................................................................................121 HYDRAULIC TANK, FILTER...................................................................................................................123 PPC LOCK VALVE...........................................................................................................................124 ACCUMULATOR..............................................................................................................................125 HYDRAULIC PUMP...........................................................................................................................126 WORK EQUIPMENT CYLINDER..................................................................................................................127 CONTROL VALVE............................................................................................................................131 CLSS.....................................................................................................................................139 PPC VALVE................................................................................................................................149 WORK EQUIPMENT...........................................................................................................................159 CUTTING EDGE, END BIT....................................................................................................................163 RIPPER...................................................................................................................................164 CAB RELATED..............................................................................................................................165 ENGINE CONTROL...........................................................................................................................166 HST CONTROL SYSTEM.......................................................................................................................167 GEAR SHIFT CONTROL SYSTEM................................................................................................................168 PARING BRAKE CONTROL SYSTEM..............................................................................................................172 COMPONENT EQUIPMENT OF SYSTEM............................................................................................................174 MONITOR SYSTEM...........................................................................................................................178 MONITOR PANEL............................................................................................................................180 SENSORS..................................................................................................................................184 20 TESTING AND ADJUSTING.....................................................................................................................189 STANDARD VALUE TABLE FOR ENGINE ........................................................................................................190 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................193 TESTING AND ADJUSTING....................................................................................................................207 LIST OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................208 SKETCH OF SPECIAL TOOL...............................................................................................................212 MEASURING ENGINE SPEED...............................................................................................................213 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).......................................................................................214 MEASURING EXHAUST TEMPERATURE .......................................................................................................216 MEASURING EXHAUST GAS COLOR..........................................................................................................218 ADJUSTING VALVE CLEARANCE............................................................................................................219 MEASURING COMPRESSION PRESSURE.......................................................................................................221 MEASURING BLOW-BY PRESSURE...........................................................................................................222 MEASURING ENGINE OIL PRESSURE........................................................................................................223 TESTING AND ADJUSTING FUEL INJECTION TIMING..........................................................................................224 BLEEDING AIR FROM FUEL CIRCUIT.......................................................................................................226 ADJUSTING ENGINE STOP SOLENOID LINKAGE...............................................................................................227 ADJUSTING ENGINE SPEED SENSOR........................................................................................................228 REPLACEMENT OF FAN BELT..............................................................................................................228 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION (WITH CAB).............................................................229 ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL...................................................................................231 TESTING AND ADJUSTING HST OIL PRESSURE...............................................................................................234 MEASURING HST SOLENOID VALVE OUTLET PRESSURE.........................................................................................238 TESTING TRAVEL DEVIATION.............................................................................................................240 ADJUSTING HST MOTOR SPEED SENSOR.....................................................................................................241 ADJUSTING PARKING BRAKE LEVER........................................................................................................244 PROCEDURE OF SIMPLE TEST OF BRAKE PERFORMANCE........................................................................................245 ADJUSTING BRAKE PEDAL LINKAGE........................................................................................................246 METHOD OF RELEASING PARKING BRAKE (PROCEDURE FOR EMERGENCY ESCAPE)...................................................................247 TESTING AND ADJUSTING IDLER CLEARANCE................................................................................................249 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................250 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE....................................................................................251 MEASURING WORK EQUIPMENT PPC VALVE OUTPUT PRESSURE...................................................................................253 ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE...........................................................................................255 ADJUSTING WORK EQUIPMENT LOCK LEVER..................................................................................................256 MEASURING LEAKAGE IN WORK EQUIPMENT CYLINDER.........................................................................................257 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.....................................................................................258 BLEEDING AIR FROM HYDRAULIC CIRCUIT..................................................................................................259 ADJUSTING PLAY OF BLAD CENTER BALL...................................................................................................260 PROCEDURE FOR TESTING DIODES.........................................................................................................261 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)............................................................................................262 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM.............................................................................303 PM-CLINIC............................................................................................................................304 TROUBLESHOOTING..........................................................................................................................333 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................334 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................335 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...............................................................................336 CHECKS BEFORE TROUBLESHOOTING........................................................................................................346 CLASSIFICATION AND PROCEDURE FOR TROUBLESHOOTING.....................................................................................347 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM............................................................350 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................363 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE..............................................................................................399 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED.........................................................................................402 ERROR CODES TABLE................................................................................................................404 INFORMATION IN TROUBLESHOOTING TABLE.............................................................................................407 ERROR CODE [6091NX] (HST CHARGE FILTER ELEMENT:CLOGGING).........................................................................409 ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION)....................................................................................410 ERROR CODE [B@BAZG] (ENGINE OIL: LOWERING OF OIL PRESSURE).......................................................................411 ERROR CODE [B@BCNS] (COOLANT: OVERHEATING).......................................................................................412 ERROR CODE [B@CRNS] (HST OIL: OVERHEATING).......................................................................................413 ERROR CODE [B@CRZG] (HST OIL: LOWERING OF OIL PRESSURE)..........................................................................414 ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT)...............................................................................415 ERROR CODE [D130KA] (SAFETY RELAY: DISCONNECTION)................................................................................417 ERROR CODE [D130KB] (SAFETY RELAY: SHORT CIRCUIT)................................................................................419 ERROR CODE[DAFRKR](MONITOR CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))....421 ERROR CODE [DAJ0KK] (HST CONTROLLER: LOWERING OF SOURCE VOLTAGE(INPUT))..........................................................423 ERROR CODE [DAJ0KT] (HST CONTROLLER: INTERNAL DEFECT OF CONTROLLER)..............................................................425 ERROR CODE [DAJ5KK] (HST CONTROLLER SENSOR POWER SUPPLY OUTPUT: LOWERING OF SOURCE VOLTAGE (INPUT))..............................427 ERROR CODE [DD12KA] (SHIFT-UP SWITCH: DISCONNECTION).............................................................................430 ERROR CODE [DD12KB] (SHIFT-UP SWITCH: SHORT CIRCUIT).............................................................................432 ERROR CODE [DD13KA] (SHIFT-DOWN SWITCH: DISCONNECTION)...........................................................................434 ERROR CODE [DD13KB] (SHIFT-DOWN SWITCH: SHORT CIRCUIT)...........................................................................436 ERROR CODE [DD14KB] (TRAVEL LOCK SW1: SHORT CIRCUIT).............................................................................438 ERROR CODE [DDDCKB] (REVERSE TRAVEL SPEED SWITCH: SHORT CIRCUIT).................................................................440 ERROR CODE [DDP6KB] (BRAKE PRESSURE SWITCH: SHORT CIRCUIT).......................................................................442 ERROR CODE [DDQ2KA] (TRAVEL LOCK SW1: DISCONNECTION).............................................................................444 ERROR CODE [DDU1FS] (PARKING BRAKE ON-OFF SWITCH: STICK).........................................................................446 ERROR CODE [DDU1KA] (PARKING BRAKE ON-OFF SWITCH: DISCONNECTION).................................................................448 ERROR CODE [DDU1KB] (PARKING BRAKE ON-OFF SWITCH:SHORT CIRCUIT)..................................................................450 ERROR CODE [DDU1KY] (PARKING BRAKE ON-OFF SWITCH: SHORT CIRCUIT WITH POWER SUPPLY LINE)..........................................452 ERROR CODE [DDU1L4] (PARKING BRAKE ON-OFF SWITCH: DISAGREEMENT OF ON AND OFF SIGNALS)............................................454 ERROR CODE [DGS1KX] (HYDRAULIC TANK OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)...........................................456 ERROR CODE [DHH5KA] (LH PUMP PRESSURE SENSOR: DISCONNECTION).....................................................................458 ERROR CODE [DHH5KB] (LH PUMP PRESSURE SENSOR: SHORT CIRCUIT).....................................................................460 ERROR CODE [DHH6KA] (RH PUMP PRESSURE SENSOR: DISCONNECTION).....................................................................462 ERROR CODE [DHH6KB] (RH PUMP PRESSURE SENSOR: SHORT CIRCUIT).....................................................................464 ERROR CODE [DK10KA] (THROTTLE ANGLE SENSOR: DISCONNECTION).......................................................................466 ERROR CODE [DK10KB] (THROTTLE ANGLE SENSOR: SHORT CIRCUIT).......................................................................468 ERROR CODE [DK12KA] (DECELERATION SENSOR: DISCONNECTION).........................................................................470 ERROR CODE [DK12KB] (DECELERATION SENSOR: SHORT CIRCUIT).........................................................................472 ERROR CODE [DK30KA] (STEERING ANGLE SENSOR: DISCONNECTION).......................................................................474 ERROR CODE [DK30KB] (STEERING ANGLE SENSOR: SHORT CIRCUIT).......................................................................476 ERROR CODE [DK30KX] (STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE)...........................................................478 ERROR CODE [DK30KZ] (STEERING ANGLE SENSOR: DISCONNECTION OR SHORT CIRCUIT)......................................................479 ERROR CODE [DA30L8] (STEERING ANGLE SENSOR: DISAGREEMENT OF ANALOG SIGNALS)......................................................480 ERROR CODE [DK31KA] (STEERING ANGLE SENSOR 2: DISCONNECTION).....................................................................481 ERROR CODE [DK31KB] (STEERING ANGLE SENSOR 2: SHORT CIRCUIT).....................................................................483 ERROR CODE [DK40KA] (BRAKE ANGLE SENSOR: DISCONNECTION)..........................................................................485 ERROR CODE [DK40KB] (BRAKE ANGLE SENSOR: SHORT CIRCUIT)..........................................................................487 ERROR CODE [DK55KX] (DIRECTIONAL POTENTIOMETER: OUT OF INPUT SIGNAL RANGE).......................................................489 ERROR CODE [DK55KZ] (DIRECTIONAL POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT)..................................................490 ERROR CODE [DK55L8] (DIRECTIONAL POTENTIOMETER: DISAGREEMENT OF ANALOG SIGNALS)..................................................491 ERROR CODE [DK56KA] (DIRECTIONAL POTENTIOMETER1: DISCONNECTION)..................................................................492 ERROR CODE [DK56KB] (DIRECTIONAL POTENTIOMETER 1: SHORT CIRCUIT).................................................................494 ERROR CODE [DK57KA] (DIRECTIONAL POTENTIOMETER 2: DISCONNECTION).................................................................496 ERROR CODE [DK57KB] (DIRECTIONAL POTENTIOMETER 2: SHORT CIRCUIT).................................................................498 ERROR CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION).........................................................................500 ERROR CODE [DLE2KB] (ENGINE SPEED SENSOR: SHORT CIRCUIT).........................................................................502 ERROR CODE [DLM0KX] (MOTOR SPEED SENSOR: OUT OF INPUT SIGNAL RANGE)..............................................................504 ERROR CODE [DLM1KA] (LEFT HAT MOTOR SPEED SENSOR: DISCONNECTION).................................................................505 ERROR CODE [DLM1KB] (LEFT HAT MOTOR SPEED SENSOR: SHORT CIRCUIT).................................................................507 ERROR CODE [DLM1MA] (LEFT HAT MOTOR SPEED SENSOR: MALFUNCTION)...................................................................509 ERROR CODE [DLM2KA] (RIGHT HST MOTOR SPEED SENSOR: DISCONNECTION)................................................................511 ERROR CODE [DLM2KB] (RIGHT HST MOTOR SPEED SENSOR: SHORT CIRCUIT)................................................................513 ERROR CODE [DLM2MA] (RIGHT HST MOTOR SPEED SENSOR: MALFUNCTION)..................................................................515 ERROR CODE [DN21FS] (CENTER BRAKE LIMIT SWITCH: FIXING)..........................................................................517 ERROR CODE [DV00KB] (BUZZER: SHORT CIRCUIT)......................................................................................519 ERROR CODE [DV20KB] (BACKUP ALARM BUZZER: SHORT CIRCUIT).........................................................................520 ERROR CODE [DW28KA] (2ND GEAR SPEED SOLENOID VALVE: DISCONNECTION)...............................................................522 ERROR CODE [DW28KB] (2ND GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT)...............................................................524 ERROR CODE [DW29KA] (3ND GEAR SPEED SOLENOID VALVE: DISCONNECTION)...............................................................526 ERROR CODE [DW29KB] (3ND GEAR SPEED SOLENOID VALVE: SHORT CIRCUIT)...............................................................528 ERROR CODE [DW4BKA] (PARKING BRAKE SOLENOID VALVE: DISCONNECTION)................................................................530 ERROR CODE [DW4BKB] (PARKING BRAKE SOLENOID VALVE: SHORT CIRCUIT)................................................................532 ERROR CODE [DW7EKA] (SLOW BRAKE SOLENOID VALVE: DISCONNECTION)...................................................................534 ERROR CODE [DW7EKB] (SLOW BRAKE SOLENOID VALVE: SHORT CIRCUIT)...................................................................536 ERROR CODE [DXA4KA] (LH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)................................................................538 ERROR CODE [DXA4KB] (LH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)................................................................540 ERROR CODE [DXA5KA] (LH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)................................................................542 ERROR CODE [DXA5KB] (LH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)................................................................544 ERROR CODE [DXA6KA] (RH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)................................................................546 ERROR CODE [DXA6KB] (RH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)................................................................548 ERROR CODE [DXA7KA] (RH PUMP F-EPC SOLENOID VALVE: DISCONNECTION)................................................................550 ERROR CODE [DXA7KB] (RH PUMP F-EPC SOLENOID VALVE: SHORT CIRCUIT)................................................................552 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................554 BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)...............................................................555 INFORMATION IN TROUBLESHOOTING TABLE.............................................................................................557 E-1 ENGINE DOES NOT START........................................................................................................558 E-2 ENGINE IS NOT PREHEATED......................................................................................................563 E-3 ENGINE DOES NOT STOP.........................................................................................................565 E-4 WHEN STARTING SWITCH IS TURNED ON,ANY ITEM DOES NOT LIGHT UP.................................................................567 E-5 WHEN STARTING SWITCH IS TURNED ON, ALL ITEMS LIGHT UP AND NONE OF THEM GOES OFF..............................................569 E-6 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING.........................................................................569 E-7 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING .......................................................................571 E-8 PREHEATING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING OPERATION..........................................................576 E-9 ENGINE COOLANT THERMOMETER IS ABNORMAL.......................................................................................578 E-10 HST OIL THERMOMETER ID ABNORMAL.............................................................................................580 E-11 FUEL LEVEL GAUGE IS ABNORMAL................................................................................................582 E-12 REVERSE TRAVEL SPEED INDICATOR IS ABNORMAL..................................................................................584 E-13 GEAR SPEED,SET TRAVEL SPEED,ANF SHIFT MODE INDICATOR IS ABNORMAL............................................................584 E-14 MULTI-INFORMATION SECTION ID ABNORMAL.......................................................................................584 E-15 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF..............................................................................584 E-16 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP..............................................................................585 E-17 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION.......................................................................586 E-18 SHIFT MODE SWITCH DOES NOT FUNCTION.........................................................................................588 E-19 BUZZER CANCEL SWITCH DOES NOT FUNCTION......................................................................................589 E-20 INFORMATION SWITCH DOES NOT FUNCTION........................................................................................591 E-21 SYSTEM IS NOT SET IN SERVICE MODE OR IS NOT SET OUT OF SERVICE MODE.........................................................593 E-23 HEADLAMP OR REAR LAMP DOES NOT LIGHT UP.....................................................................................595 E-24 CANOPY HEATER DOES NOT OPERATE[CANOPY SPECIFICATION]........................................................................597 E-25 AIR CONDITIONER DOES NOT OPERATE[CAB SPECIFICATION].........................................................................599 E-26 WINDSHIELD WIPER AND WINDSHIELD WASHER DO NOT OPERATE[CAB SPECIFICATION]....................................................604 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................610 INFORMATION IN TROUBLESHOOTING TABLE.............................................................................................611 H-1 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (NO TRAVEL SYSTEMS OPERATE)..............................612 H-2 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (ONLY RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE)......613 H-3 RIGHT AND LEFT TRAVEL SYSTEMS DO NOT OPERATE FORWARD AND IN REVERSE (ONLY 1 SYSTEM DOES NOT OPERATE).........................613 H-4 SPEED OR POWER OF TRAVEL IS LOW..............................................................................................614 H-5 GEAR IS NOT SHIFTED..........................................................................................................615 H-6 LARGE SHOCK IS MADE WHEN MACHINE STOPS TRAVELING.............................................................................616 H-7 MACHINE DEVIATES LARGELY DURING TRAVEL.......................................................................................616 H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGER..........................................................................................617 H-9 ENGINE STALLS OR ENGINE SPEED LOWERS EXTREMELY DURING TRAVEL.................................................................617 H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR ....................................................................618 H-11 WORK EQUIPMENT DOES NOT OPERATE AT ALL......................................................................................619 H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW...............................................................................620 H-13 SPEED OR POWER OF LIFTING BLADE IS LOW......................................................................................621 H-14 SPEED OR POWER OF TILTING BLADE IS LOW......................................................................................621 H-15 SPEED OR POWER OF ANGLING BLADE IS LOW......................................................................................622 H-16 TIME LAG IN LIFTING BLADE IS LARGE..........................................................................................623 H-17 HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE...................................................................................623 H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE...................................................................................623 H-19 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP AND CONTROL VALVE..................................................624 H-20 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH..............................................................625 TROUBLESHOOTING OF ENGINE (S MODE)...................................................................................................626 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................627 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................631 S-2 ENGINE DOES NOT START........................................................................................................632 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).........................................................................635 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................636 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................637 S-6 ENGINE TACKS OUTPUT (OR TACKS POWER).........................................................................................638 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...............................................................................639 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)......................................................................640 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................641 S-10 FUEL CONSUMPTION IS EXCESSIVE ..............................................................................................642 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....................................................643 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................644 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................645 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................646 S-15 ABNORMAL NOISE IS MADE......................................................................................................647 S-16 VIBRATION IS EXCESSIVE......................................................................................................648 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................649 HOW TO READ THIS MANUAL..................................................................................................................650 COATING MATERIALS LIST...................................................................................................................652 SPECIAL TOOL LIST........................................................................................................................656 SKETCHES OF SPECIAL TOOLS................................................................................................................658 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.................................................................................659 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.......................................................................................663 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL............................................................................................670 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL.............................................................................................673 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY......................................................................................675 DISASSEMBLY AND ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES.......................................................678 REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY.................................................................................682 REMOVAL AND INSTALLATION OF DAMPER.......................................................................................................685 SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY........................................................................................686 REMOVAL AND INSTALLATION OF HST MOTOR AND FINAL DRIVE ASSEMBLY...........................................................................688 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY.........................................................................................690 REMOVAL AND INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY.............................................................................700 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.......................................................................................701 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...............................................................................................704 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY........................................................................................707 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY......................................................................................711 REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY............................................................................................713 REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY..................................................................................715 DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY..................................................................................717 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY...............................................................................................725 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES................................................................................727 REMOVAL AND INSTALLATION OF OPERATOR'S SEAT FRAME ASSEMBLY...............................................................................730 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...........................................................................................734 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY......................................................................................735 REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY......................................................................................737 90 OTHERS....................................................................................................................................738 HYDRAULIC CIRCUIT DIAGRAM(1/2)...........................................................................................................739 HYDRAULIC CIRCUIT DIAGRAM(2/2)...........................................................................................................740 ELECTRICAL CIRCUIT DIAGRAM(1/4)..........................................................................................................741 ELECTRICAL CIRCUIT DIAGRAM(2/4)..........................................................................................................742 ELECTRICAL CIRCUIT DIAGRAM(3/4)..........................................................................................................743 ELECTRICAL CIRCUIT DIAGRAM(4/4)..........................................................................................................744 AIR CONDITIONER CIRCUIT DIAGRAM..........................................................................................................745
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