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KOMATSU D375A-5 SERVICE REPAIR MANUAL (SN:18200 & UP) – PDF DOWNLOAD
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- KOMATSU D375A-5 SERVICE REPAIR MANUAL
- SERIAL NUMBER:D375A-5 18200 and up
- PUBLICATION NUMBER:SEBM035200
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Description
KOMATSU D375A-5 SERVICE REPAIR MANUAL (SN:18200 & UP)
KOMATSU D375A-5 SERVICE REPAIR MANUAL (SN:18200 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D375A-5 SERVICE REPAIR MANUAL (SN:18200 & UP)
- 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 D375A-5 SERVICE REPAIR MANUAL (SN:18200 & UP)
COVER.......................................................................................................................................................................... 1 CONTENTS....................................................................................................................................................................... 2 01 GENERAL..................................................................................................................................................................... 23 SPECIFICATION DRAWINGS..................................................................................................................................................... 24 SPECIFICATIONS............................................................................................................................................................. 25 WEIGHT TABLE............................................................................................................................................................... 30 TABLE OF FUEL, COOLANT AND LUBRICANTS...................................................................................................................................... 32 10 STRUCTURE AND FUNCTION...................................................................................................................................................... 34 ENGINE CONTROL............................................................................................................................................................. 35 POWER TRAIN................................................................................................................................................................ 36 OVERALL DRAWING OF POWER TRAIN UNIT........................................................................................................................................ 38 POWER TRAIN HYDRAULIC PIPING DIAGRAM....................................................................................................................................... 40 POWER TRAIN HYDRAULIC CIRCUIT DRAWING...................................................................................................................................... 41 DAMPER, UNIVERSAL JOINT.................................................................................................................................................... 43 TORQUE CONVERTER, PTO...................................................................................................................................................... 45 TORQUE CONVERTER VALVE..................................................................................................................................................... 50 TRANSMISSION CONTROL....................................................................................................................................................... 52 TRANSMISSION............................................................................................................................................................... 53 TRANSMISSION CONTROL VALVE................................................................................................................................................. 60 TRANSMISSION LUBRICATION RELIEF VALVE...................................................................................................................................... 67 SCAVENGING PUMP STRAINER................................................................................................................................................... 68 OVERFLOW VALVE............................................................................................................................................................. 69 POWER TRAIN PUMP STRAINER.................................................................................................................................................. 71 POWER TRAIN, LUBRICATING OIL FILTER........................................................................................................................................ 72 STEERING, BRAKE CONTROL.................................................................................................................................................... 73 TRANSFER, BEVEL GEAR SHAFT, STEERING....................................................................................................................................... 77 STEERING CONTROL VALVE..................................................................................................................................................... 81 FINAL DRIVE................................................................................................................................................................ 89 TRACK FRAME................................................................................................................................................................ 93 RECOIL SPRING.............................................................................................................................................................. 95 TRACK ROLLER BOGIE......................................................................................................................................................... 97 MAIN FRAME................................................................................................................................................................. 98 SUSPENSION................................................................................................................................................................. 99 PPC CONTROL PIPING DIAGRAM.................................................................................................................................................101 WORK EQUIPMENT CONTROL.....................................................................................................................................................102 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................................104 HYDRAULIC TANK.............................................................................................................................................................106 PPC CHARGE VALVE...........................................................................................................................................................107 ACCUMULATOR................................................................................................................................................................109 PPC LOCK VALVE.............................................................................................................................................................110 PISTON VALVE...............................................................................................................................................................121 QUICK DROP VALVE...........................................................................................................................................................122 PIN PULLER SWITCH..........................................................................................................................................................123 PIN PULLER SOLENOID VALVE..................................................................................................................................................124 BLADE CONTROL KNOB.........................................................................................................................................................126 MAIN CONTROL VALVE.........................................................................................................................................................127 CYLINDER STAY..............................................................................................................................................................153 BLADE......................................................................................................................................................................154 RIPPER.....................................................................................................................................................................156 CAB MOUNT..................................................................................................................................................................158 CAB........................................................................................................................................................................159 AIR CONDITIONER............................................................................................................................................................160 MONITOR SYSTEM.............................................................................................................................................................161 SWITCH PANEL...............................................................................................................................................................169 FUSE BOX...................................................................................................................................................................169 ENGINE START SAFETY SYSTEM.................................................................................................................................................171 APS........................................................................................................................................................................172 20 TESTING AND ADJUSTING.......................................................................................................................................................174 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS..............................................................................................................................175 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.............................................................................................................................176 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS..........................................................................................................................181 STANDARD VALUE TABLE FOR MONITOR...........................................................................................................................................182 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.................................................................................................................183 MEASURING ENGINE SPEED.....................................................................................................................................................184 MEASURING EXHAUST COLOR....................................................................................................................................................185 ADJUSTING VALVE CLEARANCE..................................................................................................................................................186 MEASURING COMPRESSION PRESSURE.............................................................................................................................................187 MEASURING BLOW-BY PRESSURE.................................................................................................................................................188 MEASURING ENGINE OIL PRESSURE..............................................................................................................................................189 TESTING AND ADJUSTING FUEL INJECTION TIMING ...............................................................................................................................190 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..............................................................................................................................192 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR..........................................................................................................192 MEASURING EXHAUST TEMPERATURE..............................................................................................................................................193 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).............................................................................................................................194 MEASURING TORQUE CONVERTER STALL SPEED.....................................................................................................................................195 MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) ............................................................................................196 ADJUSTING FUEL CONTROL LINKAGE.............................................................................................................................................197 ADJUSTING DECELERATOR PEDAL................................................................................................................................................200 ADJUSTING JOYSTICK (STEERING, DIRECTIONAL, SPEED CONTROL LEVER), PARKING BRAKE LEVEL LINKAGE...............................................................................201 ADJUSTING BRAKE PEDAL LINKAGE..............................................................................................................................................205 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE...................................................................................................................................206 MEASURING POWER TRAIN OIL PRESSURE.........................................................................................................................................207 MEASURING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE..................................................................................................................210 TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE..............................................................................................................212 MEASURING PPC VALVE OUTPUT PRESSURE........................................................................................................................................213 ADJUSTING PPC VALVE........................................................................................................................................................214 MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE............................................................................................................................215 BLEEDING AIR FROM HYDRAULIC CYLINDERS......................................................................................................................................216 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................................................................216 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER..........................................................................................................217 MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER................................................................................................................................218 ADJUSTING SEMI U-TILTDOZER.................................................................................................................................................219 ADJUSTING IDLER CLEARANCE..................................................................................................................................................221 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE.............................................................................................................................221 TROUBLESHOOTING............................................................................................................................................................222 POINTS TO REMEMBER WHEN TROUBLESHOOTING ...............................................................................................................................223 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................................................224 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................................................225 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................................................233 TYPE OF CONNECTOR AND POSITION OF INSTALLATION.........................................................................................................................234 CONNECTOR ARRANGEMENT DIAGRAM..........................................................................................................................................236 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................................................241 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................251 TROUBLESHOOTING OF ENGING SYSTEM (S MODE)..............................................................................................................................253 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................................254 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................................258 S-2 ENGINE DOES NOT START..........................................................................................................................................259 1) ENGINE DOES NOT TURN........................................................................................................................................259 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS BEING INJECTED)........................................................................................260 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOS NOT START (FUEL IS BEING INJECTED)...................................................................................261 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...........................................................................................................262 S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................................................263 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................................264 S-6 ENGINE LACKS OUTPUT (NO POWER).................................................................................................................................265 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).................................................................................................................266 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................................................267 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................................................268 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................................269 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................................................................................270 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................271 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)..........................................................................................................................272 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..............................................................................................................273 S-15 ABNORMAL NOISE IS MADE........................................................................................................................................274 S-16 VIBRATION IS EXCESSIVE........................................................................................................................................275 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...........................................................................................................276 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)...............................................................................................277 H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL).......................................................................................................................279 H-2 MACHINE DOES NOT MOVE (2ND, 3RD, ENGINE RUNNING)...............................................................................................................281 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.......................................................................................................................283 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)..................................................................................................285 H-5 TIME LAG S EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION..................................................................................................286 H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STRAIGHT LINE)............................................................................................................287 H-7 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) [JOYSTICK (STEERING, DIRECTIONAL, SPEED LEVEL) OPERATED]...................................................288 H-8 MACHINE TURNS TOO FAR..........................................................................................................................................289 H-9 BRAKES DO NOT WORK.............................................................................................................................................290 H-10 POWER TRAIN OIL OVERHEATS.....................................................................................................................................291 H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW...........................................................................................................................293 H-102 WORK EQUIPMENT DOES NOT MOVE.................................................................................................................................295 H-103 BLADE LIFT SPEED IS SLOW OR LACKS POWER......................................................................................................................296 H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER......................................................................................................................296 H-105 RIPPER LIFT SPEED IS SLOW OR LACKS POWER.....................................................................................................................297 H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER.....................................................................................................................297 H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT......................................................................................................................298 H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT......................................................................................................................298 H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER..........................................................................................................................299 H-110 PIN-PULLER CYLINDER DOES NOT WORK............................................................................................................................299 H-111 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP....................................................................................................................300 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................................................301 M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN ON MONITOR PANEL).......................................................................................302 M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT..........................................................................302 M-3 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)...........................303 a) (BATTERY CHARGE) FLASHES....................................................................................................................................303 b) (ENGINE OIL PRESSURE) FLASHES...............................................................................................................................303 c) (COOLANT TEMPERATURE) FLASHES...............................................................................................................................304 d) (POWER TRAIN OIL TEMPERATURE) FLASHES.......................................................................................................................305 M-4 ABNORMALITY IN (PREHEATING)....................................................................................................................................306 a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP...................................................................................................................306 b) PREHEATING MONITOR LAMP STAYS LIGHTED UP....................................................................................................................306 M-5 ABNORMALITY IN BUZZER..........................................................................................................................................307 a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND OR BUZZER DOES NOT SOUND FOR 1 SEC. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED).......................307 b) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS.................................................................................................................307 M-6 ABNORMALITY IN WARNING LAMP....................................................................................................................................308 a) CAUTION ITEM FLASHES BUT WARNING LAMP DOES NOT FLASH, OR WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 1 SECOND....308 b) MONITOR DISPLAY IS NORMAL BUT WARNING LAMP LIGHTS UP........................................................................................................308 M-7 ABNORMALITY IN GAUGE ..........................................................................................................................................309 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE.............................................................................................................309 b) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE.........................................................................................309 c) ABNORMALITY IN FUEL LEVEL GAUGE.............................................................................................................................310 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED............................................................................................................311 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL).................................................................................312 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................................................313 E-1 ENGINE DOES NOT START..........................................................................................................................................314 E-2 DEFECTIVE OPERATION OF APS.....................................................................................................................................316 a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP DURING PREHEATING.................................................................................................316 b) PREHEATING MONITOR LAMP STAYS LIGHTED UP AFTER PREHEATING IS COMPLETED......................................................................................316 c) PREHEATING MONITOR LAMP FLASHES AFTER PREHEATING IS COMPLETED...............................................................................................317 d) PREHEATING MONITOR LAMP LIGHTS UP WHEN ENGINE IS STARTED (STARTING SWITCH AT START) AFTER PREHEATING IS COMPLETED...........................................317 e) APS IS NOT ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃.....................................................................................................318 f) APS IS ACTUATED WHEN WATER TEMPERATURE IS ABOVE 20℃.........................................................................................................320 g) APS IS ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ BUT APS SWITCH IS NOT TURNED ON.........................................................................320 E-3 DEFECTIVE OPERATION OF BACK-UP ALARM...........................................................................................................................321 a) BACK-UP ALARM DOES NOT SOUND................................................................................................................................321 b) BACK-UP ALARM DOS NOT STOP SOUNDING.........................................................................................................................321 E-4 LAMPS DO NOT LIGHT UP..........................................................................................................................................322 a) FRONT LAMPS.................................................................................................................................................322 b) WORKING LAMPS ..............................................................................................................................................322 c) REAR LAMPS (RIPPER LAMP)....................................................................................................................................324 E-5 PIN-PULLER CYLINDER DOES NOT WORK (ONLY MACHINES EQUIPPED WITH GIANT RIPPER)...................................................................................325 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................326 HOW TO READ THIS MANUAL....................................................................................................................................................329 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................................................331 SPECIAL TOOL LIST..........................................................................................................................................................333 SKETCH OF SPECIAL TOOLS....................................................................................................................................................343 STARTING MOTOR.............................................................................................................................................................350 REMOVAL................................................................................................................................................................350 INSTALLATION...........................................................................................................................................................350 ALTERNATOR.................................................................................................................................................................351 REMOVAL................................................................................................................................................................351 INSTALLATION...........................................................................................................................................................351 ENGINE OIL COOLER..........................................................................................................................................................352 REMOVAL................................................................................................................................................................352 INSTALLATION...........................................................................................................................................................353 FUEL INJECTION PUMP........................................................................................................................................................354 REMOVAL ...............................................................................................................................................................354 INSTALLATION...........................................................................................................................................................354 WATER PUMP.................................................................................................................................................................355 REMOVAL ...............................................................................................................................................................355 INSTALLATION...........................................................................................................................................................355 THERMOSTAT.................................................................................................................................................................356 REMOVAL................................................................................................................................................................356 INSTALLATION...........................................................................................................................................................356 TURBOCHARGER...............................................................................................................................................................357 REMOVAL................................................................................................................................................................357 INSTALLATION...........................................................................................................................................................358 AFTERCOOLER CORE...........................................................................................................................................................359 REMOVAL................................................................................................................................................................359 INSTALLATION...........................................................................................................................................................360 NOZZLE HOLDER..............................................................................................................................................................361 REMOVAL................................................................................................................................................................361 INSTALLATION...........................................................................................................................................................361 ENGINE FRONT SEAL..........................................................................................................................................................362 REMOVAL................................................................................................................................................................362 INSTALLATION...........................................................................................................................................................362 ENGINE REAR SEAL...........................................................................................................................................................364 REMOVAL................................................................................................................................................................364 INSTALLATION...........................................................................................................................................................364 CYLINDER HEAD..............................................................................................................................................................366 REMOVAL................................................................................................................................................................366 INSTALLATION...........................................................................................................................................................371 FUEL TANK..................................................................................................................................................................373 REMOVAL................................................................................................................................................................373 INSTALLATION...........................................................................................................................................................373 RADIATOR...................................................................................................................................................................374 REMOVAL................................................................................................................................................................374 INSTALLATION...........................................................................................................................................................375 RADIATOR GUARD ............................................................................................................................................................376 REMOVAL................................................................................................................................................................376 INSTALLATION...........................................................................................................................................................378 ENGINE.....................................................................................................................................................................379 REMOVAL................................................................................................................................................................379 INSTALLATION...........................................................................................................................................................384 DAMPER.....................................................................................................................................................................385 REMOVAL................................................................................................................................................................385 INSTALLATION...........................................................................................................................................................388 DISASSEMBLY............................................................................................................................................................390 ASSEMBLY...............................................................................................................................................................391 POWER TRAIN UNIT...........................................................................................................................................................393 REMOVAL................................................................................................................................................................393 INSTALLATION...........................................................................................................................................................397 DISCONNECTION..........................................................................................................................................................398 CONNECTION.............................................................................................................................................................403 PTO........................................................................................................................................................................405 DISASSEMBLY............................................................................................................................................................405 ASSEMBLY...............................................................................................................................................................409 TORQUE CONVERTER...........................................................................................................................................................413 DISASSEMBLY............................................................................................................................................................413 ASSEMBLY...............................................................................................................................................................419 TORQFLOW TRANSMISSION......................................................................................................................................................425 DISASSEMBLY............................................................................................................................................................425 ASSEMBLY...............................................................................................................................................................441 STEERING CASE..............................................................................................................................................................458 DISASSEMBLY............................................................................................................................................................458 ASSEMBLY...............................................................................................................................................................466 POWER TRAIN,LUBRICATION PUMP...............................................................................................................................................476 REMOVAL................................................................................................................................................................476 INSTALLATION...........................................................................................................................................................476 SCAVENGING PUMP............................................................................................................................................................477 REMOVAL................................................................................................................................................................477 INSTALLATION...........................................................................................................................................................477 TORQUE CONVERTER OIL COOLER................................................................................................................................................478 REMOVAL................................................................................................................................................................478 INSTALLATION...........................................................................................................................................................478 TORQUE CONVERTER VALVE.....................................................................................................................................................479 REMOVAL................................................................................................................................................................479 INSTALLATION...........................................................................................................................................................479 DISASSEMBLY............................................................................................................................................................480 ASSEMBLY...............................................................................................................................................................481 TRANSMISSION CONTROL VALVE.................................................................................................................................................482 REMOVAL................................................................................................................................................................482 INSTALLATION...........................................................................................................................................................482 DISASSEMBLY............................................................................................................................................................483 ASSEMBLY...............................................................................................................................................................484 TRANSMISSION LUBRICATION VALVE.............................................................................................................................................485 REMOVAL................................................................................................................................................................485 INSTALLATION...........................................................................................................................................................485 DISASSEMBLY............................................................................................................................................................485 ASSEMBLY...............................................................................................................................................................485 STEERING CONTROL VALVE.....................................................................................................................................................486 REMOVAL................................................................................................................................................................486 INSTALLATION...........................................................................................................................................................486 DISASSEMBLY............................................................................................................................................................487 ASSEMBLY...............................................................................................................................................................489 FINAL DRIVE ...............................................................................................................................................................490 REMOVAL................................................................................................................................................................490 INSTALLATION...........................................................................................................................................................490 DISASSEMBLY............................................................................................................................................................491 ASSEMBLY...............................................................................................................................................................497 TACK FRAME.................................................................................................................................................................506 REMOVAL................................................................................................................................................................506 INSTALLATION...........................................................................................................................................................506 IDLER ASSEMBLY.............................................................................................................................................................508 REMOVAL................................................................................................................................................................508 INSTALLATION...........................................................................................................................................................508 DISASSEMBLY............................................................................................................................................................509 ASSEMBLY...............................................................................................................................................................509 RECOIL SPRING..............................................................................................................................................................513 REMOVAL................................................................................................................................................................513 INSTALLATION...........................................................................................................................................................513 DISASSEMBLY............................................................................................................................................................517 ASSEMBLY...............................................................................................................................................................517 TRACK ROLLER...............................................................................................................................................................519 REMOVAL................................................................................................................................................................519 INSTALLATION...........................................................................................................................................................519 DISASSEMBLY............................................................................................................................................................522 ASSEMBLY...............................................................................................................................................................522 BOGIE ASSEMBLY.............................................................................................................................................................525 REMOVAL................................................................................................................................................................525 INSTALLATION...........................................................................................................................................................525 DISASSEMBLY............................................................................................................................................................530 ASSEMBLY...............................................................................................................................................................530 1ST BOGIE ASSEMBLY.........................................................................................................................................................532 REMOVAL................................................................................................................................................................532 INSTALLATION...........................................................................................................................................................532 TRACK SHOE.................................................................................................................................................................537 CHECK BEFORE EXPANDING.................................................................................................................................................537 EXPANDING..............................................................................................................................................................538 INSTALLATION...........................................................................................................................................................539 WHOLE DISASSEMBLY......................................................................................................................................................540 WHOLE ASSEMBLY.........................................................................................................................................................540 1. WHEN RECYCLING FOR LUBRICATED TRACK.................................................................................................................................543 2. WHEN RECYCLING FOR GREASE-FILLED TRACK..............................................................................................................................552 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS..........................................................................................................................557 ONE LINK...................................................................................................................................................................558 FIELD DISASSEMBLY......................................................................................................................................................558 FIELD ASSEMBLY.........................................................................................................................................................560 MASTER LINK................................................................................................................................................................562 FIELD DISASSEMBLY......................................................................................................................................................562 FIELD ASSEMBLY.........................................................................................................................................................562 PIVOT SHAFT ASSEMBLY.......................................................................................................................................................567 REMOVAL................................................................................................................................................................567 INSTALLATION...........................................................................................................................................................567 EQUALIZER BAR..............................................................................................................................................................568 REMOVAL................................................................................................................................................................568 INSTALLATION...........................................................................................................................................................568 EQUALIZER BAR BUSHING......................................................................................................................................................571 DISASSEMBLY............................................................................................................................................................571 ASSEMBLY...............................................................................................................................................................571 SEGMENT TOOTH..............................................................................................................................................................573 REMOVAL ...............................................................................................................................................................573 INSTALLATION...........................................................................................................................................................573 HYDRAULIC TANK.............................................................................................................................................................574 REMOVAL................................................................................................................................................................574 INSTALLATION...........................................................................................................................................................576 WORK EQUIPMENT,PPC PUMP....................................................................................................................................................577 REMOVAL................................................................................................................................................................577 INSTALLATION...........................................................................................................................................................577 BLADE LIFT VALVE...........................................................................................................................................................578 REMOVAL................................................................................................................................................................578 INSTALLATION...........................................................................................................................................................579 DISASSEMBLY............................................................................................................................................................580 ASSEMBLY...............................................................................................................................................................581 BLADE TILT,RIPPER LO VALVE.................................................................................................................................................582 REMOVAL................................................................................................................................................................582 INSTALLATION...........................................................................................................................................................583 DISASSEMBLY............................................................................................................................................................584 ASSEMBLY...............................................................................................................................................................584 RIPPER HI VALVE............................................................................................................................................................586 REMOVAL................................................................................................................................................................586 INSTALLATION...........................................................................................................................................................586 DISASSEMBLY............................................................................................................................................................587 ASSEMBLY...............................................................................................................................................................587 PPC CHARGE VALVE...........................................................................................................................................................589 REMOVAL................................................................................................................................................................589 INSTALLATION...........................................................................................................................................................589 DISASSEMBLY............................................................................................................................................................587 ASSEMBLY...............................................................................................................................................................587 BLADE PPC VALVE............................................................................................................................................................591 REMOVAL................................................................................................................................................................591 INSTALLATION...........................................................................................................................................................592 DISASSEMBLY............................................................................................................................................................593 ASSEMBLY...............................................................................................................................................................594 RIPPER PPC VALVE...........................................................................................................................................................596 REMOVAL................................................................................................................................................................596 INSTALLATION...........................................................................................................................................................597 DISASSEMBLY............................................................................................................................................................598 ASSEMBLY...............................................................................................................................................................599 BLADE LIFT CYLINDER........................................................................................................................................................600 REMOVAL................................................................................................................................................................600 INSTALLATION...........................................................................................................................................................600 BLADE TILT CYLINDER........................................................................................................................................................601 REMOVAL................................................................................................................................................................601 INSTALLATION...........................................................................................................................................................601 RIPPER LIFT CYLINDER.......................................................................................................................................................602 REMOVAL................................................................................................................................................................602 INSTALLATION...........................................................................................................................................................602 RIPPER TILT CYLINDER.......................................................................................................................................................603 REMOVAL................................................................................................................................................................603 INSTALLATION...........................................................................................................................................................603 HYDRAULIC CYLINDER.........................................................................................................................................................604 DISASSEMBLY............................................................................................................................................................604 ASSEMBLY...............................................................................................................................................................607 RIPPER PIN-PULLER..........................................................................................................................................................610 REMOVAL................................................................................................................................................................610 INSTALLATION...........................................................................................................................................................610 DISASSEMBLY............................................................................................................................................................611 ASSEMBLY...............................................................................................................................................................612 BLADE......................................................................................................................................................................614 REMOVAL................................................................................................................................................................614 INSTALLATION...........................................................................................................................................................615 DISASSEMBLY............................................................................................................................................................616 ASSEMBLY...............................................................................................................................................................618 GIANT RIPPER...............................................................................................................................................................620 DISASSEMBLY............................................................................................................................................................620 ASSEMBLY...............................................................................................................................................................622 ROPS GUARD.................................................................................................................................................................624 REMOVAL................................................................................................................................................................624 INSTALLATION...........................................................................................................................................................624 OPERATOR'S CAB.............................................................................................................................................................625 REMOVAL................................................................................................................................................................625 INSTALLATION...........................................................................................................................................................625 FLOOR FRAME................................................................................................................................................................626 REMOVAL................................................................................................................................................................626 INSTALLATION...........................................................................................................................................................630 DASHBOARD..................................................................................................................................................................632 REMOVAL................................................................................................................................................................632 INSTALLATION...........................................................................................................................................................633 MONITOR PANEL..............................................................................................................................................................634 REMOVAL................................................................................................................................................................634 INSTALLATION...........................................................................................................................................................634 APS CONTROLLER.............................................................................................................................................................635 REMOVAL................................................................................................................................................................635 INSTALLATION...........................................................................................................................................................635 AIR CONDITIONER COMPRESSOR.................................................................................................................................................636 REMOVAL................................................................................................................................................................636 INSTALLATION...........................................................................................................................................................637 AIR CONDITIONER CONDENSER..................................................................................................................................................638 REMOVAL................................................................................................................................................................638 INSTALLATION...........................................................................................................................................................638 HOOD.......................................................................................................................................................................639 REMOVAL................................................................................................................................................................639 INSTALLATION...........................................................................................................................................................639 40 MAINTENANCE STANDARD........................................................................................................................................................640 ENGINE MOUNT...............................................................................................................................................................641 DAMPER, UNIVERSAL JOINT....................................................................................................................................................642 TORQUE CONVERTER...........................................................................................................................................................643 TORQUE CONVERTER VALVE.....................................................................................................................................................644 TRANSMISSION...............................................................................................................................................................645 TRANSMISSION CONTROL VALVE.................................................................................................................................................647 POWER TRAIN LUBRICATION + POWER TRAIN PUMP.................................................................................................................................649 SCAVENGING PUMP............................................................................................................................................................650 TRANSFER, BEVEL PINION.....................................................................................................................................................651 BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE...................................................................................................................................652 STEERING CONTROL VALVE.....................................................................................................................................................654 FINAL DRIVE................................................................................................................................................................656 MAIN FRAME.................................................................................................................................................................658 IDLER......................................................................................................................................................................660 TRACK ROLLER...............................................................................................................................................................662 CARRIER ROLLER.............................................................................................................................................................663 TRACK SHOE.................................................................................................................................................................664 WORK EQUIPMENT + PPC CHARGE PUMP...........................................................................................................................................666 WORK EQUIPMENT CONTROL VALVE...............................................................................................................................................668 PPC VALVE..................................................................................................................................................................672 PPC CHARGE VALVE...........................................................................................................................................................675 WORK EQUIPMENT CYLINDER....................................................................................................................................................676 QUICK DROP VALVE...........................................................................................................................................................680 CYLINDER STAY..............................................................................................................................................................681 BLADE......................................................................................................................................................................682 RIPPER EQUIPMENT...........................................................................................................................................................687 90 OTHERS......................................................................................................................................................................691 ELECTRICAL CIRCUIT DIAGRAM (1/2)...........................................................................................................................................692 ELECTRICAL CIRCUIT DIAGRAM (2/2)...........................................................................................................................................693
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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