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Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual – PDF DOWNLOAD
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Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual
SERIAL NUMBERS:
D51EX-22 B10001 and up
D51PX-22 B10001 and up
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Description
Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual
FILE DETAILS:
Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D51EX-22, D51PX-22
Serial Number: B10001 and up
Book Code: CEBM019109
Language: English
Pages: 1262
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual
1 GENERAL :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It 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.
TESTING, ADJUSTING AND TROUBLESHOOTING:
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
OTHER:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual
FOREWORD ....................................................................................... 0 CONTENTS.................................................................................... 2 SAFETY...................................................................................... 13 SAFETY NOTICE........................................................................... 13 IMPORTANT SAFETY NOTICE............................................................. 13 GENERAL PRECAUTIONS................................................................. 13 PREPARATIONS FOR WORK............................................................... 13 PRECAUTIONS DURING WORK............................................................. 13 GENERAL..................................................................................... 15 HOW TO READ THE SHOP MANUAL................................................................. 16 VOLUMES................................................................................. 16 DISTRIBUTION AND UPDATING............................................................... 16 FILING METHOD........................................................................... 16 REVISED EDITION MARK.................................................................... 16 REVISIONS............................................................................... 16 SYMBOLS................................................................................. 16 HOISTING INSTRUCTIONS....................................................................... 17 HOISTING................................................................................ 17 WIRE ROPES.............................................................................. 17 PUSH PULL COUPLER........................................................................... 18 TYPE 1.................................................................................. 18 DISCONNECTION....................................................................... 18 CONNECTION.......................................................................... 18 TYPE 2.................................................................................. 19 DISCONNECTION....................................................................... 19 CONNECTION.......................................................................... 19 TYPE 3.................................................................................. 20 DISCONNECTION....................................................................... 20 CONNECTION.......................................................................... 20 EXPLANATION OF MAINTENANCE STANDARD TERMS................................................... 21 STANDARD TIGHTENING TORQUE.................................................................. 23 BOLTS AND NUTS.......................................................................... 23 TIGHTENING TORQUE OF HOSE NUTS.......................................................... 24 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................. 24 TIGHTENING TORQUE FOR FLARED NUTS....................................................... 24 TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS........................................ 25 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS....................................... 25 TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)............................. 25 ELECTRIC WIRE CODE.......................................................................... 26 CLASSIFICATION BY THICKNESS............................................................. 26 CLASSIFICATION BY COLOR AND CODE........................................................ 26 HOW TO READ ELECTRIC WIRE CODE.......................................................... 27 CONVERSION TABLES........................................................................... 30 METHOD OF USING THE CONVERSION TABLE.................................................... 30 COATING MATERIALS........................................................................... 36 01 GENERAL .................................................................................... 39 SPECIFICATION DRAWING....................................................................... 40 D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB................................ 40 SPECIFICATION............................................................................... 41 WEIGHT TABLE................................................................................ 45 TABLE OF FUEL, COOLANT AND LUBRICANTS....................................................... 48 RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS.................................... 50 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ................................................ 51 ENGINE AND COOLING SYSTEM................................................................... 53 ENGINE RELATED PARTS.................................................................... 53 COOLING SYSTEM.......................................................................... 55 COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)................. 58 COOLING FAN MOTOR....................................................................... 59 OIL COOLER BYPASS VALVE................................................................. 65 CHARGE SAFETY VALVE................................................................. 68 POWER TRAIN................................................................................. 70 POWER TRAIN............................................................................. 70 POWER TRAIN SYSTEM...................................................................... 71 DAMPER.................................................................................. 72 FINAL DRIVE............................................................................. 73 PATH OF POWER TRANSMISSION.............................................................. 76 UNDER CARRIAGE AND FRAME.................................................................... 77 MAIN FRAME.............................................................................. 77 TRACK FRAME AND RECOIL SPRING........................................................... 78 SUSPENSION.............................................................................. 80 IDLER................................................................................... 83 TRACK ROLLER............................................................................ 85 CARRIER ROLLER.......................................................................... 89 TRACK SHOE.............................................................................. 95 HYDRAULIC SYSTEM 1 (HST).................................................................... 100 HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM............................................. 100 HST PUMP................................................................................ 101 SAFETY-SUCTION VALVE................................................................ 109 TOWING VALVE........................................................................ 112 HST MOTOR............................................................................... 113 MOTOR CONTROL VALVE..................................................................... 125 SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE...................... 125 SOLENOID VALVE...................................................................... 127 EPC VALVE........................................................................... 128 CHARGE PUMP............................................................................. 132 HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)......................................................... 134 CLSS (CLOSED CENTER LOAD SENSING SYSTEM)................................................ 134 UNLOAD VALVE........................................................................ 138 PRESSURE COMPENSATION VALVE......................................................... 144 LS BYPASS VALVE..................................................................... 145 WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM............................................ 146 WORK EQUIPMENT AND FAN PUMP............................................................. 147 SERVO VALVE......................................................................... 152 CONTROL VALVE........................................................................... 154 QUICK DROP VALVE........................................................................ 166 BLADE PPC VALVE......................................................................... 168 RIPPER/WINCH PPC VALVE.................................................................. 174 HYDRAULIC TANK, FILTER.................................................................. 178 ACCUMULATOR............................................................................. 179 WORK EQUIPMENT.............................................................................. 180 WORK EQUIPMENT.......................................................................... 180 CUTTING EDGE AND END BIT................................................................ 185 RIPPER.................................................................................. 186 WORK EQUIPMENT CYLINDER................................................................. 187 LIFT CYLINDER....................................................................... 187 TILT CYLINDER....................................................................... 187 ANGLE CYLINDER...................................................................... 188 RIPPER CYLINDER..................................................................... 188 PISTON VALVE FOR ANGLE CYLINDER..................................................... 190 CAB AND ITS ATTACHMENTS..................................................................... 191 ROPS CAB................................................................................ 191 STEERING AND BRAKE CONTROL.............................................................. 192 WORK EQUIPMENT CONTROL.................................................................. 194 CAB DAMPER MOUNT........................................................................ 196 AIR CONDITIONER......................................................................... 197 AIR CONDITIONER AND FLOOR HEATER.................................................... 197 AIR CONDITIONER PIPING.............................................................. 198 ELECTRICAL SYSTEM........................................................................... 199 MONITOR SYSTEM.......................................................................... 199 ENGINE CONTROL.......................................................................... 201 ENGINE CONTROL SYSTEM................................................................... 202 COOLING CONTROL SYSTEM.................................................................. 204 HST CONTROL SYSTEM...................................................................... 206 GEAR SHIFT CONTROL SYSTEM............................................................... 207 GEAR SHIFTING BY OPERATOR........................................................... 207 SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS...................................... 208 CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED........................... 210 STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM........................................... 211 PARKING BRAKE CONTROL SYSTEM............................................................ 212 KOMTRAX SYSTEM.......................................................................... 214 SYSTEM COMPONENTS....................................................................... 216 MONITOR PANEL....................................................................... 216 ENGINE CONTROLLER................................................................... 220 HST CONTROLLER...................................................................... 222 ELECTRIC LEVER (FOR TRAVEL)......................................................... 224 KOMTRAX TERMINAL.................................................................... 226 SENSORS................................................................................. 227 BRAKE OIL PRESSURE SENSOR........................................................... 228 HYDRAULIC OIL TEMPERATURE SENSOR.................................................... 229 HST CIRCUIT OIL PRESSURE SENSOR..................................................... 230 AIR CLEANER CLOGGING SENSOR......................................................... 231 DECELERATOR PEDAL POTENTIOMETER..................................................... 232 BRAKE PEDAL POTENTIOMETER........................................................... 232 FUEL CONTROL DIAL................................................................... 233 FUEL LEVEL SENSOR................................................................... 234 CHARGE FILTER CLOGGING SENSOR....................................................... 235 COOLANT TEMPERATURE SENSOR.......................................................... 235 ENGINE OIL PRESSURE SWITCH.......................................................... 236 ENGINE ROTATION SENSOR.............................................................. 236 BOOST PRESSURE AND TEMPERATURE SENSOR............................................... 237 WIF SENSOR.......................................................................... 237 HST MOTOR SPEED SENSOR.............................................................. 238 20 STANDARD VALUE TABLES ....................................................................... 239 STANDARD VALUE TABLE FOR ENGINE............................................................. 240 STANDARD VALUE TABLE FOR CHASSIS............................................................ 241 PERFORMANCE MEASURING POSTURE AND METHOD.................................................... 246 30 TESTING AND ADJUSTING ....................................................................... 249 LIST OF TOOLS............................................................................... 251 ENGINE...................................................................................... 254 ENGINE SPEED............................................................................ 254 AIR INTAKE BOOST PRESSURE............................................................... 255 EXHAUST TEMPERATURE..................................................................... 256 EXHAUST GAS COLOR....................................................................... 258 VALVE CLEARANCE......................................................................... 259 COMPRESSION PRESSURE.................................................................... 262 BLOW-BY PRESSURE........................................................................ 264 ENGINE OIL PRESSURE..................................................................... 265 HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT.................................................... 266 FUEL SYSTEM................................................................................. 267 HANDLING FUEL SYSTEM PARTS.............................................................. 267 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM............................................ 267 BLEEDING AIR FROM FUEL CIRCUIT.......................................................... 268 FUEL PRESSURE........................................................................... 270 FUEL RETURN RATE AND LEAKAGE............................................................ 272 FUEL CIRCUIT FOR LEAKAGE................................................................ 275 FAN (WORK EQUIPMENT) PUMP PRESSURE.......................................................... 276 FAN SPEED................................................................................... 276 FAN SPEED SENSOR........................................................................ 277 DECELERATOR PEDAL........................................................................... 279 HST OIL PRESSURE............................................................................ 281 MOTOR CONTROL VALVE OUTLET PRESSURE......................................................... 286 TRAVEL DEVIATION........................................................................ 289 PARKING BRAKE LEVER......................................................................... 290 BRAKE PERFORMANCE........................................................................... 292 BRAKE PEDAL LINKAGE......................................................................... 293 EMERGENCY RELEASE OF PARKING BRAKE.......................................................... 295 IDLER CLEARANCE............................................................................. 298 TRACK SHOE TENSION.......................................................................... 300 WORK EQUIPMENT.............................................................................. 301 OIL PRESSURE............................................................................ 301 WORK EQUIPMENT PPC VALVE.................................................................... 303 OIL PRESSURE............................................................................ 303 PPC circuit connection diagram...................................................... 304 ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 1............................................ 305 LOCK LEVER ADJUSTMENT....................................................................... 306 CYLINDER LEAKAGE............................................................................ 307 HYDRAULIC CIRCUIT........................................................................... 309 RELEASING RESIDUAL PRESSURE............................................................. 309 BLEEDING AIR............................................................................ 310 BLADE CENTER BALL ADJUSTMENT................................................................ 311 BLADE PITCH BALL ADJUSTMENT................................................................. 311 DIODES...................................................................................... 312 PROCEDURE FOR TESTING................................................................... 312 MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS.................................................... 314 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM.................................. 375 ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED............................................ 377 ITEMS TO BE ADJUSTED.................................................................... 377 HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT............................................. 378 MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT.............................................. 381 PM-CLINIC................................................................................... 383 PM-CLINIC SERVICE....................................................................... 383 PM-CLINIC INSPECTION SHEET (1/2)........................................................ 386 PM-CLINIC INSPECTION SHEET (2/2)........................................................ 387 PM-CLINIC UNDERCARRIAGE CHECK SHEET..................................................... 388 UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)........................................... 389 UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)........................................... 390 PM-CLINIC UNDERCARRIAGE CHECK SHEET..................................................... 391 UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)........................................... 392 UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)........................................... 393 40 TROBULESHOOTING (GENERAL) ............................................................... 395 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................... 396 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................... 398 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................... 399 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.......................................... 399 HANDLING ELECTRONIC CONTROL UNIT........................................................ 404 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS............................. 405 ELECTRIC WIRE CODE.......................................................................... 406 CLASSIFICATION BY THICKNESS............................................................. 406 CLASSIFICATION BY COLOR AND CODE........................................................ 406 HOW TO READ ELECTRIC WIRE CODE.......................................................... 407 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.................................... 409 CHECKS BEFORE TROUBLESHOOTING............................................................... 411 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS................................... 412 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.......................................... 413 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................. 416 T-ADAPTER TABLE............................................................................. 440 MODE CHART.................................................................................. 444 40 TROUBLESHOOTING (BY ERROR CODE) .......................................................... 447 TROUBLESHOOTING BY ERROR CODE............................................................... 453 INFORMATION IN TROUBLESHOOTING TABLE........................................................ 460 ERROR CODE [6091NX]......................................................................... 462 HST CHARGE FILTER ELEMENT CLOGGING...................................................... 462 ERROR CODE [AA10NX]......................................................................... 464 AIR CLEANER CLOGGING.................................................................... 464 ERROR CODE [AB00MA]......................................................................... 466 ALTERNATOR MALFUNCTION.................................................................. 466 ERROR CODE [B@BAZG]......................................................................... 467 ENGINE OIL LOWERING OF OIL PRESSURE..................................................... 467 ERROR CODE [B@BCNS]..................................................................... 468 COOLANT OVERHEAT........................................................................ 468 ERROR CODE [B@CRNS]......................................................................... 469 HST OIL OVERHEATING..................................................................... 469 ERROR CODE [B@CRZG]......................................................................... 470 HST OIL LOWERING OF OIL PRESSURE........................................................ 470 ERROR CODE [CA111].......................................................................... 471 ABNORMALITY IN ENGINE CONTROLLER........................................................ 471 ERROR CODE [CA115].......................................................................... 472 ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL.......................................... 472 ERROR CODE [CA122].......................................................................... 474 CHARGE PRESSURE SENSOR TOO HIGH......................................................... 474 ERROR CODE [CA123].......................................................................... 476 CHARGE PRESSURE SENSOR TOO LOW.......................................................... 476 ERROR CODE [CA131].......................................................................... 478 DECELERATOR PEDAL SENSOR TOO HIGH....................................................... 478 ERROR CODE [CA132].......................................................................... 480 DECELERATOR PEDAL SENSOR TOO LOW........................................................ 480 ERROR CODE [CA144].......................................................................... 482 COOLANT TEMPERATURE SENSOR TOO HIGH..................................................... 482 ERROR CODE [CA145].......................................................................... 484 COOLANT TEMPERATURE SENSOR TOO LOW...................................................... 484 ERROR CODE [CA153].......................................................................... 486 CHARGE TEMPERATURE SENSOR TOO HIGH...................................................... 486 ERROR CODE [CA154].......................................................................... 488 CHARGE TEMPERATURE SENSOR TOO low....................................................... 488 ERROR CODE [CA187].......................................................................... 490 SENSOR POWER SORCE EXCESSIVELY LOW...................................................... 490 ERROR CODE [CA221].......................................................................... 492 ATMOSPHERIC PRESSURE SENSOR TOO HIGH.................................................... 492 ERROR CODE [CA222].......................................................................... 494 ATMOSPHERIC PRESSURE SENSOR TOO LOW..................................................... 494 ERROR CODE [CA227].......................................................................... 496 SENSOR POWER SORCE EXCESSIVELY HIGH..................................................... 496 ERROR CODE [CA234].......................................................................... 498 ENGINE OVERSPEED........................................................................ 498 ERROR CODE [CA238].......................................................................... 499 ABNORMAL POWER SOURCE FOR NE SPEED SENSOR............................................... 499 ERROR CODE [CA271].......................................................................... 500 IMV/PCV1 SHORT CIRCUITED................................................................ 500 ERROR CODE [CA272].......................................................................... 502 IMV/PCV1 OPEN........................................................................... 502 ERROR CODE [CA322].......................................................................... 504 NO.1 INJECTOR SHOWING OPEN OR SHORT..................................................... 504 ERROR CODE [CA323].......................................................................... 506 NO.5 INJECTOR SHOWING OPEN OR SHORT..................................................... 506 ERROR CODE [CA324].......................................................................... 508 NO.3 INJECTOR SHOWING OPEN OR SHORT..................................................... 508 ERROR CODE [CA325].......................................................................... 510 NO.6 INJECTOR SHOWING OPEN OR SHORT..................................................... 510 ERROR CODE [CA331].......................................................................... 512 NO.2 INJECTOR SHOWING OPEN OR SHORT..................................................... 512 ERROR CODE [CA332].......................................................................... 514 NO.4 INJECTOR SHOWING OPEN OR SHORT..................................................... 514 ERROR CODE [CA342].......................................................................... 516 ENGINE CONTROLLER DATA MATCHING ERROR................................................... 516 ERROR CODE [CA352].......................................................................... 517 SENSOR POWER SOURCE TOO LOW............................................................. 517 ERROR CODE [CA386].......................................................................... 518 SENSOR POWER SOURCE TOO HIGH............................................................ 518 ERROR CODE [CA428].......................................................................... 520 WATER IN FUEL SENSOR VOLTAGE TOO HIGH................................................... 520 ERROR CODE [CA429].......................................................................... 522 WATER IN FUEL SENSOR VOLTAGE TOO LOW.................................................... 522 ERROR CODE [CA435].......................................................................... 524 ABNORMAL ENGINE OIL PRESSURE SWITCH..................................................... 524 ERROR CODE [CA441].......................................................................... 526 POWER SOURCE VOLTAGE IS TOO LOW......................................................... 526 ERROR CODE [CA442].......................................................................... 528 POWER SOURCE VOLTAGE TOO HIGH........................................................... 528 ERROR CODE [CA449].......................................................................... 530 COMMON RAIL PRESSURE TOO HIGH........................................................... 530 ERROR CODE [CA451].......................................................................... 532 COMMON RAIL PRESSURE TOO HIGH........................................................... 532 ERROR CODE [CA452].......................................................................... 534 COMMON RAIL PRESSURE TOO LOW............................................................ 534 ERROR CODE [CA488].......................................................................... 536 CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED.......................................... 536 ERROR CODE [CA553].......................................................................... 537 COMMON RAIL PRESSURE TOO HIGH........................................................... 537 ERROR CODE [CA559].......................................................................... 538 LOSS OF PRESSURE FEED FROM SUPPLY PUMP.................................................. 538 ERROR CODE [CA689].......................................................................... 540 ABNORMAL ENGINE NE SPEED SENSOR......................................................... 540 ERROR CODE [CA731].......................................................................... 542 ABNORMAL ENGINE BKUP SPEED SENSOR PHASE................................................. 542 ERROR CODE [CA757].......................................................................... 544 LOSS OF ALL ENGINE CONTROLLER DATA...................................................... 544 ERROR CODE [CA778].......................................................................... 546 ABNORMAL ENGINE BKUP SPEED SENSOR....................................................... 546 ERROR CODE [CA1633]......................................................................... 548 ABNORMAL KOMNET......................................................................... 548 ERROR CODE [CA2185]......................................................................... 550 DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH.......................................... 550 ERROR CODE [CA2186]......................................................................... 551 DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW........................................... 551 ERROR CODE [CA2249]......................................................................... 552 LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2).............................................. 552 ERROR CODE [CA2311]......................................................................... 554 ABNORMAL IMV SOLENOID................................................................... 554 ERROR CODE [CA2555]......................................................................... 556 AIR INTAKE HEATER RELAY DISCONNECTION................................................... 556 ERROR CODE [CA2556]......................................................................... 558 AIR INTAKE HEATER RELAY SHORT CIRCUIT................................................... 558 ERROR CODE [D130KA]......................................................................... 560 NEUTRAL SAFETY RELAY DISCONNECTION...................................................... 560 ERROR CODE [D130KB]......................................................................... 562 NEUTRAL SAFETY RELAY SHORT CIRCUIT...................................................... 562 ERROR CODE [DAFRKR]......................................................................... 564 CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER........................................ 564 ERROR CODE [DAFRMC]......................................................................... 566 CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER..................................... 566 ERROR CODE [DAJ000]......................................................................... 568 HST CONTROLLER MEMORY ERROR............................................................. 568 ERROR CODE [DAJ0KK]......................................................................... 570 HST CONTROLLER LOWERING OF SOURCE VOLTAGE............................................... 570 ERROR CODE [DAJ0KQ]......................................................................... 572 HST CONTROLLER MACHINE CODE ERROR....................................................... 572 ERROR CODE [DAJ0KT]......................................................................... 573 HST CONTROLLER MEMORY ERROR............................................................. 573 ERROR CODE [DAJ5KK]......................................................................... 574 HST CONTROLLER POWER SUPPLY LOWING...................................................... 574 ERROR CODE [DAJ6KK]......................................................................... 576 HST POWER SUPPLY LOWING................................................................. 576 ERROR CODE [DAJRKR]......................................................................... 578 CAN COMMUNICATION HST CONTROLLER DEFECTIVE.............................................. 578 ERROR CODE [DB2RKR]......................................................................... 580 CAN COMMUNICATION HST CONTROLLER DEFECTIVE.............................................. 580 ERROR CODE [DD12KA]......................................................................... 582 SHIFT UP SWITCH DISCONNECTION........................................................... 582 ERROR CODE [DD12KB]......................................................................... 584 SHIFT UP SWITCH SHORT CIRCUIT........................................................... 584 ERROR CODE [DD13KA]......................................................................... 586 SHIFT DOWN SWITCH DISCONNECTION......................................................... 586 ERROR CODE [DD13KB]......................................................................... 588 SHIFT DOWN SWITCH SHORT CIRCUIT......................................................... 588 ERROR CODE [DD14KB]......................................................................... 590 TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT................................................ 590 ERROR CODE [DD1NL4]......................................................................... 592 FAN ROTATION SELECTOR SWITCH DISAGREEMENT............................................... 592 ERROR CODE [DDDCKB]......................................................................... 594 REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT............................................... 594 ERROR CODE [DDP6KA]......................................................................... 596 BRAKE OIL PRESSURE SENSOR DISCONNECTION................................................. 596 ERROR CODE [DDP6KB]......................................................................... 598 BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT................................................. 598 ERROR CODE [DDP6MA]......................................................................... 600 BRAKE OIL PRESSURE SENSOR MALFUNCTION................................................... 600 ERROR CODE [DDQ2KA]......................................................................... 602 TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION................................................ 602 ERROR CODE [DDT0L4]......................................................................... 604 SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS....................................... 604 ERROR CODE [DDU1FS]......................................................................... 606 TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING............................................... 606 ERROR CODE [DDU1KA]......................................................................... 608 TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION................................................ 608 ERROR CODE [DDU1KY]......................................................................... 610 TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE................................. 610 ERROR CODE [DGS1KA]......................................................................... 612 HST OIL TEMPERATURE SENSOR DISCONNECTION................................................ 612 ERROR CODE [DGS1KX]......................................................................... 614 HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE.................................... 614 ERROR CODE [DHH5KA]......................................................................... 615 LEFT HST PUMP PRESSURE SENSOR DISCONNECTION............................................. 615 ERROR CODE [DHH5KB]......................................................................... 617 LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT............................................. 617 ERROR CODE [DHH6KA]......................................................................... 619 RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION............................................ 619 ERROR CODE [DHH6KB]......................................................................... 621 RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT............................................ 621 ERROR CODE [DK10KA]......................................................................... 623 FUEL DIAL SENSOR DISCONNECTION.......................................................... 623 ERROR CODE [DK10KB]......................................................................... 625 FUEL DIAL SENSOR SHORT CIRCUIT.......................................................... 625 ERROR CODE [DK30KA]......................................................................... 627 STEERING ANGLE SENSOR 1 DISCONNECTION................................................... 627 ERROR CODE [DK30KB]......................................................................... 629 STEERING ANGLE SENSOR 1 SHORT CIRCUIT................................................... 629 ERROR CODE [DK30KX]......................................................................... 631 STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE......................................... 631 ERROR CODE [DK30KZ]......................................................................... 632 STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT.................................... 632 ERROR CODE [DK30L8]......................................................................... 633 STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS.................................... 633 ERROR CODE [DK31KA]......................................................................... 635 STEERING ANGLE SENSOR DISCONNECTION..................................................... 635 ERROR CODE [DK31KB]......................................................................... 637 STEERING ANGLE SENSOR 2 SHORT CIRCUIT................................................... 637 ERROR CODE [DK40KA]......................................................................... 639 BRAKE PEDAL SENSOR DISCONNECTION........................................................ 639 ERROR CODE [DK40KB]......................................................................... 641 BRAKE PEDAL SENSOR SHORT CIRCUIT........................................................ 641 ERROR CODE [DK55KX]......................................................................... 643 DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE..................................... 643 ERROR CODE [DK55KZ]......................................................................... 644 DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT................................ 644 ERROR CODE [DK55L8]......................................................................... 645 DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS................................ 645 ERROR CODE [DK56KA]......................................................................... 647 DIRECTIONAL POTENTIOMETER 1 DISCONNECTION............................................... 647 ERROR CODE [DK56KB]......................................................................... 649 DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT............................................... 649 ERROR CODE [DK57KA]......................................................................... 651 DIRECTIONAL POTENTIOMETER 2 DISCONNECTION............................................... 651 ERROR CODE [DK57KB]......................................................................... 653 DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT............................................... 653 ERROR CODE [DLM0KX]......................................................................... 655 HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE....................................... 655 ERROR CODE [DLM1KA]......................................................................... 657 LEFT HST MOTOR SPEED SENSOR DISCONNECTION............................................... 657 ERROR CODE [DLM1KB]......................................................................... 659 LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT.............................................. 659 ERROR CODE [DLM1MA]......................................................................... 661 LEFT HST MOTOR SPEED SENSOR: MALFUNCTION................................................ 661 ERROR CODE [DLM2KA]......................................................................... 663 RIGHT HST MOTOR SPEED SENSOR DISCONNECTION.............................................. 663 ERROR CODE [DLM2KB]......................................................................... 665 RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT.............................................. 665 ERROR CODE [DLM2MA]......................................................................... 667 RIGHT HST MOTOR SPEED SENSOR MALFUNCTION................................................ 667 ERROR CODE [DLM3KA]......................................................................... 669 FAN SPEED SENSOR DISCONNECTION.......................................................... 669 ERROR CODE [DLM3KB]......................................................................... 671 FAN SPEED SENSOR: SHORT CIRCUIT......................................................... 671 ERROR CODE [DN21FS]......................................................................... 673 BRAKE PEDAL AND PROXIMITY SWITCH FIXING................................................. 673 ERROR CODE [DV00KB]......................................................................... 675 CAUTION BUZZER SHORT CIRCUIT............................................................ 675 ERROR CODE [DV20KB]......................................................................... 676 BACK ALARM BUZZER SHORT CIRCUIT......................................................... 676 ERROR CODE [DW4BKA]......................................................................... 677 PARKING BRAKE SOLENOID VALVE DISCONNECTION.............................................. 677 ERROR CODE [DW4BKB]......................................................................... 679 PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT.............................................. 679 ERROR CODE [DW4BKY]......................................................................... 681 PARKING BRAKE SOLENOID VALVE SHORTED.................................................... 681 ERROR CODE [DW7BKA]......................................................................... 682 FAN REVERSE SOLENOID VALVE DISCONNECTION................................................ 682 ERROR CODE [DW7BKB]......................................................................... 682 FAN REVERSE SOLENOID VALVE SHORT CIRCUIT................................................ 683 ERROR CODE [DW7BKY]......................................................................... 684 FAN REVERSE SOLENOID VALVE SHORTED...................................................... 684 ERROR CODE [DW7EKA]......................................................................... 685 SLOW BRAKE SOLENOID VALVE DISCONNECTION................................................. 685 ERROR CODE [DW7EKB]......................................................................... 689 SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT................................................. 689 ERROR CODE [DW7EKY]......................................................................... 691 SLOW BRAKE SOLENOID VALVE SHORTED....................................................... 691 ERROR CODE [DWN5KA]......................................................................... 693 FAN EPC SOLENOID VALVE DISCONNECTION.................................................... 693 ERROR CODE [DWN5KB]......................................................................... 695 FAN EPC SOLENOID VALVE SHORT CIRCUIT.................................................... 695 ERROR CODE [DWN5KY]......................................................................... 697 FAN EPC SOLENOID VALVE SHORTED.......................................................... 697 ERROR CODE [DXA4KA]......................................................................... 699 LF HST PUMP EPC SOLENOID VALVE DISCONNECTION............................................ 699 ERROR CODE [DXA4KB]......................................................................... 701 LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT............................................ 701 ERROR CODE [DXA4KY]......................................................................... 702 LF HST PUMP EPC SOLENOID VALVE SHORTED.................................................. 702 ERROR CODE [DXA5KA]......................................................................... 703 LR HST PUMP EPC SOLENOID VALVE DISCONNECTION............................................ 703 ERROR CODE [DXA5KB]......................................................................... 705 LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT............................................ 705 ERROR CODE [DXA5KY]......................................................................... 706 LR HST PUMP EPC SOLENOID VALVE SHORTED.................................................. 706 ERROR CODE [DXA6KA]......................................................................... 707 RF HST PUMP EPC SOLENOID VALVE DISCONNECTION............................................ 707 ERROR CODE [DXA6KB]......................................................................... 709 RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT............................................ 709 ERROR CODE [DXA6KY]......................................................................... 710 RF HST PUMP EPC SOLENOID VALVE SHORTED.................................................. 710 ERROR CODE [DXA7KA]......................................................................... 711 RR HST PUMP EPC SOLENOID VALVE DISCONNECTION............................................ 711 ERROR CODE [DXA7KB]..................................................................... 712 RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT............................................ 712 ERROR CODE [DXA7KY]......................................................................... 713 RR HST PUMP EPC SOLENOID VALVE SHORTED.................................................. 713 ERROR CODE [DXK1KA]......................................................................... 714 LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION......................................... 714 ERROR CODE [DXK1KB]......................................................................... 715 LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT......................................... 715 ERROR CODE [DXK1KY]......................................................................... 716 LEFT HST MOTOR EPC SOLENOID VALVE SHORTED............................................... 716 ERROR CODE [DXK2KA]......................................................................... 717 RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION........................................ 717 ERROR CODE [DXK2KB]......................................................................... 718 RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT........................................ 718 ERROR CODE [DXK2KY]......................................................................... 719 RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED.............................................. 719 40 TROUBLESHOOTING (E-MODE) .................................................................... 723 BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)................................................ 725 CONNECTION TABLE OF FUSE BOX............................................................ 725 INFORMATION IN TROUBLESHOOTING TABLE........................................................ 727 E-1......................................................................................... 728 STARTING MOTOR DOES NOT ROTATE.......................................................... 728 E-2......................................................................................... 732 ENGINE IS NOT PRE-HEATED................................................................ 732 E-3......................................................................................... 736 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT.............................. 736 E-4......................................................................................... 738 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING.................................... 738 E-5......................................................................................... 740 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING................................... 740 E-6......................................................................................... 744 PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION............................... 744 E-7......................................................................................... 746 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY................................... 746 E-8......................................................................................... 747 HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY................................... 747 E-9......................................................................................... 748 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY............................................. 748 E-10........................................................................................ 750 TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY.............................................. 750 E-11........................................................................................ 750 MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY........................................ 750 E-12........................................................................................ 751 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF.......................................... 751 E-13........................................................................................ 752 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP.......................................... 752 E-14........................................................................................ 754 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION................................... 754 E-15........................................................................................ 756 SHIFT MODE SWITCH DOES NOT FUNCTION..................................................... 756 E-16........................................................................................ 758 BUZZER CANCEL SWITCH DOES NOT FUNCTION.................................................. 758 E-17........................................................................................ 760 INFORMATION SWITCH DOES NOT FUNCTION.................................................... 760 E-18........................................................................................ 762 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET.................................... 762 E-19........................................................................................ 764 BACKUP ALARM DOES NOT SOUND............................................................. 764 E-20........................................................................................ 765 THE HORN DOES NOT SOUND OR DOES NOT STOP................................................ 765 E-21........................................................................................ 766 WORK EQUIPMENT DOES NOT MOVE............................................................ 766 E-22........................................................................................ 768 HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP................................................ 768 E-23........................................................................................ 772 FOOT HEATER DOES NOT OPERATE............................................................ 772 E-24........................................................................................ 776 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION].................................... 776 E-25........................................................................................ 781 WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]..................................... 781 E-26........................................................................................ 794 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY................................................ 794 40 TROUBLESHOOTING (H-MODE) .................................................................... 797 INFORMATION IN TROUBLESHOOTING TABLE........................................................ 798 H-1......................................................................................... 799 RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE................................................ 799 H-2......................................................................................... 801 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE............................................ 801 H-3......................................................................................... 802 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE............................................ 802 H-4......................................................................................... 803 SPEED OR POWER OF TRAVEL IS LOW......................................................... 803 H-5......................................................................................... 804 GEAR IS NOT SHIFTED..................................................................... 804 H-6......................................................................................... 805 LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl.............................. 805 H-7......................................................................................... 806 MACHINE DEVIATES LARGELY DURING TRAVEL.................................................. 806 H-8......................................................................................... 807 HYDRAULIC DRIFT OF TRAVEL IS LARGE...................................................... 807 H-9......................................................................................... 808 ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl................................... 808 H-10........................................................................................ 809 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR................................. 809 H-11........................................................................................ 810 WORK EQUIPMENT DOSE NOT OPERATE AT ALL.................................................. 810 H-12........................................................................................ 811 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW........................................... 811 H-13........................................................................................ 812 SPEED OR POWER OF LIFTING BLADE IS LOW.................................................. 812 H-14........................................................................................ 813 SPEED OR POWER OF TILTING BLADE IS LOW.................................................. 813 H-15........................................................................................ 814 SPEED OR POWER OF ANGLING BLADE IS LOW.................................................. 814 H-16........................................................................................ 815 TIME LAG IN LIFTING BLADE IS LARGE...................................................... 815 H-17........................................................................................ 816 HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE............................................... 816 H-18........................................................................................ 817 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE............................................... 817 H-19........................................................................................ 818 ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND CONTROL VALVE......................... 818 H-20........................................................................................ 819 HST OIL TEMPERATURE RISES TOO HIGH...................................................... 819 H-21........................................................................................ 820 FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)............................................. 820 40 TROUBLESHOOTING (S-MODE) .................................................................... 821 METHOD OF USING TROUBLESHOOTING CHARTS...................................................... 822 (S-1) ENGINE STARTING PERFORMANCE IS POOR................................................... 826 (S-2) ENGINE DOES NOT CRANK................................................................. 827 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK................................... 828 SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START...................................... 829 (S-3) ENGINE DOES NOT RUN SMOOTHLY.......................................................... 830 (S-4) ENGINE STOPS DURING OPERATIONS........................................................ 831 (S-5) ENGINE SPEED HUNTS.................................................................... 832 (S-6) ENGINE LACKS POWER.................................................................... 833 (S-7) EXHAUST SMOKE IS BLACK................................................................ 835 (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE................................. 836 (S-9) OIL BECOMES CONTAMINATED QUICKLY...................................................... 837 (S-10) FUEL CONSUMPTION IS EXCESSIVE........................................................ 838 (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR................................ 839 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP.................................................. 840 (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)....................................... 841 (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)........................................... 842 (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING....................................... 843 (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING........................................... 844 50 DISASSEMBLY AND ASSEMBLY .................................................................... 845 HOW TO USE THIS MANUAL...................................................................... 848 REMOVAL AND INSTALLATION OF COMPONENTS.................................................. 848 Special Tools....................................................................... 848 OVERHAUL OF COMPONENTS.................................................................. 849 Special Tools....................................................................... 849 Disassembly Procedures.............................................................. 849 Assembly Procedures................................................................. 849 PRECAUTIONS WHEN CARRYING OUT AN OPERATION.................................................. 850 SPECIAL TOOL LIST........................................................................... 852 SKETCH OF SPECIAL TOOLS................................................................. 859 CONNECTOR REPAIR PROCEDURES................................................................. 874 CONTACT TERMINAL REMOVAL (HD30 TYPE).................................................... 874 STRIPPING INSULATION.................................................................... 875 CRIMPING CONTACT TERMINAL (HD30 TYPE)................................................... 876 INSERTION OF CONTACT TERMINAL (HD30 TYPE)............................................... 877 CONTACT TERMINAL REMOVAL (DT TYPE)...................................................... 878 STRIPPING INSULATION.................................................................... 879 CRIMPING CONTACT TERMINAL (DT TYPE)..................................................... 880 INSERTION OF CONTACT TERMINAL (DT TYPE)................................................. 881 NOSE GUARD (HOOD)........................................................................... 883 REMOVAL................................................................................. 883 OPENING FRONT GRILL................................................................. 883 REMOVING SIDE PANELS................................................................ 884 DISCONNECTING HOOD-RELATED COMPONENTS............................................... 884 REMOVAL OF HOOD..................................................................... 885 INSTALLATION............................................................................ 887 MUFFLER AND EXHAUST STACK................................................................... 889 REMOVAL................................................................................. 889 INSTALLATION............................................................................ 890 CAB......................................................................................... 891 REMOVAL................................................................................. 891 FLOOR ACCESS PLATE.................................................................. 894 LIFTING CAB OFF MACHINE............................................................. 897 INSTALLATION............................................................................ 900 MONITOR PANEL AND HST CONTROLLER............................................................ 905 REMOVAL................................................................................. 905 INSTALLATION............................................................................ 907 KOMTRAX CONTROLLER.......................................................................... 908 REMOVAL................................................................................. 908 INSTALLATION............................................................................ 908 SEAT........................................................................................ 909 REMOVAL................................................................................. 909 INSTALLATION............................................................................ 909 AIR CONDITIONER/HEATER...................................................................... 910 DISASSEMBLY OF AIR CONDITIONER.......................................................... 910 REMOVING CONDENSER.................................................................. 911 BLOWER MOTORS AND EVAPORATOR........................................................ 913 ASSEMBLY OF AIR CONDITIONER............................................................. 914 FOOT HEATER................................................................................. 915 REMOVAL................................................................................. 915 INSTALLATION............................................................................ 916 FOOT HEATER OVERHAUL PROCEDURES............................................................. 917 OVERHAUL PROCEDURES..................................................................... 917 ASSEMBLY PROCEDURES..................................................................... 919 ENGINE AND HST PUMP......................................................................... 921 REMOVAL................................................................................. 921 BELLY PANS.......................................................................... 921 DRAINING THE COOLING SYSTEM......................................................... 921 DRAINING THE HYDRAULIC SYSTEM....................................................... 922 DISCONNECTING COMPONENTS............................................................ 923 LIFTING ENGINE AND HST PUMP ASSEMBLY................................................ 929 INSTALLATION............................................................................ 931 INSTALL ENGINE AND HST PUMP ASSEMBLY................................................ 931 REMOVAL FROM ENGINE..................................................................... 933 INSTALLATION TO ENGINE.................................................................. 936 DRIVE DAMPENER.............................................................................. 937 REMOVAL................................................................................. 937 INSTALLATION............................................................................ 938 HST PUMP OVERHAUL PROCEDURES................................................................ 939 DISASSEMBLY PROCEDURES.................................................................. 939 REMOVAL OF ACCESSORIES.............................................................. 939 REMOVAL OF REAR PUMP................................................................ 940 REMOVAL OF END CAP.................................................................. 940 DISASSEMBLY OF CYLINDER BLOCK AND PISTONS........................................... 941 DISASSEMBLY OF ROCKER CAM........................................................... 942 REMOVAL OF FRONT SHAFT.............................................................. 943 DISASSEMBLY OF SHAFT................................................................ 944 DISASSEMBLY OF FRONT COVER.......................................................... 945 DISASSEMBLY FRONT SERVO PISTON...................................................... 946 DISASSEMBLY OF END CAP.............................................................. 947 DISASSEMBLY OF REAR PUMP............................................................ 947 DISASSEMBLY OF REAR SHAFT........................................................... 947 ASSEMBLY PROCEDURES..................................................................... 948 INSTALLATION OF REAR SERVO PISTON................................................... 949 INSTALLATION OF REAR COVER.......................................................... 951 INSTALLATION OF REAR SHAFT.......................................................... 952 ASSEMBLY OF REAR ROCKER CAM......................................................... 953 INSTALLATION OF REAR CYLINDER BLOCK AND PISTON...................................... 954 ASSEMBLY OF END CAP................................................................. 955 ASSEMBLY OF FRONT COVER............................................................. 957 INSTALLATION OF FRONT OIL SEAL...................................................... 957 INSTALLATION OF END CAP............................................................. 957 INSTALLATION OF REAR PUMP........................................................... 958 INSTALLATION OF ACCESSORIES......................................................... 959 WORK EQUIPMENT PUMP OVERHAUL PROCEDURES..................................................... 960 DISASSEMBLY PROCEDURES.................................................................. 960 PUMP................................................................................ 960 (PC VALVE).......................................................................... 961 (LS VALVE).......................................................................... 961 REMOVAL OF END CAP.................................................................. 962 DISASSEMBLY OF CYLINDER BLOCK AND PISTON............................................ 962 DISASSEMBLY OF SHAFT ASSEMBLY....................................................... 963 DISASSEMBLY OF ROCKER CAM........................................................... 965 REMOVAL OF BALLS AND PISTON......................................................... 965 ASSEMBLY PROCEDURES..................................................................... 967 INSTALLATION OF PUMP CASE........................................................... 967 INSTALLATION OF ROCKER CAM.......................................................... 967 ASSEMBLY AND INSTALLATION OF SHAFT.................................................. 968 INSTALLATION OF OIL SEAL............................................................ 969 INSTALLATION OF CYLINDER BLOCK AND PISTON........................................... 970 INSTALLATION OF END CAP............................................................. 971 ASSEMBLY OF SERVO VALVE............................................................. 971 INSTALLATION OF SERVO VALVE ASSEMBLY................................................ 973 REMOVAL................................................................................. 974 INSTALL................................................................................. 975 CHARGE PUMP OVERHAUL PROCEDURES......................................................... 976 TOOLS REQUIRED...................................................................... 976 DISASSEMBLY PROCEDURES.................................................................. 976 INSPECT PARTS FOR WEAR.............................................................. 980 ASSEMBLY PROCEDURES..................................................................... 982 GENERAL NOTES....................................................................... 982 PLACING PUMP BACK INTO SERVICE...................................................... 987 DIESEL ENGINE OVERHAUL PROCEDURES........................................................... 988 DISASSEMBLY OF EXTERNAL COMPONENTS...................................................... 988 PREPARATION WORK.................................................................... 988 STARTING MOTOR...................................................................... 989 ENGINE SLING BRACKET ON REAR SIDE................................................... 989 FAN PULLEY.......................................................................... 989 VIBRATION DAMPER AND CRANKSHAFT PULLEY.............................................. 989 BELT TENSIONER...................................................................... 990 FAN HUB............................................................................. 990 ALTERNATOR.......................................................................... 990 THERMOSTAT.......................................................................... 991 WATER PUMP.......................................................................... 991 TURBOCHARGER AND EXHAUST MANIFOLD................................................... 991 FUEL FILTER ASSEMBLY................................................................ 992 WIRING HARNESS ASSEMBLY............................................................. 992 FUEL PIPING AND COMMON RAIL......................................................... 993 DISASSEMBLY OF ENGINE TOP END........................................................... 994 INTAKE MANIFOLD..................................................................... 994 VALVE COVER HOUSING................................................................. 994 ROCKER ARM ASSEMBLY AND CROSSHEAD................................................... 995 PUSH RODS........................................................................... 995 FUEL INJECTORS...................................................................... 995 CYLINDER HEAD....................................................................... 996 REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP.................................. 998 OIL COOLER.......................................................................... 998 ENGINE CONTROLLER................................................................... 998 FUEL SUPPLY PUMP.................................................................... 999 DISASSEMBLY OF ENGINE LOWER END.........................................................1000 FLYWHEEL............................................................................1000 REAR OIL SEAL.......................................................................1000 FLYWHEEL HOUSING....................................................................1001 OIL PAN.............................................................................1001 FRONT COVER.........................................................................1001 OIL PUMP............................................................................1002 CAMSHAFT............................................................................1002 GEAR HOUSING........................................................................1003 PISTONS AND CONNECTING RODS.........................................................1003 CRANKSHAFT..........................................................................1004 PISTON COOLING NOZZLES..............................................................1006 TAPPETS.............................................................................1006 CYLINDER BLOCK......................................................................1006 ASSEMBLY OF ENGINE LOWER END............................................................1007 PREPARATION WORK....................................................................1007 TAPPETS.............................................................................1007 PISTON COOLING NOZZLE...............................................................1007 CRANKSHAFT..........................................................................1008 MAIN CAP MOUNTING BOLTS.............................................................1009 PISTON AND CONNECTING ROD ASSEMBLY..................................................1010 GEAR HOUSING........................................................................1014 CAMSHAFT............................................................................1015 FLYWHEEL HOUSING....................................................................1016 REAR OIL SEAL.......................................................................1017 FLYWHEEL............................................................................1018 OIL PUMP............................................................................1019 FRONT COVER.........................................................................1020 OIL PAN.............................................................................1021 VIBRATION DAMPER....................................................................1022 INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP.............................1023 FUEL SUPPLY PUMP....................................................................1023 ENGINE CONTROLLER...................................................................1023 OIL COOLER..........................................................................1023 CYLINDER HEAD.......................................................................1025 FUEL INJECTORS......................................................................1027 PUSH RODS...........................................................................1028 ROCKER ARM ASSEMBLY.................................................................1028 ADJUSTING VALVE CLEARANCE...........................................................1028 VALVE COVER HOUSING.................................................................1029 AIR INTAKE MANIFOLD COVER...........................................................1030 ASSEMBLY OF EXTERNAL COMPONENTS.........................................................1032 PREPARATION WORK....................................................................1032 HARNESS ASSEMBLY....................................................................1032 FUEL FILTER ASSEMBLY................................................................1032 EXHAUST MANIFOLD AND TURBOCHARGER...................................................1032 WATER PUMP..........................................................................1033 THERMOSTAT..........................................................................1033 ALTERNATOR..........................................................................1034 FAN HUB.............................................................................1034 BELT TENSIONER......................................................................1035 FAN PULLEY..........................................................................1035 ENGINE SLING BRACKET ON REAR SIDE...................................................1035 STARTER MOTOR.......................................................................1035 REFILLING WITH OIL..................................................................1036 TRACK SYSTEM................................................................................1038 SPREADING THE TRACK.....................................................................1038 (CONVENTIONAL TYPE TRACK SHOE)..........................................................1038 Whole disassembly...................................................................1062 Whole assembly......................................................................1065 1. When recycling for lubricated track..............................................1065 FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)...................1075 Special tools...........................................................................1075 Disassembly.............................................................................1075 Assembly................................................................................1077 FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)...........................1083 Special tools...........................................................................1083 Disassembly.............................................................................1084 Assembly................................................................................1088 TRACK FRAME.................................................................................1091 REMOVAL OF TRACK FRAME..................................................................1091 REMOVING TRACKS.....................................................................1091 TRACK FRAME REMOVAL PREPARATIONS....................................................1094 LIFTING TRACK FRAME FROM MACHINE....................................................1096 FRONT TRACK IDLER...........................................................................1100 REMOVING FRONT IDLER....................................................................1100 PULLING IDLER FROM TRACK FRAME......................................................1101 INSTALLING FRONT IDLER..................................................................1103 TRACK ROLLER................................................................................1104 REMOVAL.................................................................................1104 INSTALLATION............................................................................1104 TRACK ROLLER OVERHAUL PROCEDURES........................................................1105 DISASSEMBLY.........................................................................1105 ASSEMBLY............................................................................1106 CARRIER ROLLER OVERHAUL PROCEDURES......................................................1110 DISASSEMBLY.........................................................................1110 ASSEMBLY............................................................................1111 FINAL DRIVE.................................................................................1112 FINAL DRIVE REMOVAL.....................................................................1112 INSTALLING THE FINAL DRIVE..............................................................1116 FINAL DRIVE OVERHAUL PROCEDURES.............................................................1118 DISASSEMBLY PROCEDURES..................................................................1118 DRAINING OIL........................................................................1118 COVER...............................................................................1119 RING GEAR...........................................................................1119 NO. 1 PLANETARY CARRIER ASSEMBLY....................................................1120 NO. 1 SUN GEAR......................................................................1120 NO. 2 SUN GEAR......................................................................1120 NO. 2 PLANETARY CARRIER ASSEMBLY....................................................1121 HUB ASSEMBLY........................................................................1122 NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY).........................................1123 ASSEMBLY OF FINAL DRIVE.................................................................1124 NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY).........................................1124 ASSEMBLY OF HUB.....................................................................1124 NO. 2 PLANETARY CARRIER ASSEMBLY....................................................1127 NO. 2 SUN GEAR......................................................................1128 NO. 1 SUN GEAR......................................................................1128 NO. 1 PLANETARY CARRIER ASSEMBLY....................................................1128 RING GEAR...........................................................................1129 COVER...............................................................................1130 REFILLING WITH OIL..................................................................1130 TRAVEL MOTOR OVERHAUL PROCEDURES............................................................1132 DISASSEMBLY PROCEDURES..................................................................1132 TRAVEL MOTOR........................................................................1132 REMOVAL OF END COVER................................................................1132 DISASSEMBLY OF END COVER............................................................1133 REMOVAL OF RELIEF VALVE.............................................................1133 DISASSEMBLY OF SHUTTLE VALVE........................................................1134 REMOVAL OF CYLINDER BLOCK...........................................................1134 REMOVAL OF PISTONS..................................................................1134 DISASSEMBLY OF BRAKE AND PISTON.....................................................1135 REMOVAL AND DISASSEMBLY OF DRIVE SHAFT..............................................1135 REMOVAL OF OIL SEAL.................................................................1136 ASSEMBLY PROCEDURES.....................................................................1137 INSTALLATION OF MOTOR CASE..........................................................1137 Install of oil seal.................................................................1137 ASSEMBLY OF DRIVE SHAFT.............................................................1143 ASSEMBLY OF PISTONS.................................................................1144 INSTALLATION OF DRIVE SHAFT ASSEMBLY................................................1144 INSTALLATION OF DISCS AND PLATES....................................................1145 INSTALLATION OF BRAKE PISTON........................................................1145 ASSEMBLY OF END COVER...............................................................1145 ASSEMBLY OF SHUTTLE VALVE...........................................................1146 ASSEMBLY OF MAIN PISTON.............................................................1146 INSTALLATION OF MAIN VALVE..........................................................1147 INSTALLATION OF VALVE PLATE.........................................................1147 NSTALLATION OF END COVER............................................................1148 CHECK OF SHAFT ROTATION TORQUE......................................................1149 FAN MOTOR...................................................................................1150 REMOVAL PROCEDURES......................................................................1150 DISCONNECTING THE GRILL FROM THE FAN................................................1150 DISCONNECTING HYDRAULIC FAN MOTOR...................................................1151 REMOVING THE FAN GUARD..............................................................1152 REMOVING THE FAN MOTOR..............................................................1153 INSTALLATION PROCEDURES.................................................................1154 FAN MOTOR OVERHAUL PROCEDURES...............................................................1156 DISASSEMBLY PROCEDURES..................................................................1156 REMOVAL OF END COVER................................................................1156 DISASSEMBLY OF END COVER............................................................1156 DISASSEMBLY OF PILOT VALVE..........................................................1157 CYLINDER BLOCK, SHAFT AND PISTON....................................................1158 DISASSEMBLY OF CYLINDER BLOCK AND PISTON............................................1158 DISASSEMBLY OF SHAFT................................................................1159 DISASSEMBLY OF MOTOR CASE...........................................................1159 ASSEMBLY PROCEDURES.....................................................................1160 INSTALLATION OF MOTOR CASE..........................................................1160 ASSEMBLY AND INSTALLATION OF SHAFT..................................................1160 ASSEMBLY OF CYLINDER BLOCK AND PISTON...............................................1161 INSTALLATION OF CYLINDER BLOCK AND PISTON...........................................1162 INSTALLATION OF OIL SEAL............................................................1163 ASSEMBLY OF END COVER...............................................................1163 INSTALLATION OF END COVER...........................................................1165 CHECK OF SHAFT ROTATION TORQUE......................................................1166 DB 12 VALVE.................................................................................1168 REMOVAL.................................................................................1168 INSTALLATION............................................................................1171 COOLING PACKAGE.............................................................................1172 REMOVING THE GRILL AND COOLING FAN ASSEMBLY.............................................1172 REMOVING THE GRILL FRAME............................................................1172 REMOVING THE COOLING FAN ASSEMBLY...................................................1179 REMOVING THE COOLING PACKAGE............................................................1183 REMOVING THE FAN SHROUD.............................................................1183 REMOVING THE RADIATOR...............................................................1186 REMOVING THE OIL COOLER.............................................................1188 REMOVING THE AIR CHARGE COOLER......................................................1189 INSTALLING THE COOLING PACKAGE..........................................................1191 INSTALLING THE GRILL AND COOLING FAN ASSEMBLY...........................................1192 FUEL TANK...................................................................................1196 REMOVING THE FUEL TANK..................................................................1196 PREPARATIONS FOR REMOVAL............................................................1196 LIFTING THE FUEL TANK OFF THE MACHINE...............................................1199 INSTALLING THE FUEL TANK................................................................1200 HYDRAULIC TANK..............................................................................1201 REMOVING THE HYDRAULIC TANK.............................................................1201 PREPARATIONS FOR REMOVAL............................................................1201 LIFTING THE HYDRAULIC TANK OFF THE MACHINE..........................................1205 INSTALLING THE HYDRAULIC TANK...........................................................1207 WORK EQUIPMENT..............................................................................1208 REMOVING OR INSTALLING PINS.............................................................1208 FRONT BLADE, TILT AND ANGLE CYLINDERS...................................................1209 REMOVAL.............................................................................1209 ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY..........................................1214 PITCH ROD...........................................................................1214 CENTER BALL.........................................................................1215 INSTALLATION........................................................................1215 “C” FRAME...............................................................................1216 REMOVAL.............................................................................1216 INSTALLATION........................................................................1218 LIFT CYLINDERS..........................................................................1219 REMOVAL.............................................................................1219 INSTALLATION........................................................................1220 CYLINDER OVERHAUL PROCEDURES................................................................1221 DISASSEMBLY PROCEDURES..................................................................1221 PISTON AND ROD......................................................................1221 PISTON AND HEAD ASSEMBLY............................................................1222 DISASSEMBLY OF GLAND NUT............................................................1222 ASSEMBLY PROCEDURES.....................................................................1222 GLAND NUT ASSEMBLY AND PISTON ASSEMBLY..............................................1222 DISASSEMBLY OF PISTON...............................................................1223 PISTON ROD ASSEMBLY.................................................................1224 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY.......................................1040 (PLUS TYPE TRACK SHOE)..................................................................1040 Expansion normal....................................................................1040 Installation........................................................................1040 WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)....1041 Special tools.......................................................................1041 Whole disassembly...................................................................1041 Whole assembly......................................................................1046 WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE).........................1061 Special tools...........................................................................1061 90 OTHERS ......................................................................................1225 CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM................................1227 CONNECTOR LIST..........................................................................1227 CONNECTOR LOCATION VIEW.....................................................................1231 CAB ELECTRICAL ACCESSORIES..................................................................1245 AIR CONDITIONER AND HEATER UNIT.............................................................1247 HYDRAULIC SYSTEM (VIEW 1 OF 2)..............................................................1249 VIEW (2 OF 2)...........................................................................1251 IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5)....................................1253 CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 )...................................1255 ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5).............................................1257 MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)................................................1259 KOMTRAX AND CONNECTORS (VIEW 5 OF 5)....................................................1261
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