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KOMATSU D575A-2 SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD
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- KOMATSU D575A-2 SERVICE REPAIR MANUAL
- SERIAL NUMBER:10001 & UP
- PUBLICATION NUMBER:SEBM000105
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Description
KOMATSU D575A-2 SERVICE REPAIR MANUAL (SN:10001 & UP)
KOMATSU D575A-2 SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D575A-2 SERVICE REPAIR MANUAL (SN:10001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” 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. - MAINTENANCE STANDARD
This section gives the judgement standards when Inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU D575A-2 SERVICE REPAIR MANUAL (SN:10001 & UP)
MAIN MENU............................................................................................................................................. 0 CONTENTS.............................................................................................................................................. 2 01 GENERAL............................................................................................................................................ 21 SPECIFICATIONS.................................................................................................................................... 22 WEIGHT TABLE...................................................................................................................................... 26 FUEL, COOLANT AND LUBRICANTS...................................................................................................................... 28 10 STRUCTURE AND FUNCTION ............................................................................................................................ 30 RADIATOR, OIL COOLER ............................................................................................................................. 31 FUEL PIPING DRAWING .............................................................................................................................. 33 ENGINE CONTROL ................................................................................................................................... 34 ENGINE CONTROL HYDRAULIC BOOSTER ............................................................................................................. 35 POWER TRAIN SYSTEM ............................................................................................................................... 40 POWER TRAIN SKELTON .......................................................................................................................... 41 POWER TRAIN HYDRAULIC PIPING ..................................................................................................................... 42 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ............................................................................................................ 44 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS (Engine running transmission shift lever in “NEUTRAL”, steering levers and brake pedal not operated).... 45 DAMPER ........................................................................................................................................... 46 TORQUE CONVERTER, PTO ............................................................................................................................ 47 TORQUE CONVERTER FILTER, TORQUE CONVERTER RELIEF VALVE .......................................................................................... 51 TRANSMISSION CONTROL ............................................................................................................................. 52 TRANSMISSION ..................................................................................................................................... 53 POWER TRAIN .................................................................................................................................. 56 TRANSMISSION CONTROL VALVE ....................................................................................................................... 59 PILOT REDUCING VALVE ......................................................................................................................... 61 PRIORITY VALVE ............................................................................................................................... 62 MODULATING VALVE ............................................................................................................................. 63 REDUCING VALVE ............................................................................................................................... 66 TRANSMISSION LUBRICATION VALVE .............................................................................................................. 67 SPEED, DIRECTIONAL SELECTOR VALVE ............................................................................................................ 68 STEERING CLUTCH, BRAKE CONTROL ................................................................................................................... 73 STEERING CLUTCH, BRAKE CONTROL CIRCUIT DIAGRAM ................................................................................................... 74 STEERING CLUTCH, BRAKE CONTROL CIRCUIT SCHEMATICS................................................................................................. 75 STEERING CONTROL VALVE ........................................................................................................................... 76 STEERING CLUTCH, STEERING BRAKE .................................................................................................................. 82 FINAL DRIVE ...................................................................................................................................... 86 LUBRICATION PUMP ............................................................................................................................. 89 LUBRICATION VALVE ............................................................................................................................ 90 TRACK FRAME ...................................................................................................................................... 91 RECOIL SPRING..................................................................................................................................... 93 HYDRAULIC ASSIST RETURN VALVE..................................................................................................................... 94 TRACK ROLLER BOGIE ............................................................................................................................... 95 SUSPENSION ....................................................................................................................................... 96 HYDRAULIC PIPING DIAGRAM FOR COOLING FAN DRIVE AND WORK EQUIPMENT ................................................................................ 98 COOLING FAN DRIVE SYSTEM ..................................................................................................................... 98 BLADE SYSTEM.................................................................................................................................. 99 RIPPER SYSTEM.................................................................................................................................100 WORK EQUIPMENT CONTROL, ENGINE CONTROL BOOSTER SYSTEM ........................................................................................101 CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM.............................................................................................102 HYDRAULIC CIRCUIT DIAGRAM FOR COOLING FAN DRIVE AND WORK EQUIPMENT............................................................................103 HYDRAULIC CIRCUIT SCHMATICS FOR COOLING FAN DRIVE AND WORK EQUIPMENT (Engine running, work equipment control lever in ......................104 HYDRAULIC TANK....................................................................................................................................105 ACCUMULATOR (For work equipment circuit) .........................................................................................................106 COOLING FAN DRIVE CIRCUIT SCHEMATICS (Engine running) ............................................................................................107 MAIN RELIEF VALVE FOR COOLING FAN DRIVE ..........................................................................................................108 PPC VALVE ........................................................................................................................................109 FOR BLADE ....................................................................................................................................109 FOR RIPPER....................................................................................................................................111 ACCUMULATOR (For PPC circuit).....................................................................................................................115 PPC RELIEF VALVE .................................................................................................................................116 PPC SHUTTLE VALVE ................................................................................................................................117 MAIN CONTROL VALVE ...............................................................................................................................118 BLADE VALVE ..................................................................................................................................118 RIPPER VALVE .................................................................................................................................120 RIPPER BYPASS VALVE ..............................................................................................................................125 DUAL TILT SOLENOID VALVE .........................................................................................................................126 PISTON VALVE......................................................................................................................................127 QUICK DROP VALVE .................................................................................................................................128 OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT.......................................................................................................129 PIN-PULLER HYDRAULIC CIRCUIT SCHEMATICS (Engine running, Pin-puller switch is at “HOLD”) .........................................................135 PIN-PULLER HYDRAULIC CIRCUIT DIAGRAM .............................................................................................................135 PIN-PULLER SOLENOID VALVE ........................................................................................................................136 PIN-PULLER SWITCH ................................................................................................................................138 PIN-PULLER CYLINDER ..............................................................................................................................139 CYLINDER STAY ....................................................................................................................................140 U-DOZER (K-link type) ............................................................................................................................141 VARIABLE GIANT RIPPER ............................................................................................................................143 ELECTRIC CIRCUIT DIAGRAM..........................................................................................................................145 ELECTRIC CIRCUIT DIAGRAM INSIDE CAB ..........................................................................................................146 EVMS..............................................................................................................................................147 MONITOR PANEL ................................................................................................................................148 SENSOR .......................................................................................................................................150 RADIATOR WATER LEVEL SENSOR ..................................................................................................................150 FUEL LEVEL SENSOR ............................................................................................................................151 HYDRAULIC OIL TEMPERATURE SENSOR .............................................................................................................152 ENGINE OIL PRESSURE SENSOR ...................................................................................................................152 ENGINE WATER TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE SENSOR ...........................................................................153 ENGINE OIL LEVEL SENSOR ......................................................................................................................153 20 TESTING AND ADJUSTING..............................................................................................................................154 STANDARD VALUE TABLE FOR ENGINE...................................................................................................................155 STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................156 STANDARD VALUE TABLE FOR ELECTRIC SYSTEM..........................................................................................................162 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................164 ADJUSTING VALVE CLEARANCE.........................................................................................................................165 MEASURING COMPRESSION PRESSURE....................................................................................................................166 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................................167 ADJUSTING FUEL INJECTION PUMP RACK LINKAGE........................................................................................................169 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.....................................................................................................170 MEASURING EXHAUST TEMPERATURE.....................................................................................................................171 MEASURING BLOWBY..................................................................................................................................172 MEASURING COOLING FAN SPEED.......................................................................................................................173 MEASURING TORQUE CONVERTER STALL SPEED............................................................................................................174 MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (Full stall)....................................................................175 MEASURING, ADJUSTING FAN PUMP RELIEF PRESSURE.....................................................................................................176 MEASURING FAN PUMP DISCHARGE AMOUNT...............................................................................................................177 MEASURING FAN MOTOR DRAIN AMOUNT..................................................................................................................177 MEASURING POWER TRAIN OIL PRESSURE................................................................................................................178 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE...........................................................................................181 PROCEDURE FOR RELEASING STEERING BRAKE............................................................................................................181 TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (Main relief pressure) AND PPC CIRCUIT PRESSURE.............................................182 WORK EQUIPMENT CIRCUIT............................................................................................................................183 PPC CIRCUIT.......................................................................................................................................184 MEASURING PPC VALVE OUTPUT PRESSURE...............................................................................................................185 ADJUSTING WORK EQUIPMENT, PPC VALVE...............................................................................................................186 RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON MACHINES EQUIPPED WITH PPC VALVE..................................................................187 BLEEDING AIR FROM HYDRAULIC CYLINDER..............................................................................................................187 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER.................................................................................188 MEASURING PIN-PULLER SOLENOID VALVE OUTPUT PRESSURE...............................................................................................189 ADJUSTING FUEL CONTROL LINKAGE....................................................................................................................190 ADJUSTMENT OF GEARSHIFT LEVER LINKAGE.............................................................................................................192 ADJUSTMENT OF STEERING LEVER LINKAGE..............................................................................................................194 ADJUSTMENT OF BRAKE PEDAL LINKAGE.................................................................................................................196 PROCEDURE FOR TESTING SENSORS.....................................................................................................................198 TROUBLESHOOTING...................................................................................................................................200 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................201 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................................202 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....................................................................................................203 HANDLING CONNECTORS...........................................................................................................................210 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................211 METHOD OF MATRIX TROUBLESHOOTING CHART........................................................................................................212 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................216 TYPE OF CONNECTOR AND POSITION OF INSTALLATION................................................................................................218 LOCATION OF CONNECTOR, SENSOR.................................................................................................................220 CONNECTION TABLE FOR CONNECTOR................................................................................................................221 ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM...................................................................................................226 STARTING CIRCUIT..........................................................................................................................226 RIPPER PIN-PULLER, DUAL TILT SOLENOID SYSTEM..............................................................................................227 MONITOR SYSTEM............................................................................................................................228 TROUBLESHOOTING OF ENGINE SYSTEM..............................................................................................................229 S-1 Starting performance is poor..........................................................................................................230 S-2 Engine does not start.................................................................................................................231 (1) Engine does not turn..............................................................................................................231 (2) Engine turns but no exhaust smoke comes out.......................................................................................232 (3) Exhaust smoke comes out but engine does not start.................................................................................233 S-3 Engine does not pick up smoothly......................................................................................................234 S-4 Engine stops during operations........................................................................................................235 S-5 Engine does not rotate smoothly.......................................................................................................236 S-6 Engine lacks output (No power)........................................................................................................237 S-7 Exhaust smoke is black................................................................................................................238 S-8 Oil consumption is excessive..........................................................................................................239 S-9 Oil becomes contaminated quickly......................................................................................................240 S-10 Fuel consumption is excessive........................................................................................................241 S-11 Oil is in cooling water, or water spurts back, or water level goes down..............................................................242 S-12 Oil pressure lamp lights up..........................................................................................................243 S-13 Oil level rises......................................................................................................................244 S-14 Water temperature becomes too high...................................................................................................245 S-15 Abnormal noise is made...............................................................................................................246 S-16 Vibration is excessive...............................................................................................................247 TROUBLESHOOTING OF ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM.....................................................................................248 TABLE OF FAILURE MODES AND CAUSES.........................................................................................................249 TROUBLESHOOTING OF ELECTRICAL SYSTEM......................................................................................................250 E-1 Engine doesn’t start..............................................................................................................251 E-2 Dual tilt cannot be used (Pitch can be used)......................................................................................254 E-3 Pitch dozer cannot be used (Dual tilt can be used)................................................................................255 E-4 Neither dual tilt nor pitch dozer can be used.....................................................................................256 E-5 Pin-puller cylinder does not work.................................................................................................257 a) Pin cannot be removed..........................................................................................................257 b) Pin cannot be inserted.........................................................................................................258 E-6 Head lamps do not light up........................................................................................................259 a) Left head lamp does not light up...............................................................................................259 b) Right head lamp does not light up..............................................................................................259 E-7 Rear lamps do not light up........................................................................................................260 E-8 Working lamp does not light up....................................................................................................261 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM...........................................................................................263 H-1 Brakes do not work................................................................................................................264 H-2 Machine does not turn.............................................................................................................265 H-3 There is travel deviation.........................................................................................................266 H-4 Machine turns only in one direction (Lever operated)..............................................................................267 H-5 Time lag is excessive.............................................................................................................268 H-6 Machine travels only in one direction (Forward or in reverse).....................................................................270 H-7 Machine does not move (2nd, 3rd)..................................................................................................271 H-8 Machine does not move in any speed range..........................................................................................273 H-9 Torque converter overheats........................................................................................................275 H-10 Abnormal noise from around hydraulic pump........................................................................................277 H-11 Blade RAISE speed slow or work equipment lacks power.............................................................................278 H-12 Ripper lift speed slow, or lacks power...........................................................................................279 H-13 Excessive hydraulic drift of blade...............................................................................................280 H-14 Excessive hydraulic drift of ripper..............................................................................................280 H-15 Pin-puller cylinder does not work................................................................................................281 H-16 Fan speed is slow (Coolant or torque converter overheats)........................................................................281 TROUBLESHOOTING MACHINE MONITOR SYSTEM........................................................................................................282 M-1 No display appears on the monitor panel when the starting switch is ON................................................................283 M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out..................................................283 M-3 When starting switch is ON (Engine stopped), CHECK items show abnormality ............................................................284 a) Abnormality in radiator water level................................................................................................284 b) Abnormality in engine oil level....................................................................................................285 M-4 When starting switch is ON and engine is started, CAUTION items flash.................................................................286 a) Charge level flashes...............................................................................................................286 b) Engine oil pressure flashes........................................................................................................286 c) Coolant level flashes..............................................................................................................286 d) Coolant temperature flashes........................................................................................................286 e) Torque converter oil temperature flashes...........................................................................................287 f) Hydraulic oil temperature flashes..................................................................................................287 M-5 Abnormality in buzzer.................................................................................................................290 a) CAUTION items are flashing, but buzzer does not sound..............................................................................290 b) No abnormal display is given on monitor, but buzzer sound..........................................................................290 M-6 Abnormality in gauge..................................................................................................................291 a) Abnormality in coolant temperature gauge...........................................................................................291 b) Abnormality in torque converter oil temperature gauge..............................................................................292 c) Abnormality in fuel level gauge....................................................................................................293 M-7 Service meter does not move after engine is started...................................................................................294 M-8 Panel lighting for monitor panel does not light up (Liquid crystal display is normal).................................................295 30 DISASSEMBLY AND ASSEMBLY ..........................................................................................................................296 METHOD OF USING MANUAL ...........................................................................................................................299 PRECAUTIONS WHEN CARRYING OUT OPERATION ..........................................................................................................301 SPECIAL TOOL LIST.................................................................................................................................303 STARTING MOTOR....................................................................................................................................311 REMOVAL.......................................................................................................................................311 INSTALLATION..................................................................................................................................311 ALTERNATOR........................................................................................................................................312 REMOVAL.......................................................................................................................................312 INSTALLATION..................................................................................................................................312 ENGINE OIL COOLER.................................................................................................................................313 REMOVAL ......................................................................................................................................313 INSTALLATION..................................................................................................................................314 POWER TRAIN OIL COOLER............................................................................................................................315 REMOVAL.......................................................................................................................................315 INSTALLATION..................................................................................................................................317 HYDRAULIC COOLER..................................................................................................................................318 REMOVAL.......................................................................................................................................318 INSTALLATION..................................................................................................................................318 FUEL INJECTION PUMP (Left and right)..............................................................................................................319 REMOVAL.......................................................................................................................................319 INSTALLATION..................................................................................................................................322 WATER PUMP........................................................................................................................................323 REMOVAL.......................................................................................................................................323 INSTALLATION..................................................................................................................................323 TURBOCHARGER......................................................................................................................................324 REMOVAL.......................................................................................................................................324 INSTALLATION..................................................................................................................................324 AFTER-COOLER CORE.................................................................................................................................326 REMOVAL.......................................................................................................................................326 INSTALLATION..................................................................................................................................326 NOZZLE HOLDER.....................................................................................................................................327 REMOVAL.......................................................................................................................................327 INSTALLATION..................................................................................................................................327 CYLINDER HEAD.....................................................................................................................................328 REMOVAL.......................................................................................................................................328 INSTALLATION..................................................................................................................................332 RADIATOR..........................................................................................................................................334 REMOVAL ......................................................................................................................................334 INSTALLATION..................................................................................................................................335 FAN MOTOR.........................................................................................................................................336 REMOVAL.......................................................................................................................................336 INSTALLATION..................................................................................................................................338 ENGINE............................................................................................................................................339 REMOVAL ......................................................................................................................................339 INSTALLATION..................................................................................................................................344 DAMPER............................................................................................................................................345 REMOVAL.......................................................................................................................................345 INSTALLATION..................................................................................................................................346 DISASSEMBLY...................................................................................................................................347 ASSEMBLY......................................................................................................................................348 POWER TRAIN.......................................................................................................................................350 REMOVAL.......................................................................................................................................350 INSTALLATION..................................................................................................................................354 PTO, TORQUE CONVERTER.............................................................................................................................356 REMOVAL ......................................................................................................................................356 INSTALLATION..................................................................................................................................359 DISCONNECTION.................................................................................................................................360 CONNECTION....................................................................................................................................361 PTO...............................................................................................................................................362 DISASSEMBLY...................................................................................................................................362 ASSEMBLY......................................................................................................................................367 TORQUE CONVERTER..................................................................................................................................373 DISASSEMBLY...................................................................................................................................373 ASSEMBLY......................................................................................................................................377 TORQFLOW TRANSMISSION.............................................................................................................................381 REMOVAL.......................................................................................................................................381 INSTALLATION..................................................................................................................................382 DISASSEMBLY...................................................................................................................................383 ASSEMBLY......................................................................................................................................395 STEERING, LUBRICATION PUMP........................................................................................................................409 REMOVAL.......................................................................................................................................409 INSTALLATION..................................................................................................................................409 STEERING CASE.....................................................................................................................................410 REMOVAL.......................................................................................................................................410 INSTALLATION..................................................................................................................................411 DISASSEMBLY...................................................................................................................................412 ASSEMBLY......................................................................................................................................418 STEERING CLUTCH...................................................................................................................................427 DISASSEMBLY...................................................................................................................................427 ASSEMBLY......................................................................................................................................429 STEERING BRAKE....................................................................................................................................433 DISASSEMBLY...................................................................................................................................430 ASSEMBLY......................................................................................................................................433 TRANSMISSION CONTROL VALVE........................................................................................................................438 REMOVAL.......................................................................................................................................438 INSTALLATION..................................................................................................................................438 DISASSEMBLY...................................................................................................................................439 ASSEMBLY .....................................................................................................................................439 STEERING CONTROL VALVE............................................................................................................................444 REMOVAL.......................................................................................................................................444 INSTALLATION..................................................................................................................................444 DISASSEMBLY...................................................................................................................................445 ASSEMBLY......................................................................................................................................445 POWER TRAIN.......................................................................................................................................447 REMOVAL.......................................................................................................................................447 INSTALLATION..................................................................................................................................447 TRANSMISSION LUBRICATION PUMP.....................................................................................................................448 REMOVAL.......................................................................................................................................448 INSTALLATION..................................................................................................................................448 SCAVENGING PUMP...................................................................................................................................449 REMOVAL.......................................................................................................................................449 INSTALLATION..................................................................................................................................449 FINAL DRIVE.......................................................................................................................................450 REMOVAL.......................................................................................................................................450 INSTALLATION..................................................................................................................................450 DISASSEMBLY...................................................................................................................................451 ASSEMBLY......................................................................................................................................461 TRACK FRAME.......................................................................................................................................474 REMOVAL.......................................................................................................................................474 INSTALLATION..................................................................................................................................476 HYDRAULIC ASSIST, RECOIL SPRING...................................................................................................................477 REMOVAL ......................................................................................................................................477 INSTALLATION..................................................................................................................................478 DISASSEMBLY...................................................................................................................................479 ASSEMBLY......................................................................................................................................485 IDLER.............................................................................................................................................492 REMOVAL.......................................................................................................................................490 INSTALLATION..................................................................................................................................491 DISASSEMBLY...................................................................................................................................492 ASSEMBLY......................................................................................................................................494 TRACK ROLLER......................................................................................................................................496 REMOVAL.......................................................................................................................................496 INSTALLATION..................................................................................................................................498 DISASSEMBLY...................................................................................................................................499 ASSEMBLY......................................................................................................................................501 BOGIE.............................................................................................................................................503 REMOVAL.......................................................................................................................................503 INSTALLATION..................................................................................................................................503 DISASSEMBLY...................................................................................................................................504 ASSEMBLY......................................................................................................................................507 CARRIER ROLLER....................................................................................................................................510 REMOVAL.......................................................................................................................................510 INSTALLATION..................................................................................................................................510 DISASSEMBLY...................................................................................................................................511 ASSEMBLY......................................................................................................................................513 TRACK SHOE........................................................................................................................................516 CHECKING......................................................................................................................................516 REMOVAL.......................................................................................................................................516 INSTALLATION..................................................................................................................................520 OVERALL DISASSEMBLY...........................................................................................................................521 OVERALL ASSEMBLY..............................................................................................................................526 PRESS FITTING JIG DIMENSION TABLE FOR LINK PRESS..............................................................................................540 FIELD DISASSEMBLY OF ONE LINK ................................................................................................................541 FIELD ASSEMBLY OF ONE LINK ...................................................................................................................543 DISASSEMBLY OF MASTER LINK ...................................................................................................................545 ASSEMBLY OF MASTER LINK ......................................................................................................................547 PIVOT SHAFT.......................................................................................................................................551 REMOVAL.......................................................................................................................................551 INSTALLATION..................................................................................................................................552 EQUALIZER BAR.....................................................................................................................................553 REMOVAL.......................................................................................................................................553 INSTALLATION..................................................................................................................................555 HYDRAULIC, PPC PUMP...............................................................................................................................558 REMOVAL.......................................................................................................................................558 INSTALLATION..................................................................................................................................558 FAN, HYDRAULIC PUMP...............................................................................................................................559 REMOVAL.......................................................................................................................................559 INSTALLATION..................................................................................................................................559 BLADE VALVE.......................................................................................................................................560 REMOVAL.......................................................................................................................................560 INSTALLATION..................................................................................................................................560 DISASSEMBLY...................................................................................................................................562 ASSEMBLY......................................................................................................................................562 RIPPER VALVE......................................................................................................................................564 REMOVAL.......................................................................................................................................564 INSTALLATION..................................................................................................................................564 DISASSEMBLY...................................................................................................................................565 ASSEMBLY......................................................................................................................................565 MAIN RELIEF VALVE.................................................................................................................................567 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ....................................................................................................567 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ......................................................................................................567 BLADE LIFT CYLINDER...............................................................................................................................568 REMOVAL.......................................................................................................................................568 INSTALLATION..................................................................................................................................568 BLADE TILT CYLINDER...............................................................................................................................569 REMOVAL.......................................................................................................................................569 INSTALLATION..................................................................................................................................569 RIPPER LIFT CYLINDER..............................................................................................................................570 REMOVAL.......................................................................................................................................570 INSTALLATION..................................................................................................................................570 RIPPER TILT CYLINDER..............................................................................................................................571 REMOVAL.......................................................................................................................................571 INSTALLATION..................................................................................................................................571 HYDRAULIC CYLINDER................................................................................................................................572 DISASSEMBLY...................................................................................................................................572 ASSEMBLY......................................................................................................................................575 PIN-PULLER CYLINDER...............................................................................................................................578 REMOVAL.......................................................................................................................................578 INSTALLATION..................................................................................................................................578 DISASSEMBLY...................................................................................................................................579 ASSEMBLY......................................................................................................................................580 BLADE PPC VALVE...................................................................................................................................582 REMOVAL.......................................................................................................................................582 INSTALLATION..................................................................................................................................582 DISASSEMBLY...................................................................................................................................583 ASSEMBLY......................................................................................................................................583 RIPPER PPC VALVE..................................................................................................................................585 REMOVAL.......................................................................................................................................585 INSTALLATION..................................................................................................................................585 DISASSEMBLY...................................................................................................................................586 ASSEMBLY......................................................................................................................................586 BLADE (K-link type)...............................................................................................................................587 REMOVAL.......................................................................................................................................587 INSTALLATION..................................................................................................................................588 DISASSEMBLY...................................................................................................................................589 ASSEMBLY......................................................................................................................................591 VARIABLE GIANT RIPPER.............................................................................................................................594 DISASSEMBLY...................................................................................................................................594 ASSEMBLY......................................................................................................................................597 OPERATOR’S SEAT FRAME.............................................................................................................................600 REMOVAL.......................................................................................................................................600 INSTALLATION..................................................................................................................................602 CAB...............................................................................................................................................603 REMOVAL.......................................................................................................................................603 INSTALLATION..................................................................................................................................604 ROPS..............................................................................................................................................605 REMOVAL.......................................................................................................................................605 INSTALLATION..................................................................................................................................605 40 MAINTENANCE STANDARD ..............................................................................................................................606 ENGINE MOUNT .....................................................................................................................................607 DAMPER ...........................................................................................................................................608 TORQUE CONVERTER, PTO.............................................................................................................................609 TRANSMISSION .....................................................................................................................................611 TRANSMISSION CONTROL VALVE .......................................................................................................................613 SPEED, DIRECTIONAL SELECTOR VALVE ................................................................................................................615 STEERING CONTROL VALVE ...........................................................................................................................616 STEERING CLUTCH, STEERING BRAKE ..................................................................................................................618 FINAL DRIVE ......................................................................................................................................621 TRACK FRAME ......................................................................................................................................623 RECOIL SPRING ....................................................................................................................................625 HYDRAULIC ASSIST RETURN VALVE ....................................................................................................................626 IDLER ............................................................................................................................................627 TRACK ROLLER BOGIE ...............................................................................................................................628 TRACK ROLLER .....................................................................................................................................629 TRACK SHOE (Lubricated track link) ...............................................................................................................631 SUSPENSION .......................................................................................................................................633 HYDRAULIC PUMP ...................................................................................................................................634 SAL(4)-140+125...............................................................................................................................634 SAR(4)-250....................................................................................................................................635 SAL(4)-200+160................................................................................................................................636 SAR(4)-125+125+(1)-32.........................................................................................................................637 WORK EQUIPMENT CYLINDER ..........................................................................................................................639 PIN PULLER CYLINDER ..............................................................................................................................642 CYLINDER STAY ....................................................................................................................................643 U-DOZER (K-link type) ............................................................................................................................645 CUTTING EDGES AND END BITS........................................................................................................................647 VARIABLE GIANT RIPPER ............................................................................................................................648
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
