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Komatsu D575A-3 Super Dozer 10101 and up Crawler Bulldozer Shop Manual – PDF DOWNLOAD
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Komatsu D575A-3 Super Dozer Crawler Bulldozer Shop Manual
Book Code: SEBM022003
MACHINE MODEL SERIAL NUMBER
D575A-3 SUPER DOZER 10101 and up
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Description
Komatsu D575A-3 Super Dozer Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D575A-3 Super Dozer Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D575A-3 Super Dozer
Serial Number: 10101 and up
Book Code: SEBM022003
Language: English
Pages: 866
File Format: Portable Document Format (PDF)
KOMATSU D575A-3 SUPER DOZER 10101 AND UP CRAWLER BULLDOZER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu D575A-3 Super Dozer Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D575A-3 Super Dozer Crawler Bulldozer Shop Manual
COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 2 SAFETY........................................................................................................................................... 7 SAFETY NOTICE................................................................................................................................ 7 FOREWORD......................................................................................................................................... 9 GENERAL...................................................................................................................................... 9 HOW TO READ THE SHOP MANUAL.................................................................................................................. 10 HOISTING INSTRUCTIONS........................................................................................................................ 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULLTYPE COUPLER.................................................................................... 12 COATING MATERIALS............................................................................................................................ 14 STANDARD TIGHTENING TORQUE................................................................................................................... 16 ELECTRIC WIRE CODE........................................................................................................................... 19 CONVERSION TABLE............................................................................................................................. 20 UNITS........................................................................................................................................ 26 01 GENERAL....................................................................................................................................... 27 SPECIFICATION DRAWING........................................................................................................................ 28 SPECIFICATIONS............................................................................................................................... 30 WEIGHT TABLE................................................................................................................................. 34 TABLE OF FUEL, COOLANT AND LUBRICANTS........................................................................................................ 36 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD.................................................................................................. 39 RADIATOR, OIL COOLER......................................................................................................................... 40 ENGINE CONTROL............................................................................................................................... 42 POWER TRAIN SYSTEM........................................................................................................................... 43 POWER TRAIN SKELTON.......................................................................................................................... 44 POWER TRAIN HYDRAULIC PIPING................................................................................................................. 45 DAMPER....................................................................................................................................... 47 TORQUE CONVERTER, PTO........................................................................................................................ 49 TORQUE CONVERTER VALVE....................................................................................................................... 56 TORQUE CONVERTER LOCK-UP CONTROL SYSTEM...................................................................................................... 66 TORQUE CONVERTER FILTER...................................................................................................................... 69 TRANSMISSION CONTROL......................................................................................................................... 70 TRANSMISSION................................................................................................................................. 71 TRANSMISSION CONTROL VALVE................................................................................................................... 80 LUBRICATION RELIEF VALVE..................................................................................................................... 90 STEERING CLUTCH, BRAKE CONTROL............................................................................................................... 92 STEERING CONTROL VALVE....................................................................................................................... 93 STEERING CLUTCH, STEERING BRAKE.............................................................................................................. 99 FINAL DRIVE..................................................................................................................................108 TRACK FRAME..................................................................................................................................116 IDLER........................................................................................................................................120 CARRIER ROLLER...............................................................................................................................122 TRACK ROLLER.................................................................................................................................124 TRACK SHOE...................................................................................................................................126 RECOIL SPRING................................................................................................................................130 TRACK ROLLER BOGIE...........................................................................................................................132 SUSPENSION...................................................................................................................................134 HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT..................................................................................................138 CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM............................................................................................141 HYDRAULIC TANK...............................................................................................................................142 PITCH, TILT SELECTOR SOLENOID VALVE ASSEMBLY.................................................................................................143 PPC VALVE....................................................................................................................................146 SAFETY LOCK VALVE, PPC ACCUMULATOR...........................................................................................................150 PPC RELIEF VALVE.............................................................................................................................151 MAIN CONTROL VALVE...........................................................................................................................152 PITCH SELECTOR SOLENOID VALVE................................................................................................................158 PITCH PRIORITY SOLENOID VALVE................................................................................................................159 PITCH ASSIST SOLENOID VALVE..................................................................................................................160 BLADE CONTROL KNOB...........................................................................................................................161 PISTON VALVE.................................................................................................................................162 QUICK DROP VALVE.............................................................................................................................163 WORK EQUIPMENT CYLINDER......................................................................................................................164 CYLINDER STAY, YOKE..........................................................................................................................166 WORK EQUIPMENT...............................................................................................................................168 COUNTERWEIGHT................................................................................................................................172 AIR CONDITIONER..............................................................................................................................174 ENGINE CONTROL SYSTEM........................................................................................................................176 ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER.............................................................................183 MONITOR SYSTEM...............................................................................................................................186 SENSOR.......................................................................................................................................192 MODE SELECTION SYSTEM........................................................................................................................197 BLADE CONTROL SYSTEM.........................................................................................................................200 ACTUAL ELECTRICAL WIRING DIAGRAM.............................................................................................................204 20 TESTING AND ADJUSTING.........................................................................................................................208 STANDARD VALUE TABLE FOR ENGINE..............................................................................................................209 STANDARD VALUE TABLE FOR CHASSIS.............................................................................................................210 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS............................................................................................216 TESTING AND ADJUSTING........................................................................................................................222 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.........................................................................................223 MEASURING ENGINE SPEED...................................................................................................................225 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...........................................................................................226 MEASURING EXHAUST TEMPERATURE............................................................................................................227 MEASURING EXHAUST COLOR..................................................................................................................228 ADJUSTING VALVE CLEARENCE................................................................................................................229 MEASURING COMPRESSION PRESSURE...........................................................................................................230 MEASURING BLOW-BY-PRESSURE...............................................................................................................231 MEASURING ENGINE OIL PRESSURE............................................................................................................232 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................232 TESTING AND ADJUSTING FAN BELT TENSION...................................................................................................235 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................235 TESTING AND ADJUSTING BELT TENTENSION FOR AIR CONDITIONER COMPRESSOR.....................................................................236 ADJUSTING ENGINE SPEED SENSOR............................................................................................................236 MEASURING COOLING FAN SPEED..............................................................................................................237 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL .......................................................................................238 MEASURING TORQUE CONVERTER STALL SPEED...................................................................................................239 MEASURING TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL ) SPEED.............................................................240 MEASURING POWER TRAIN OIL PRESSURE.......................................................................................................241 PROCEDURE FOR RELEASING STEERING BRAKE...................................................................................................245 SIMPLE PROCEURE FOR TESTING BRAKE PERFORMANCE............................................................................................245 ADJUSTING BRAKE PEDAL LINKAGE............................................................................................................246 ADJUSTING CLEARENCE OF IDLER.............................................................................................................247 TESTING AND ADJUSTING TRACK SHOE TENSION.................................................................................................248 TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (MAIN RELIEF AND PPC CIRCUIT)......................................................248 MEASURING PPC VALVE OUTPUT PRESSURE......................................................................................................250 ADJUSTING PPC VALVE......................................................................................................................251 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE...................................................................................251 MEASURING LEAKAGE INSIDE CYLINDER........................................................................................................252 RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON PPC VALUE ...............................................................................253 BLEEDING AIR FROM HYDRAULIC CYLINDER.....................................................................................................253 ADJUSTING WORK EQUIPMENT SAFETY LEVER....................................................................................................253 PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE...........................................................................................254 TROUBLESHOOTING..............................................................................................................................256 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................257 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................258 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................................................................................259 CHECKS BEFORE TROUBLESHOOTING............................................................................................................268 CONNECTOR ARRANGEMENT DIAGRAM............................................................................................................269 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................................................................275 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE..................................................................................................311 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.......................................................................314 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....................................................................................320 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................362 TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)...............................................................................................364 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................365 ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM..........................................................................................367 SERVICE CODES OF NETWORK SYSTEM......................................................................................................368 N-1 (E0101) ABNORMALITY IN NETWORK SYSTEM (ENGINE CONTROLLER SYSTEM) IS DISPLAYED....................................................369 N-2 (E0104) ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL SYSTEM) IS DISPLAYED........................................................370 N-3 (E0105) ABNORMALITY IN NETWORK SYSTEM (STEERING CONTROLLER SYSTEM) IS DISPLAYED..................................................371 N-4 (E0101), (E0104), AND (E0105) ARE DISPLAYED AT SAME TIME (ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED)............................372 N-5 (E0152) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED...............................................................................373 N-6 (E0164) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED...............................................................................373 N-7 (E0436) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED...............................................................................374 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE).....................................................................................375 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................376 E-1 (E0401) ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED.......................................................384 E-2 (E0402) ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED............................................................................384 E-3 (E0403) MISTAKEN CONNECTION IN ENGINE CONTROLLER IS DISPLAYED....................................................................385 E-4 (E0405) ABNORMALITY IN FUEL CONTROL DIAL SYSTEM IS DISPLAYED.....................................................................386 E-5 (E0406) ABNORMALITY IN DECELERATION POTENTIOMETER IS DISPLAYED...................................................................388 E-6 (E0407) ABNORMALITY IN SHOE SLIP CONTROL COMMAND VALUE IS DISPLAYED..............................................................390 E-7 (E0409) ABNORMALITY IN ENGINE SPEED SENSOR "A" SYSTEM IS DISPLAYED...............................................................391 E-8 (E0410) ABNORMALITY IN ENGINE SPEED SENSOR "B" SYSTEM IS DISPLAYED...............................................................392 E-9 (E0411) ABNORMALITY IN RIGHT RACK SENSOR SYSTEM IS DISPLAYED.....................................................................393 E-10 (E0412) ABNORMALITY IN LEFT RACK SENSOR SYSTEM IS DISPLAYED.....................................................................394 E-11 (E0413) ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED.............................................................395 E-12 (E0421) SHORT CIRCUIT IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED............................................................396 E-13 (E0422) DISCONNECTION IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED............................................................397 E-14 (E0423) SHORT CIRCUIT IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED.............................................................398 E-15 (E0424) DISCONNECTION IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED.............................................................399 E-16 (E0425) SHORT CIRCUIT IN RIGHT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED...........................................................400 E-17 (E0426) DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED............................................................401 E-18 (E0427) SHORT CIRCUIT IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED............................................................402 E-19 (E0428) DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED............................................................403 E-20 (E0433) SHORT CIRCUIT IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED...........................................................404 E-21 (E0434) DISCONNECTION IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED...........................................................405 E-22 (E0435) ABNORMALITY IN ENGINE WATER TEMPERATURE SENSOR SYSTEM IS DISPLAYED......................................................406 E-23 (E0437) ABNORMALITY IN RIGHT GOVERNOR SERVO IS DISPLAYED........................................................................407 E-24 (E0438) ABNORMALITY IN LEFT GOVERNOR SERVO IS DISPLAYED.........................................................................407 E-25 (E0440) DISCONNECTION SOLENOID POWER SOURCE "1" SYSTEM IS DISPLAYED.............................................................408 E-26 (E0441) DISCONNECTION IN POWER SUPPLY SYSTEM "2" OF SOLENOID IS DISPLAYED.......................................................408 E-27 (E0442) ABNORMALITY IN ENGINE CONTROLLER BACKUP POWER SOURCE SYSTEM IS DISPLAYED................................................409 E-28 (E0443) ABNORMALITY IN ENGINE CONTROLLER SWITCH POWER SOURCE SYSTEM IS DISPLAYED................................................410 E-29 (E0455) ENGINE OVERHEATING IS DISPLAYED.........................................................................................411 E-30 (E0456) SHORT CIRCUIT IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED..........................................................412 E-31 (E0457) DISCONNECTION IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED..........................................................413 E-32 ENGINE DOES NOT REVOLVE WHEN STARTING SWITCH IS TURNED TO "ON" POSITION.........................................................414 E-33 ENGINE DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO "OFF" POSITION...........................................................417 TROUBLESHOOTING OF STEERING CONTROLLER SYSTEM (ST MODE)..................................................................................418 SERVICE CODE AND ABNORMAL SYSTEM.....................................................................................................419 ST-1 (E0111) ABNORMALITY IN STEERING CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED....................................................423 ST-2 (E0143) ABNORMALITY IN STEERING CONTROLLER 5V POWER SOURCE IS DISPLAYED.........................................................424 ST-3 (E0145) ABNORMALITY IN STEERING CONTROLLER SENSOR POWER SOURCE IS DISPLAYED.....................................................425 ST-4 (E0151) ABNORMALITY IN SPECIFICATION SELECTION IS DISPLAYED.....................................................................426 ST-5 (E0161) ABNORMALITY IN STEERING CONTROLLER E2PROM IS DISPLAYED..................................................................427 ST-6 (E0660) DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM..........................................................................428 ST-7 (E0661) SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM..........................................................................428 ST-8 (E0721) ABNORMALITY IN PITCH ANGLE SENSOR SYSTEM IS DISPLAYED...................................................................429 ST-9 (E0730, E0731, E0732) ABNORMALITY IN TRAVEL LOWER SWING SYSTEM..................................................................430 ST-10 (E0733) ABNORMALITY IN SWING POTENTIOMETER "1" SYSTEM IS DISPLAYED.............................................................430 ST-11 (E0734) ABNORMALITY IN SWING POTENTIOMETER "2" SYSTEM IS DISPLAYED.............................................................432 ST-12 (E0735) LAG OF SWING SIGNAL....................................................................................................433 ST-13 (E0736) ABNORMALITY IN BRAKE POTENTIOMETER SYSTEM IS DISPLAYED.................................................................434 ST-14 (E0750) DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM.....................................................................436 ST-15 (E0751) SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM.....................................................................437 ST-16 (E0752) DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM......................................................................438 ST-17 (E0753) SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM......................................................................439 ST-18 (E0754) DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM......................................................................440 ST-19 (E0755) SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM......................................................................441 ST-20 (E0756) DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM.......................................................................442 ST-21 (E0757) SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM.......................................................................443 ST-22 (E0760) ABNORMALITY IN RIGHT STEERING CLUTCH OIL PRESSURE SYSTEM...............................................................444 ST-23 (E0761) SHORT CIRCUIT IN RIGHT STEERING CLUTCH OIL PRESSURE SYSTEM.............................................................444 ST-24 (E0762) ABNORMALITY IN LEFT STEERING CLUTCH OIL PRESSURE SYSTEM................................................................445 ST-25 (E0763) SHORT CIRCUIT IN LEFT STEERING CLUTCH OIL PRESSURE SYSTEM..............................................................445 ST-26 (E0764) ABNORMALITY IN RIGHT STEERING BRAKE OIL PRESSURE SYSTEM................................................................446 ST-27 (E0765) SHORT CIRCUIT IN RIGHT STEERING BRAKE OIL PRESSURE SYSTEM..............................................................446 ST-28 (E0766) ABNORMALITY IN LEFT STEERING BRAKE OIL PRESSURE SYSTEM.................................................................447 ST-29 (E0767) SHORT CIRCUIT IN LEFT STEERING BRAKE OIL PRESSURE SYSTEM...............................................................447 ST-30 (E0779) DISCONNECTION IN EMERGENCY STOP PREVENTION SOLENOID SYSTEM.............................................................448 ST-31 (E0780) SHORT CIRCUIT IN EMERGENCY STOP PREVENTION SOLENOID SYSTEM.............................................................449 ST-32 (E0781) ABNORMALITY IN TRAVEL LOCK SWITCH SYSTEM...............................................................................450 A. WHEN ONLY E0781 IS DISPLAYED..................................................................................................450 B. WHEN BOTH E0781 AND E0238 ARE DISPLAYED.......................................................................................452 ST-33 (E0782) DISAGREEMENT IN TRAVEL LOCK............................................................................................454 ST-34 (E0930) ABNORMALITY IN ENGINE SPEED SENSOR "B" SYSTEM IS DISPLAYED.............................................................454 ST-35 (E0933) ABNORMALITY IN BEVEL SPEED SENSOR "A" SYSTEM IS DISPLAYED..............................................................455 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)...............................................................................456 SERVICE CODE AND ABNORMAL SYSTEM.....................................................................................................458 T-1 (E0112) ABNORMALITY IN TRANSMISSION CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED.................................................466 T-2 (E0142) ABNORMALITY IN TRANSMISSION CONTROLLER 5V POWER SOURCE IS DISPLAYED......................................................467 T-3 (E0146) ABNORMALITY IN TRANSMISSION CONTROLLER SENSOR POWER SOURCE IS DISPLAYED..................................................468 T-4 (E0160) ABNORMALITY IN TRANSMISSION CONTROLLER E2PROM IS DISPLAYED...............................................................468 T-5 (E0178), (E0179) DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM IS DISPLAYED.......................................................469 T-6 (E0212) SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED...................................................470 T-7 (E0213) DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED...................................................471 T-8 (E0221) ABNORMALITY IN PITCH ANGLE SENSOR SYSTEM IS DISPLAYED....................................................................472 T-9 (E0222) DISCONNECTION IN BEVEL SPEED SENSOR SYSTEM IS DISPLAYED..................................................................473 T-10 (E0225) SLIP OF POWER TRAIN CLUTCH..............................................................................................474 T-11 (E0230), (E0231), (E0232) ABNORMALITY IN TRAVEL LEVER DIRECTIONAL SYSTEM IS DISPLAYED...........................................474 T-12 (E0233) ABNORMALITY IN JOYSTICK (DIRECTIONAL SHIFT LEVER) POTENTIOMETER "1" SYSTEM IS DISPLAYED.................................475 T-13 (E0234) ABNORMALITY IN JOYSTICK (DIRECTIONAL SHIFT LEVER) POTENTIOMETER "2" SYSTEM IS DISPLAYED.................................476 T-14 (E0235) LAG OF FORWARD-REVERSE SIGNAL...........................................................................................477 T-15 (E0236) ABNORMALITY IN SHIFT-UP SWITCH SYSTEM IS DISPLAYED......................................................................477 T-16 (E0237) ABNORMALITY IN SHIFT-DOWN SWITCH SYSTEM.................................................................................479 T-17 (E0238) ABNORMALITY IN TRAVEL LOCK SWITCH SYSTEM................................................................................481 A. WHEN ONLY E0238 IS DISPLAYED..................................................................................................481 B. WHEN BOTH E0238 AND E0781 ARE DISPLAYED.......................................................................................483 T-18 (E0239) DISAGREEMENT IN TRAVEL LOCK.............................................................................................485 T-19 (E0250) DISCONNECTION IN FORWARD CLUTCH ECMV SYSTEM.............................................................................485 T-20 (E0251) SHORT CIRCUIT IN FORWARD CLUTCH ECMV SYSTEM.............................................................................486 T-21 (E0252) DISCONNECTION IN REVERSE CLUTCH ECMV SYSTEM.............................................................................487 T-22 (E0253) SHORT CIRCUIT IN REVERSE CLUTCH ECMV SYSTEM.............................................................................488 T-23 (E0254) DISCONNECTION IN 1ST CLUTCH ECMV SYSTEM.................................................................................489 T-24 (E0255) SHORT CIRCUIT IN 1ST CLUTCH ECMV SYSTEM.................................................................................490 T-25 (E0256) DISCONNECTION IN 2ND CLUTCH ECMV SYSTEM.................................................................................491 T-26 (E0257) SHORT CIRCUIT IN 2ND CLUTCH ECMV SYSTEM.................................................................................492 T-27 (E0258) DISCONNECTION IN 3RD CLUTCH ECMV SYSTEM.................................................................................493 T-28 (E0259) SHORT CIRCUIT IN 3RD CLUTCH ECMV SYSTEM.................................................................................494 T-29 (E0260) ABNORMALITY IN FORWARD CLUTCH OIL PRESSURE SYSTEM.......................................................................495 T-30 (E0261) SHORT CIRCUIT IN FORWARD CLUTCH OIL PRESSURE SYSTEM.....................................................................495 T-31 (E0262) ABNORMALITY IN REVERSE CLUTCH OIL PRESSURE SYSTEM.......................................................................496 T-32 (E0263) SHORT CIRCUIT IN REVERSE CLUTCH OIL PRESSURE SYSTEM.....................................................................496 T-33 (E0264) ABNORMALITY IN 1ST CLUTCH OIL PRESSURE SYSTEM...........................................................................497 T-34 (E0265) SHORT CIRCUIT IN 1ST CLUTCH OIL PRESSURE SYSTEM.........................................................................497 T-35 (E0266) ABNORMALITY IN 2ND CLUTCH OIL PRESSURE SYSTEM...........................................................................498 T-36 (E0267) SHORT CIRCUIT IN 2ND CLUTCH OIL PRESSURE SYSTEM.........................................................................498 T-37 (E0268) ABNORMALITY IN 3RD CLUTCH OIL PRESSURE SYSTEM...........................................................................499 T-38 (E0269) SHORT CIRCUIT IN 3RD CLUTCH OIL PRESSURE SYSTEM.........................................................................499 T-39 (E0270) DOUBLE FAILURE IN TRANSMISSION CLUTCH (CLUTCH IS NOT ENGAGED)...........................................................500 T-40 (E0271) DOUBLE FAILURE IN TRANSMISSION CLUTCH (CLUTCH IS NOT DISENGAGED)........................................................500 T-41 (E0273) ABNORMALITY IN NEUTRAL SIGNAL SYSTEM IS DISPLAYED.......................................................................500 T-42 (E0301) ABNORMALITY IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED.........................................................501 T-43 (E0302) ABNORMALITY IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED.........................................................502 T-44 (E0303) ABNORMALITY IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED........................................................503 T-45 (E0304) ABNORMALITY IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED........................................................504 T-46 (E0305) SHORT CIRCUIT IN BLADE RAISE OIL PRESSURE SWITCH SYSTEM IS DISPLAYED....................................................505 T-47 (E0311) ABNORMALITY IN PITCH-DUMP SWITCH SYSTEM.................................................................................506 T-48 (E0312) ABNORMALITY IN PITCH-BACK SWITCH SYSTEM.................................................................................508 T-49 (E0313) DISCONNECTION IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED................................................................510 T-50 (E0314) SHORT CIRCUIT IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED................................................................511 T-51 (E0315) DISCONNECTION IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED................................................................512 T-52 (E0316) SHORT CIRCUIT IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED................................................................513 T-53 (E0317) DISCONNECTION IN LIFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED...........................................................514 T-54 (E0318) SHORT CIRCUIT IN LEFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED...........................................................515 T-55 (E0319) DISCONNECTION IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED..........................................................516 T-56 (E0320) SHORT CIRCUIT IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED..........................................................517 T-57 (E0341) DISCONNECTION IN BLADE LIFT "1" PUMP CUT SOLENOID SYSTEM IS DISPLAYED...................................................518 T-58 (E0342) SHORT CIRCUIT IN BLADE LIFT "1" PUMP CUT SOLENOID SYSTEM IS DISPLAYED...................................................519 T-59 (E0343) DISCONNECTION IN PITCH DUMP ASSIST RELAY SYSTEM IS DISPLAYED............................................................520 T-60 (E0344) SHORT CIRCUIT IN PITCH DUMP ASSIST RELAY SYSTEM IS DISPLAYED............................................................520 T-61 (E0345) DISCONNECTION IN PITCH SOLENOID SYSTEM IS DISPLAYED.....................................................................521 T-62 (E0346) SHORT CIRCUIT IN PITCH SOLENOID SYSTEM IS DISPLAYED.....................................................................522 T-63 (E0347) DISCONNECTION IN PITCH PRIORITY SOLENOID SYSTEM IS DISPLAYED............................................................523 T-64 (E0348) SHORT CIRCUIT IN PITCH PRIORITY SOLENOID SYSTEM IS DISPLAYED............................................................524 T-65 (E0364) DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR 1 (200 PUMP) SYSTEM IS DISPLAYED....................................525 T-66 (E0365) SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR 1 (200 PUMP) SYSTEM IS DISPLAYED....................................526 T-67 (E0366) DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR 2 (200 PUMP) SYSTEM IS DISPLAYED....................................527 T-68 (E0367) SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR 2 (200 PUMP) SYSTEM IS DISPLAYED....................................528 T-69 (E0372) SHORT CIRCUIT IN BLADE RAISE (FULL) OIL PRESSURE SWITCH SYSTEM IS DISPLAYED.............................................529 T-70 (E0486) ABNORMALITY IN SPECIFICATION SELECTION IS DISPLAYED.....................................................................530 T-71 (E0610), (E0611) DISCONNECTION IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED........................................................531 T-72 (E0931) ABNORMALITY IN ENGINE SPEED SENSOR "B" SYSTEM IS DISPLAYED..............................................................532 T-73 (E0932) ABNORMALITY IN BEVEL SPEED SENSOR A SYSTEM IS DISPLAYED.................................................................533 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)..................................................................................535 TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM)...........................................................536 H-1 BRAKES DO NOT WORK...............................................................................................................538 H-2 MACHINE DOES NOT TURN (MACHINE CAN TRAVEL ONLY IN A STRAIGHT LINE)...............................................................539 H-3 THERE IS TRAVEL DEVIATION........................................................................................................540 H-4 MACHINE TURNS ONLY IN ONE DIRECTION (LEVER OPERATED).............................................................................541 H-5 TIME LAG IS EXCESSIVE............................................................................................................542 H-6 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)....................................................................543 H-7 MACHINE DOES NOT MOVE (2ND, 3RD).................................................................................................544 H-8 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.........................................................................................546 H-9 TORQUE CONVERTER OVERHEATS.......................................................................................................547 H-10 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP.......................................................................................549 H-11 BLADE RAISE SPEED SLOW OR WORK EQUIPMENT LACKS POWER............................................................................550 H-12 BLADE PITCH SPEED SLOW OR BLADE PITCH LACKS POWER...............................................................................551 H-13 EXCESSIVE HYDRAULIC DRIFT OF BLADE..............................................................................................552 H-14 EXCESSIVE HYDRAULIC DRIFT OF BLADE PITCH........................................................................................552 TROUBLESHOOTING OF MONITOR PANEL AND ELECTRICAL SYSTEM (M MODE)..........................................................................553 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................555 M-1 (E0120) SHORT CIRCUIT IN CAUTION LAMP OUTPUT SYSTEM IS DISPLAYED.................................................................557 M-2 (E0121) SHORT CIRCUIT IN CAUTION BUZZER SYSTEM IS DISPLAYED......................................................................558 M-3 (E0211) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER OIL TEMPERATURE) IS DISPLAYED...............................................559 M-4 (E0329) ABNORMALITY IN HYDRAULIC OIL TEMPERATURE IS DISPLAYED....................................................................559 M-5 (E0430) ABNORMALITY IN ENGINE OIL PRESSURE IS DISPLAYED..........................................................................560 M-6 (E0431) ABNORMALITY IN RADIATOR WATER LEVEL IS DISPLAYED.........................................................................560 M-7 (E0432) ABNORMALITY IN ENGINE WATER TEMPERATURE IS DISPLAYED.....................................................................561 M-8 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL GIVES NO DISPLAY................................................................562 A. CAUTION MODULE (GUAGE/LAMP UNIT) GIVES NO DISPLAY.............................................................................562 B. TACHOMETER MODULE (TACHOMETER/SERVICE METER UNIT) GIVES NO DISPLAY............................................................563 M-9 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT.....................................564 A. CAUTION MODULE (GAUGE/LAMP UNIT) DISPLAYS ALL STAY LIGHTED UP AND DO NOT GO OUT...............................................564 B. TACHOMETER MODULE (TACHOMETER/SERVICE METER UNIT) DISPLAYS ALL STAY LIGHTED UP AND DO NOT GO OUT..............................564 M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK BEFORE STARTING ITEMS FLASH...........................................565 A. (RADIATOR WATER LEVEL) FLASHES................................................................................................565 B. (ENGINE OIL LEVEL) FLASHES....................................................................................................566 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT BATTERY CHARGE, ENGINE OIL PRESSURE CAUTION........567 A. ENGINE OIL PRESSURE SENSOR SYSTEM.............................................................................................567 B. ALTERNATOR SYSTEM.............................................................................................................568 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT THERE IS NO ABNORMALITY IN CHECKS BEFORE ST........569 A. (BATTERY CHARGE) FLASHES......................................................................................................569 B. (ENGINE OIL PRESSURE) FLASHES.................................................................................................570 C. (RADIATOR WATER LEVEL) FLASHES................................................................................................570 D. (ENGINE WATER TEMPERATURE) FLASHES............................................................................................571 E. (POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE) FLASHES......................................................................572 F. (HYDRAULIC OIL TEMPERATURE) FLASHES...........................................................................................573 G. (AIR CLEANER CLOGGING) FLASHES................................................................................................574 M-13 ABNORMALITY IN CAUTION BUZZER...................................................................................................575 A. CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND, OR BUZZER DOES NOT SOUND FOR 1 SECOND AFTER STARTING SWITCH IS TURNED ON......575 B. NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS......................................................................575 M-14 ABNORMALITY IN CAUTION LAMP.....................................................................................................577 A. CAUTION ITEM FLASHES BUT CAUTION LAMP DOES NOT FLASH, OR CAUTION LAMP DOES NOT LIGHT UP FOR 2 SECONDS AFTER STARTING SWITC....577 B. NO ABNORMALITY IS DISPLAYED ON MONITOR BUT CAUTION LAMP LIGHTS UP.............................................................577 M-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...................................................................................579 A. ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE...............................................................579 B. ENGINE WATER TEMPERATURE GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL).......................................579 M-16 ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE.............................................................581 A. POWER TRAIN OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE............................................................581 B. POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL).................581 M-17 ABNORMALITY IN FUEL LEVEL GAUGE.................................................................................................583 A. FUEL LEVEL GAUGE ALWAYS DISPLAY FULL..........................................................................................583 B. FUEL LEVEL GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL).....................................................583 M-18 SPEED RANGE DISPLAY SHOWS "--", ENGINE SPEED IS NOT DISPLAYED...................................................................585 M-19 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING...........................................................................585 M-20 ABNORMALITY IN SERVICE MODE.....................................................................................................586 A. DOES NOT SWITCH TO SERVICE MODE EVEN WHEN SERVICE SWITCH IS OPERATED..........................................................586 B. STAYS IN SERVICE MODE.........................................................................................................586 M-21 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL).........................................588 A. TACHOMETER MODULE LAMP DOES NOT LIGHT UP......................................................................................588 B. CAUTION MODULE LAMP DOES NOT LIGHT UP.........................................................................................588 C. SWITCH MODULE LAMP DOES NOT LIGHT UP..........................................................................................589 M-22 L.H. FRONT LAMP DO NOT LIGHT UP.................................................................................................590 A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP....................................................................590 M-23 R.H. FRONT LAMP DO NOT LIGHT UP.................................................................................................591 A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP....................................................................591 M-24 L.H. WORKING LAMPS DO NOT LIGHT UP..............................................................................................592 A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP....................................................................592 M-25 R.H. WORKING LAMPS DO NOT LIGHT UP..............................................................................................593 A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP....................................................................593 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................................594 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................596 S-1 Starting performance is poor (Starting always takes time)........................................................................599 S-2 Engine does not start............................................................................................................600 (1) Engine does not turn.........................................................................................................600 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).......................................................601 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)...................................................602 S-3 Engine does not pick-up smoothly (Follow-up is poor).............................................................................603 S-4 Engine stops during operations (with electronical governor)......................................................................604 S-5 Engine does not rotate smoothly (Hunting) (with electronical governor)...........................................................605 S-6 Engine lacks output (no power) (with electronical governor)......................................................................606 S-7 Exhaust gas is black (incomplete combustion) (with electronical governor)........................................................607 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........................................................................608 S-9 Oil becomes contaminated quickly.................................................................................................609 S-10 Fuel consumption is excessive (with electronical governor).....................................................................610 S-11 Oil is in cooling water, or water spurts back, or water level goes down........................................................611 S-12 Oil pressure caution lamp lights up (Drop in oil pressure)......................................................................612 S-13 Oil level rises.................................................................................................................613 S-14 Water temperature becomes too high (Overheating)................................................................................614 S-15 Abnormal noise is made..........................................................................................................615 S-16 Vibration is excessive..........................................................................................................616 S-17 Abnormality in governor servo system is displayed in troubleshooting for engine controller......................................617 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................619 METHOD OF USING MANUAL.......................................................................................................................621 PRECATIONS WHEN CARRYING OUT OPERATION.......................................................................................................622 SPECIAL TOOL LIST............................................................................................................................624 ENGINE OIL COOLER............................................................................................................................637 REMOVAL..................................................................................................................................637 INSTALLATION.............................................................................................................................638 FUEL INJECTION PUMP..........................................................................................................................638 REMOVAL..................................................................................................................................638 INSTALLATION.............................................................................................................................640 AFTER-COOLER CORE............................................................................................................................641 REMOVAL AND INSTALLATION.................................................................................................................641 NOZZLER HOLDER...............................................................................................................................642 REMOVAL AND INSTALLATION.................................................................................................................642 CYLINDER HEAD................................................................................................................................643 REMOVAL..................................................................................................................................643 INSTALLATION.............................................................................................................................645 HYDRAULIC COOLER.............................................................................................................................647 REMOVAL AND INSTALLATION.................................................................................................................647 RADIATOR.....................................................................................................................................648 REMOVAL..................................................................................................................................648 INSTALLATION.............................................................................................................................650 FAN DRIVE SUPPORT............................................................................................................................651 REMOVAL..................................................................................................................................651 INSTALLATION.............................................................................................................................653 FAN DRIVE PULLEY (FAN END)...................................................................................................................654 REMOVAL AND INSTALLATION.................................................................................................................654 DISASSEMBLY..............................................................................................................................654 ASSEMBLY.................................................................................................................................655 FAN DRIVE PULLEY (ENGINE END)................................................................................................................657 REMOVAL..................................................................................................................................657 INSTALLATION.............................................................................................................................658 DISASSEMBLY .............................................................................................................................658 ASSEMBLY.................................................................................................................................659 DAMPER.......................................................................................................................................660 REMOVAL .................................................................................................................................660 INSTALLATION.............................................................................................................................662 DISASSEMBLY..............................................................................................................................662 ASSEMBLY.................................................................................................................................663 POWER TRAIN..................................................................................................................................665 REMOVAL..................................................................................................................................665 INSTALLATION.............................................................................................................................669 PTO, TORQUE CONVERTER........................................................................................................................671 REMOVAL..................................................................................................................................671 INSTALLATION.............................................................................................................................673 DISCONNECTON.............................................................................................................................674 CONNECTION...............................................................................................................................675 PTO..........................................................................................................................................676 DISASSEMBLY..............................................................................................................................676 ASSEMBLY.................................................................................................................................679 TORQUE CONVERTER.............................................................................................................................683 DISASSEMBLY..............................................................................................................................683 ASSEMBLY.................................................................................................................................687 TORQFLOW TRANSMISSION........................................................................................................................692 REMOVAL..................................................................................................................................692 INSTALLATION.............................................................................................................................693 DISASSEMBLY..............................................................................................................................694 ASSEMBLY.................................................................................................................................701 STEERING CASE................................................................................................................................711 REMOVAL..................................................................................................................................711 INSTALLATION.............................................................................................................................712 DISASSEMBLY..............................................................................................................................713 ASSEMBLY.................................................................................................................................717 STEERING CLUTCH..............................................................................................................................726 DISASSEMBLY..............................................................................................................................726 ASSEMBLY.................................................................................................................................727 STEERING BRAKE...............................................................................................................................728 DISASSEMBLY..............................................................................................................................728 ASSEMBLY.................................................................................................................................730 TORQUE CONVERTER VALVE.......................................................................................................................735 REMOVAL..................................................................................................................................735 INSTALLATION.............................................................................................................................736 DISASSEMBLY..............................................................................................................................737 ASSEMBLY.................................................................................................................................739 TRANSMISSION CONTROL VALVE...................................................................................................................741 REMOVAL AND INSTALLATION.................................................................................................................741 DISASSEMBLY..............................................................................................................................742 ASSEMBLY.................................................................................................................................743 POWER TRAIN PUMP.............................................................................................................................744 REMOVAL AND INSTALLATION.................................................................................................................744 TRANSMISSION LUBRICATION PUMP................................................................................................................744 REMOVAL AND INSTALLATION.................................................................................................................744 SCAVENGING PUMP..............................................................................................................................745 REMOVAL AND INSTALLATION.................................................................................................................745 FINAL DRIVE..................................................................................................................................745 REMOVAL..................................................................................................................................745 INSTALLATION.............................................................................................................................746 DISASSEMBLY..............................................................................................................................747 ASSEMBLY.................................................................................................................................752 TRACK FRAME..................................................................................................................................762 REMOVAL..................................................................................................................................762 INSTALLATION.............................................................................................................................764 RECOIL SPRING, TUBE..........................................................................................................................765 REMOVAL AND INSTALLATION.................................................................................................................765 DISASSEMBLY..............................................................................................................................766 ASSEMBLY.................................................................................................................................770 IDLER YOKE CYLINDER..........................................................................................................................773 DISASSEMBLY..............................................................................................................................773 ASSEMBLY.................................................................................................................................774 IDLER........................................................................................................................................775 DISASSEMBLY..............................................................................................................................775 ASSEMBLY.................................................................................................................................776 TRACK ROLLER.................................................................................................................................778 REMOVAL..................................................................................................................................778 INSTALLATION.............................................................................................................................779 DISASSEMBLY..............................................................................................................................780 ASSEMBLY.................................................................................................................................781 BOGIE........................................................................................................................................783 REMOVAL..................................................................................................................................783 INSTALLATION.............................................................................................................................784 DISASSEMBLY..............................................................................................................................784 ASSEMBLY.................................................................................................................................786 TRACK SHOE...................................................................................................................................789 CHECKING BEFORE REMOVAL..................................................................................................................789 REMOVAL..................................................................................................................................789 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)...................................................................................789 INSTALLATION.............................................................................................................................793 DISASSEMBLY..............................................................................................................................794 ASSEMBLY.................................................................................................................................798 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.............................................................................................812 FIELD DISASSEMBLY OF ONE LINK................................................................................................................813 DISASSEMBLY..............................................................................................................................813 ASSEMBLY.................................................................................................................................814 MASTER LINK..................................................................................................................................816 DISASSEMBLY..............................................................................................................................816 ASSEMBLY.................................................................................................................................817 ADJUSTING TRACK SHOE TENSION.................................................................................................................819 PIVOT SHAFT..................................................................................................................................820 REMOVAL AND INSTALLATION.................................................................................................................820 EQUALIZER BAR................................................................................................................................821 REMOVAL..................................................................................................................................821 INSTALLATION.............................................................................................................................822 REPLACING EQUALIZER BAR BUSHING..............................................................................................................823 SEGMENT TEETH................................................................................................................................824 REMOVAL AND INSTALLATION.................................................................................................................824 WORK EQIPMENT PUMP...........................................................................................................................825 REMOVAL AND INSTALLATION.................................................................................................................825 WORK EQUIPMENT ASSIST, CONTROL PUMP..........................................................................................................826 REMOVAL AND INSTALLATION.................................................................................................................826 BLADE VALVE..................................................................................................................................827 REMOVAL AND INSTALLATION.................................................................................................................827 DISASSEMBLY..............................................................................................................................829 ASSEMBLY.................................................................................................................................831 MAIN RELIEF VALVE............................................................................................................................833 DISASSEMBLY AND ASSEMBLY.................................................................................................................833 BLADE LIFT CYLINDER..........................................................................................................................834 REMOVAL AND INSTALLATION.................................................................................................................834 BLADE PITCH CYLINDER.........................................................................................................................835 REMOVAL AND INSTALLATION.................................................................................................................835 HYDRAULIC CYLINDER...........................................................................................................................836 DISASSEMBLY..............................................................................................................................836 ASSEMBLY.................................................................................................................................838 BLADE PPC VALUE..............................................................................................................................840 REMOVAL..................................................................................................................................840 INSTALLATION.............................................................................................................................841 DISASSEMBLY..............................................................................................................................841 ASSEMBLY.................................................................................................................................842 BLADE........................................................................................................................................843 REMOVAL..................................................................................................................................843 INSTALLATION.............................................................................................................................844 DISASSEMBLY..............................................................................................................................845 ASSEMBLY.................................................................................................................................846 POTENTIOMETER................................................................................................................................848 REMOVAL..................................................................................................................................848 INSTALLATION.............................................................................................................................849 OPERATOR'S COMPARTMENT FRAME ................................................................................................................849 REMOVAL..................................................................................................................................849 INSTALLATION.............................................................................................................................851 CAB..........................................................................................................................................852 REMOVAL..................................................................................................................................852 INSTALLATION.............................................................................................................................853 ROPS.........................................................................................................................................853 REMOVAL..................................................................................................................................853 INSTALLATION.............................................................................................................................854 COUNTERWEIGHT FRAME..........................................................................................................................854 REMOVAL AND INSTALLATION.................................................................................................................854 BLADE CYLINDER SUPPORT.......................................................................................................................855 REMOVAL..................................................................................................................................855 INSTALLATION.............................................................................................................................856 90 OTHERS........................................................................................................................................857 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM........................................................................................................858 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT.................................................................................................859 ELECTRICAL CIRCUIT DIAGRAM (1/7).............................................................................................................860 ELECTRICAL CIRCUIT DIAGRAM (2/7).............................................................................................................861 ELECTRICAL CIRCUIT DIAGRAM (3/7).............................................................................................................862 ELECTRICAL CIRCUIT DIAGRAM (4/7).............................................................................................................863 ELECTRICAL CIRCUIT DIAGRAM (5/7).............................................................................................................864 ELECTRICAL CIRCUIT DIAGRAM (6/7).............................................................................................................865 ELECTRICAL CIRCUIT DIAGRAM (7/7).............................................................................................................866
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