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KOMATSU WB93R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00300 – PDF
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Description
KOMATSU WB93R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00300 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WB93R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00300 – PDF DOWNLOAD
Language : English
Pages : 1646
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WB93R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00300 – PDF DOWNLOAD
00 INDEX AND FOREWORD......................................................................... 3 INDEX..................................................................................... 4 FOREWORD, SAFETY, BASIC INFORMATION....................................................... 16 HOW TO READ THE SHOP MANUAL........................................................... 16 SAFETY NOTICE FOR OPERATION........................................................... 18 PRECAUTIONS TO PREVENT FIRE........................................................... 26 ACTIONS IF FIRE OCCURS................................................................ 28 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.......................................... 29 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS......................................... 30 PRECAUTIONS FOR DEF................................................................... 31 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.................................... 31 PRECAUTIONS FOR ADDING............................................................ 31 PRECAUTIONS FOR STORING........................................................... 31 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE........................................... 31 THE OTHER PRECAUTIONS............................................................. 31 STORE AdBlue/DEF...................................................................... 32 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.......................................... 33 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS............................... 36 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT......................................... 43 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT........................................ 45 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...................................... 46 PRACTICAL USE OF KOMTRAX.............................................................. 47 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER......................................... 48 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER............. 48 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER............. 49 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER............. 50 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................ 52 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR............................. 56 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR..................... 57 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL................... 59 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH................... 60 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE.............. 62 HOW TO READ ELECTRICAL WIRE CODE...................................................... 63 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD......................................... 67 STANDARD TIGHTENING TORQUE TABLE...................................................... 70 CONVERSION TABLE...................................................................... 77 ABBREVIATION LIST..................................................................... 82 01 SPECIFICATIONS............................................................................. 85 CONTENTS.................................................................................. 86 SPECIFICATIONS............................................................................ 87 SPECIFICATION DRAWING................................................................. 87 SPECIFICATION DRAWING: WB93R-8E0.................................................. 87 SPECIFICATIONS........................................................................ 89 SPECIFICATIONS: WB93R-8E0......................................................... 89 WEIGHT TABLE.......................................................................... 95 WEIGHT TABLE: WB93R-8E0........................................................... 95 FUEL, COOLANT, LUBRICANTS............................................................. 97 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................. 97 10 STRUCTURE AND FUNCTION..................................................................... 99 CONTENTS.................................................................................. 100 UREA SCR SYSTEM........................................................................... 102 LAYOUT DRAWING OF UREA SCR SYSTEM..................................................... 102 UREA SCR SYSTEM DIAGRAM............................................................... 105 FUNCTION OF UREA SCR SYSTEM........................................................... 107 FUNCTION OF DEF SYSTEM............................................................ 107 INDUCEMENT STRATEGY............................................................... 108 COMPONENT PARTS OF UREA SCR SYSTEM.................................................... 115 DOC AND DEF MIXING TUBE........................................................... 115 DPF/SCR ASSEMBLY.................................................................. 117 DEF TANK.......................................................................... 119 DEF PUMP.......................................................................... 121 DEF INJECTOR...................................................................... 122 DEF HOSE.......................................................................... 123 DEF TANK HEATING VALVE............................................................ 124 HYDRAULIC SYSTEM.......................................................................... 125 LAYOUT DRAWING OF HYDRAULIC SYSTEM.................................................... 125 CLSS.................................................................................. 127 STRUCTURE OF CLSS................................................................. 127 FUNCTION OF CLSS.................................................................. 128 COMPONENT PARTS OF HYDRAULIC SYSTEM................................................... 130 HYDRAULIC TANK.................................................................... 130 MAIN PUMP......................................................................... 132 CONTROL VALVE..................................................................... 145 POWER TRAIN SYSTEM........................................................................ 188 LAYOUT DRAWING OF POWER TRAIN SYSTEM.................................................. 188 OPERATION OF POWER TRAIN SYSTEM....................................................... 190 COMPONENT PARTS OF POWER TRAIN SYSTEM................................................. 191 TRANSMISSION...................................................................... 191 DRIVE SHAFT....................................................................... 198 TRANSMISSION CONTROL VALVE........................................................ 200 AXLE.............................................................................. 201 WORK EQUIPMENT SYSTEM..................................................................... 211 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM............................................... 211 LOADER WORK EQUIPMENT PPC VALVE....................................................... 214 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 214 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 216 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 220 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 222 BACKHOE PPC VALVE..................................................................... 227 STRUCTURE OF LH BACKHOE PPC VALVE................................................. 227 STRUCTURE OF RH BACKHOE PPC VALVE................................................. 229 OUTRIGGER PPC VALVE................................................................... 231 STRUCTURE OF OUTRIGGER PPC VALVE.................................................. 231 OPERATION OF OUTRIGGER PPC VALVE.................................................. 232 STEERING UNIT......................................................................... 236 BRAKE PUMP............................................................................ 237 SOLENOID VALVES....................................................................... 238 SOLENOID VALVE GROUP (HYDRAULIC CONTROLS SPECIFICATION)........................... 238 SOLENOID VALVE GROUP (MECHANICAL CONTROLS SPECIFICATION).......................... 239 TELESCOPIC ARM SOLENOID VALVE..................................................... 239 SIDE DIGGING BOOM SOLENOID VALVE.................................................. 240 2-ATTACHMENT SOLENOID VALVE....................................................... 241 HAMMER SOLENOID VALVE............................................................. 242 PPC CIRCUIT ACCUMULATOR............................................................... 243 SAFETY VALVES......................................................................... 244 LOADER ARM SAFETY VALVE........................................................... 244 LOADER BUCKET SAFETY VALVE........................................................ 245 BACKHOE BOOM SAFETY VALVE......................................................... 246 BACKHOE ARM SAFETY VALVE.......................................................... 247 OUTRIGGER SAFETY VALVE............................................................ 248 WORK EQUIPMENT............................................................................ 249 STRUCTURE OF LOADER WORK EQUIPMENT.................................................... 249 STRUCTURE OF BACKHOE WORK EQUIPMENT................................................... 250 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM.................................. 251 20 STANDARD VALUE TABLE....................................................................... 253 CONTENTS.................................................................................. 254 STANDARD VALUE TABLE FOR ENGINE........................................................... 255 STANDARD VALUE TABLE FOR ENGINE: WB93R-8E0............................................ 255 STANDARD VALUE TABLE FOR MACHINE.......................................................... 258 STANDARD VALUE TABLE FOR MACHINE: WB93R-8E0........................................... 258 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE................................. 278 30 TESTING AND ADJUSTING...................................................................... 285 CONTENTS.................................................................................. 286 ENGINE AND COOLING SYSTEM................................................................. 289 TEST VISUAL CHECK CRANKCASE SYSTEM.................................................... 289 TEST CHECK CYLINDER MECHANICS......................................................... 291 CHECK CYLINDER COMPRESSION........................................................ 291 CHECK CYLINDER PRESSURE LOSS...................................................... 292 TEST CHECK EGR VALVE ACTUATOR......................................................... 293 TEST CHECK EXTERNAL FUEL LEAKAGE ENGINE AREA.......................................... 295 TEST CHECK PRESSURE LIMITING VALVE (PLV) BACKFLOW RATE................................ 297 TEST CHECK TURBO SYSTEM............................................................... 299 TEST CHECK INTAKE AIR SYSTEM.......................................................... 301 TEST CHECK COOLING SYSTEM............................................................. 303 CHECK COOLANT TANK................................................................ 303 CHECK COOLANT TEMPERATURE SENSOR.................................................. 304 READ OUT COOLANT TEMPERATURE SENSOR VALUE......................................... 304 VISUALLY CHECK COOLING SYSTEM..................................................... 305 MECHANICALLY CHECK WATER PUMP..................................................... 305 FAN ACTIVATION CHECK.............................................................. 306 VISCO FAN ACTIVATION CHECK........................................................ 306 ENGINE TEMPERATURE ADJUSTMENT CHECK............................................... 306 CHECK PRESSURE BETWEEN MAIN FILTER AND HIGH PRESSURE PUMP............................. 308 TEST CHECK HIGH PRESSURE PUMP BACKFLOW RATE........................................... 311 TEST CHECK HIGH PRESSURE SYSTEM BACKFLOW RATE......................................... 313 PRESSURE TEST RAIL PRESSURE ADJUSTMENT CHECK.......................................... 315 PRESSURE TEST CHECK RAIL PRESSURE DURING RAIL......................................... 316 PRESSURE TEST CHECK PRESSURE BETWEEN GEAR PUMP AND MAIN FILTER........................ 317 TEST CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR................................. 319 VISUALLY CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR......................... 319 READ OUT INTAKE AIR PRESSURE SENSOR VALUE......................................... 319 PRESSURE TEST CHECK SUCTION PRESSURE BETWEEN TANK AND PRE-FILTER...................... 320 PRESSURE TEST CHECK SUCTION PRESSURE AFTER PRE-FILTER................................. 322 TEST CHECK WATER IN FUEL SENSOR PLAUSIBILITY.......................................... 324 TEST CHECK EXTERNAL FUEL LEAKAGE HIGH PRESSURE SYSTEM................................. 325 TEST CHECK SINGLE INJECTOR BACKFLOW RATE.............................................. 326 TEST INJECTOR CUT OUT ACTIVATION CHECK................................................ 328 TEST ENGINE SPEED..................................................................... 329 PREPARATION FOR TESTING ENGINE SPEED.............................................. 329 TEST ENGINE LOW IDLE SPEED........................................................ 329 TEST ENGINE HIGH IDLE SPEED....................................................... 329 TEST ENGINE LOW IDLE SPEED AT PUMP AT RELIEF...................................... 330 TEST ENGINE HIGH IDLE SPEED WITH TORQUE CONVERTER AT STALL........................ 330 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF AND TORQUE CONVERTER AT STALL..... 330 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)........... 331 TEST EXHAUST GAS COLOR................................................................ 332 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER..................................... 332 TEST EXHAUST GAS COLOR BY SMOKE METER............................................. 332 STEERING SYSTEM........................................................................... 334 CHECK LEAKAGES IN STEERING CYLINDER................................................... 334 TEST STEERING CIRCUIT OIL PRESSURE.................................................... 335 ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE.......................... 336 TOE-IN ADJUSTMENT................................................................. 336 ADJUSTMENT WITH REFERENCE STEERING ANGLE.......................................... 338 ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE.................. 339 STEERING ANGLE CHECKING AND ADJUSTMENT............................................ 339 BRAKE SYSTEM.............................................................................. 342 TEST BRAKE SYSTEM PRESSURE............................................................ 342 TEST BRAKE SYSTEM LEAKAGE............................................................. 344 TEST BRAKE PISTON STROKE.............................................................. 345 BLEED AIR FROM THE BRAKE CIRCUIT...................................................... 346 TEST AND ADJUST PARKING BRAKE SYSTEM.................................................. 347 TEST PARKING BRAKE................................................................ 347 ADJUST PARKING BRAKE.............................................................. 348 HYDRAULIC SYSTEM.......................................................................... 349 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................ 349 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.................................... 349 RELEASE REMAINING PRESSURE IN LOADER HYDRAULIC CYLINDER CIRCUIT................... 349 RELEASE REMAINING PRESSURE IN BACKHOE HYDRAULIC CYLINDER CIRCUIT.................. 349 TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE............................................ 350 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE........................................... 351 TEST AND ADJUST UNLOAD PRESSURE................................................... 354 TEST AND ADJUST RELIEF PRESSURE................................................... 354 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE)........................................ 355 ADJUST SECONDARY VALVE............................................................ 355 TEST BACKHOE BOOM OVERLOAD SWITCH................................................. 356 TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE.......................................... 357 TEST CONTROL CIRCUIT OIL PRESSURE................................................. 357 ADJUST CONTROL CIRCUIT OIL PRESSURE............................................... 357 MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE....................................... 358 MEASURE PUMP PC CONTROL OIL PRESSURE.............................................. 358 ADJUST PUMP PC CONTROL OIL PRESSURE............................................... 360 MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE....................................... 362 MEASURE PUMP LS CONTROL OIL PRESSURE.............................................. 362 ADJUST PUMP LS CONTROL OIL PRESSURE............................................... 363 TEST SOLENOID VALVE OUTLET PRESSURE................................................... 364 TEST PPC VALVE OUTLET PRESSURE........................................................ 365 ADJUST WORK EQUIPMENT PPC VALVES PLAY................................................. 367 TEST TRANSMISSION OIL PRESSURE........................................................ 368 TEST.............................................................................. 369 WORK AFTER FINISH TEST............................................................ 370 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT.......................... 371 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER ARM CYLINDER......................... 371 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER BUCKET CYLINDER...................... 371 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BOOM CYLINDER....................... 372 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE ARM CYLINDER........................ 372 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BUCKET CYLINDER..................... 372 TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM SWING CYLINDER......................... 372 BLEED AIR FROM HYDRAULIC SYSTEM....................................................... 373 BLEED AIR FROM HYDRAULIC PUMP..................................................... 373 BLEED AIR FROM CYLINDERS.......................................................... 373 WORK EQUIPMENT............................................................................ 375 OUTRIGGER SENSOR AND SAFETY SYSTEM.................................................... 375 CHECK AND ADJUST OUTRIGGER SENSOR................................................. 375 TEST CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM................................ 377 ADJUST RETURN TO DIG SENSOR........................................................... 378 ADJUST TELESCOPIC ARM GUIDE SLACK..................................................... 379 PREPARATION FOR ADJUSTING GUIDE SLACK............................................. 379 REGISTRATION OF GUIDE SLACK....................................................... 379 ELECTRICAL SYSTEM......................................................................... 381 START UP KOMTRAX TERMINAL............................................................. 381 LAMP DISPLAY OF KOMTRAX TERMINAL...................................................... 385 ADJUST FRONT PANEL SETTINGS........................................................... 388 PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................... 389 BATTERY DISCONNECT SWITCH............................................................. 390 TEST DIODES........................................................................... 391 TEST DIODES BY DIGITAL TESTER..................................................... 391 TEST DIODES BY ANALOG TESTER...................................................... 391 40 TROUBLESHOOTING............................................................................ 393 CONTENTS.................................................................................. 394 RELATED INFORMATION TO TROUBLESHOOT....................................................... 402 PRECAUTIONS FOR TROUBLESHOOTING....................................................... 402 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................. 403 GENERAL TROUBLESHOOTING POINTS........................................................ 405 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................ 406 CHECKS BEFORE TROUBLESHOOTING......................................................... 407 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING........................................... 409 WALK-AROUND CHECK................................................................. 409 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.......................................... 411 CHECK FUEL LEVEL AND TYPE......................................................... 411 CHECK WATER SEPARATOR AND DRAIN WATER AND SEDIMENT................................ 411 CHECK AdBlue(R) LEVEL AND TYPE.................................................... 413 REPLACE FUEL PREFILTER............................................................ 413 REPLACE FUEL MAIN FILTER.......................................................... 415 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE........................... 416 CHECK COOLANT LEVEL (EXPANSION TANK).............................................. 417 CHECK AIR CLEANER CLOGGING........................................................ 418 CLEAN OUTER ELEMENT............................................................... 418 REPLACE INNER ELEMENT............................................................. 420 CHECK HYDRAULIC OIL LEVEL......................................................... 421 CHECK HYDRAULIC OIL STRAINER...................................................... 422 REPLACE HYDRAULIC OIL FILTER...................................................... 424 CHECK OIL LEVEL IN TRANSMISSION CASE.............................................. 425 CHECK FRONT AXLE OIL LEVEL........................................................ 426 CHECK REAR AXLE OIL LEVEL......................................................... 426 BLEED AIR FROM SYSTEM............................................................. 427 CHECK ELECTRIC EQUIPMENT.......................................................... 427 CONNECTOR CONTACT IDENTIFICATION...................................................... 432 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................... 474 FUSE LOCATION TABLE................................................................... 480 FAILURE CODE TABLE.................................................................... 484 MACHINE ECU FAILURE CODE TABLE.................................................... 484 MONITOR ECU FAILURE CODE TABLE.................................................... 486 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)......................................... 488 Failure Code [#T0022]................................................................. 488 Failure Code [#T0023]................................................................. 493 Failure Code [#T0037]................................................................. 498 Failure Code [#T0038]................................................................. 501 Failure Code [#T0039]................................................................. 505 Failure Code [#T0040]................................................................. 509 Failure Code [#T0041]................................................................. 513 Failure Code [#T0042]................................................................. 517 Failure Code [#T0043]................................................................. 520 Failure Code [#T0044]................................................................. 524 Failure Code [#T0045]................................................................. 528 Failure Code [#T0046]................................................................. 532 Failure Code [#T0055]................................................................. 536 Failure Code [#T0056]................................................................. 540 Failure Code [#T0057]................................................................. 541 Failure Code [#T0058]................................................................. 545 Failure Code [#T0061]................................................................. 549 Failure Code [#T0062]................................................................. 552 Failure Code [#T0068]................................................................. 555 Failure Code [#T0069]................................................................. 556 Failure Code [#T0073]................................................................. 558 Failure Code [#T0075]................................................................. 560 Failure Code [#T0077]................................................................. 561 Failure Code [#T0078]................................................................. 562 Failure Code [#T0079]................................................................. 564 Failure Code [#T0080]................................................................. 566 Failure Code [#T0081]................................................................. 568 Failure Code [#T0082]................................................................. 570 Failure Code [#T0083]................................................................. 571 Failure Code [#T0084]................................................................. 572 Failure Code [#T0085]................................................................. 573 Failure Code [#T0090]................................................................. 574 Failure Code [#T0091]................................................................. 577 Failure Code [#T0092]................................................................. 579 Failure Code [#T0093]................................................................. 580 Failure Code [#T0094]................................................................. 582 Failure Code [#T0103]................................................................. 584 Failure Code [#T0105]................................................................. 587 Failure Code [#T0108]................................................................. 590 Failure Code [#T0109]................................................................. 592 Failure Code [#T0110]................................................................. 594 Failure Code [#T0111]................................................................. 596 Failure Code [#T0112]................................................................. 598 Failure Code [#T0113]................................................................. 600 Failure Code [#T0114]................................................................. 602 Failure Code [#T0115]................................................................. 604 Failure Code [#T0116]................................................................. 606 Failure Code [#T0123]................................................................. 608 Failure Code [#T0124]................................................................. 609 Failure Code [#T0125]................................................................. 610 Failure Code [#T0126]................................................................. 611 Failure Code [#T0127]................................................................. 612 Failure Code [#T0128]................................................................. 613 Failure Code [#T0129]................................................................. 614 Failure Code [#T0147]................................................................. 615 Failure Code [#T0148]................................................................. 617 Failure Code [#T0151]................................................................. 619 Failure Code [#T0152]................................................................. 620 Failure Code [#T0168]................................................................. 621 Failure Code [#T0169]................................................................. 622 Failure Code [#T0170]................................................................. 623 Failure Code [#T0173]................................................................. 624 Failure Code [#T0174]................................................................. 625 Failure Code [#T0183]................................................................. 626 Failure Code [#T0185]................................................................. 627 Failure Code [#T0188]................................................................. 628 Failure Code [#T0191]................................................................. 629 Failure Code [#T0192]................................................................. 632 Failure Code [#T0193]................................................................. 633 Failure Code [#T0196]................................................................. 634 Failure Code [#T0198]................................................................. 635 Failure Code [#T0199]................................................................. 636 Failure Code [#T0200]................................................................. 637 Failure Code [#T0201]................................................................. 638 Failure Code [#T0204]................................................................. 639 Failure Code [#T0205]................................................................. 641 Failure Code [#T0207]................................................................. 642 Failure Code [#T0208]................................................................. 644 Failure Code [#T0209]................................................................. 646 Failure Code [#T0210]................................................................. 647 Failure Code [#T0211]................................................................. 648 Failure Code [#T0213]................................................................. 650 Failure Code [#T0215]................................................................. 651 Failure Code [#T0217]................................................................. 654 Failure Code [#T0219]................................................................. 655 Failure Code [#T0220]................................................................. 656 Failure Code [#T0221]................................................................. 657 Failure Code [#T0232]................................................................. 658 Failure Code [#T0236]................................................................. 659 Failure Code [#T0237]................................................................. 661 Failure Code [#T0238]................................................................. 663 Failure Code [#T0239]................................................................. 665 Failure Code [#T0240]................................................................. 667 Failure Code [#T0241]................................................................. 669 Failure Code [#T0242]................................................................. 671 Failure Code [#T0247]................................................................. 674 Failure Code [#T0248]................................................................. 677 Failure Code [#T0249]................................................................. 678 Failure Code [#T0251]................................................................. 681 Failure Code [#T0252]................................................................. 683 Failure Code [#T0254]................................................................. 685 Failure Code [#T0255]................................................................. 688 Failure Code [#T0256]................................................................. 690 Failure Code [#T0257]................................................................. 692 Failure Code [#T0258]................................................................. 693 Failure Code [#T0259]................................................................. 694 Failure Code [#T0260]................................................................. 695 Failure Code [#T0261]................................................................. 696 Failure Code [#T0262]................................................................. 697 Failure Code [#T0263]................................................................. 698 Failure Code [#T0264]................................................................. 699 Failure Code [#T0266]................................................................. 700 Failure Code [#T0267]................................................................. 701 Failure Code [#T0268]................................................................. 702 Failure Code [#T0269]................................................................. 703 Failure Code [#T0270]................................................................. 704 Failure Code [#T0272]................................................................. 705 Failure Code [#T0273]................................................................. 706 Failure Code [#T0274]................................................................. 707 Failure Code [#T0278]................................................................. 708 Failure Code [#T0279]................................................................. 710 Failure Code [#T0280]................................................................. 712 Failure Code [#T0281]................................................................. 713 Failure Code [#T0282]................................................................. 714 Failure Code [#T0283]................................................................. 715 Failure Code [#T0284]................................................................. 716 Failure Code [#T0285]................................................................. 718 Failure Code [#T0292]................................................................. 719 Failure Code [#T0293]................................................................. 721 Failure Code [#T0295]................................................................. 723 Failure Code [#T0303]................................................................. 725 Failure Code [#T0305]................................................................. 727 Failure Code [#T0308]................................................................. 728 Failure Code [#T0310]................................................................. 729 Failure Code [#T0311]................................................................. 730 Failure Code [#T0314]................................................................. 731 Failure Code [#T0318]................................................................. 732 Failure Code [#T0319]................................................................. 733 Failure Code [#T0320]................................................................. 734 Failure Code [#T0321]................................................................. 735 Failure Code [#T0322]................................................................. 737 Failure Code [#T0323]................................................................. 739 Failure Code [#T0324]................................................................. 741 Failure Code [#T0328]................................................................. 743 Failure Code [#T0329]................................................................. 745 Failure Code [#T0338]................................................................. 748 Failure Code [#T0339]................................................................. 750 Failure Code [#T0350]................................................................. 752 Failure Code [#T0356]................................................................. 754 Failure Code [#T0357]................................................................. 757 Failure Code [#T0400]................................................................. 760 Failure Code [#T0401]................................................................. 764 Failure Code [#T0402]................................................................. 768 Failure Code [#T0403]................................................................. 770 Failure Code [#T0404]................................................................. 772 Failure Code [#T0405]................................................................. 774 Failure Code [#T0406]................................................................. 775 Failure Code [#T0407]................................................................. 776 Failure Code [#T0408]................................................................. 778 Failure Code [#T0409]................................................................. 780 Failure Code [#T0410]................................................................. 782 Failure Code [#T0411]................................................................. 784 Failure Code [#T0412]................................................................. 785 Failure Code [#T0413]................................................................. 786 Failure Code [#T0414]................................................................. 788 Failure Code [#T0415]................................................................. 790 Failure Code [#T0416]................................................................. 791 Failure Code [#T0417]................................................................. 793 Failure Code [#T0418]................................................................. 795 Failure Code [#T0419]................................................................. 796 Failure Code [#T0420]................................................................. 799 Failure Code [#T0421]................................................................. 801 Failure Code [#T0422]................................................................. 803 Failure Code [#T0423]................................................................. 805 Failure Code [#T0424]................................................................. 807 Failure Code [#T0425]................................................................. 808 Failure Code [#T0426]................................................................. 810 Failure Code [#T0427]................................................................. 814 Failure Code [#T0428]................................................................. 816 Failure Code [#T0429]................................................................. 820 Failure Code [#T0430]................................................................. 821 Failure Code [#T0431]................................................................. 823 Failure Code [#T0432]................................................................. 825 Failure Code [#T0433]................................................................. 827 Failure Code [#T0434]................................................................. 829 Failure Code [#T0435]................................................................. 831 Failure Code [#T0436]................................................................. 833 Failure Code [#T0439]................................................................. 835 Failure Code [#T0440]................................................................. 837 Failure Code [#T0441]................................................................. 839 Failure Code [#T0442]................................................................. 842 Failure Code [#T0443]................................................................. 844 Failure Code [#T0444]................................................................. 846 Failure Code [#T0445]................................................................. 848 Failure Code [#T0446]................................................................. 849 Failure Code [#T0447]................................................................. 850 Failure Code [#T0448]................................................................. 851 Failure Code [#T0449]................................................................. 853 Failure Code [#T0450]................................................................. 855 Failure Code [#T0451]................................................................. 857 Failure Code [#T0452]................................................................. 859 Failure Code [#T0453]................................................................. 861 Failure Code [#T0454]................................................................. 863 Failure Code [#T0455]................................................................. 865 Failure Code [#T0456]................................................................. 867 Failure Code [#T0457]................................................................. 869 Failure Code [#T0458]................................................................. 871 Failure Code [#T0459]................................................................. 874 Failure Code [#T0460]................................................................. 876 Failure Code [#T0461]................................................................. 878 Failure Code [#T0462]................................................................. 879 Failure Code [#T0463]................................................................. 884 Failure Code [#T0464]................................................................. 885 Failure Code [#T0465]................................................................. 886 Failure Code [#T0466]................................................................. 887 Failure Code [#T0467]................................................................. 890 Failure Code [#T0468]................................................................. 893 Failure Code [#T0469]................................................................. 896 Failure Code [#T0470]................................................................. 899 Failure Code [#T0500]................................................................. 902 Failure Code [#T0501]................................................................. 903 Failure Code [#T0502]................................................................. 904 Failure Code [#T0504]................................................................. 905 Failure Code [#T0508]................................................................. 909 Failure Code [#T0509]................................................................. 911 Failure Code [#T0510]................................................................. 912 Failure Code [#T0511]................................................................. 916 Failure Code [#T0512]................................................................. 920 Failure Code [#T0513]................................................................. 924 Failure Code [#T0517]................................................................. 928 Failure Code [#T0519]................................................................. 929 Failure Code [#T0520]................................................................. 931 Failure Code [#T0521]................................................................. 935 Failure Code [#T0522]................................................................. 939 Failure Code [#T0530]................................................................. 943 Failure Code [#T0531]................................................................. 944 Failure Code [#T0532]................................................................. 945 Failure Code [#T0533]................................................................. 950 Failure Code [#T0534]................................................................. 951 Failure Code [#T0535]................................................................. 956 Failure Code [#T0536]................................................................. 961 Failure Code [#T0537]................................................................. 966 Failure Code [#T0538]................................................................. 967 Failure Code [#T0539]................................................................. 969 Failure Code [#T0540]................................................................. 970 Failure Code [#T0541]................................................................. 971 Failure Code [#T0542]................................................................. 973 Failure Code [#T0543]................................................................. 974 Failure Code [#T0544]................................................................. 975 Failure Code [#T0545]................................................................. 976 Failure Code [#T0546]................................................................. 977 Failure Code [#T0547]................................................................. 979 Failure Code [#T0550]................................................................. 981 Failure Code [#T0551]................................................................. 982 Failure Code [#T0555]................................................................. 984 Failure Code [#T0556]................................................................. 987 Failure Code [#T0557]................................................................. 988 Failure Code [#T0558]................................................................. 989 Failure Code [#T0565]................................................................. 990 Failure Code [#T0566]................................................................. 992 Failure Code [#T0567]................................................................. 994 Failure Code [#T0568]................................................................. 996 Failure Code [#T0573]................................................................. 998 Failure Code [#T0574].................................................................1000 Failure Code [#T0575].................................................................1002 Failure Code [#T0576].................................................................1003 Failure Code [#T0577].................................................................1004 Failure Code [#T0578].................................................................1005 Failure Code [#T0579].................................................................1006 Failure Code [#T0580].................................................................1007 Failure Code [#T0581].................................................................1008 Failure Code [#T0582].................................................................1009 Failure Code [#T0583].................................................................1010 Failure Code [#T0584].................................................................1011 Failure Code [#T0585].................................................................1012 Failure Code [#T0586].................................................................1013 Failure Code [#T0587].................................................................1014 Failure Code [#T0588].................................................................1015 Failure Code [#T0589].................................................................1016 Failure Code [#T0590].................................................................1017 Failure Code [#T0591].................................................................1018 Failure Code [#T0592].................................................................1019 Failure Code [#T0593].................................................................1020 Failure Code [#T0594].................................................................1021 Failure Code [#T0595].................................................................1022 Failure Code [#T0596].................................................................1023 Failure Code [#T0597].................................................................1024 Failure Code [#T0598].................................................................1025 Failure Code [#T0599].................................................................1026 Failure Code [#T0600].................................................................1027 Failure Code [#T0601].................................................................1028 Failure Code [#T0602].................................................................1029 Failure Code [#T0603].................................................................1030 Failure Code [#T0604].................................................................1031 Failure Code [#T0605].................................................................1032 Failure Code [#T0606].................................................................1033 Failure Code [#T0607].................................................................1034 Failure Code [#T0608].................................................................1035 Failure Code [#T0609].................................................................1036 Failure Code [#T0610].................................................................1037 Failure Code [#T0611].................................................................1038 Failure Code [#T0612].................................................................1039 Failure Code [#T0613].................................................................1040 Failure Code [#T0614].................................................................1041 Failure Code [#T0615].................................................................1042 Failure Code [#T0616].................................................................1043 Failure Code [#T0617].................................................................1044 Failure Code [#T0618].................................................................1045 Failure Code [#T0619].................................................................1046 Failure Code [#T0620].................................................................1047 Failure Code [#T0621].................................................................1048 Failure Code [#T0622].................................................................1049 Failure Code [#T0623].................................................................1050 Failure Code [#T0624].................................................................1051 Failure Code [#T0625].................................................................1052 Failure Code [#T0626].................................................................1053 Failure Code [#T0627].................................................................1054 Failure Code [#T0628].................................................................1055 Failure Code [#T0630].................................................................1056 Failure Code [#T0631].................................................................1057 Failure Code [#T0632].................................................................1058 Failure Code [#T0633].................................................................1059 Failure Code [#T0634].................................................................1060 Failure Code [#T0635].................................................................1061 Failure Code [#T0636].................................................................1062 Failure Code [#T0637].................................................................1063 Failure Code [#T0638].................................................................1064 Failure Code [#T0639].................................................................1065 Failure Code [#T0640].................................................................1066 Failure Code [#T0641].................................................................1067 Failure Code [#T0642].................................................................1068 Failure Code [#T0643].................................................................1069 Failure Code [#T0644].................................................................1070 Failure Code [#T0645].................................................................1071 Failure Code [#T0646].................................................................1072 Failure Code [#T0647].................................................................1073 Failure Code [#T0648].................................................................1074 Failure Code [#T0649].................................................................1075 Failure Code [#T0650].................................................................1076 Failure Code [#T0651].................................................................1077 Failure Code [#T0652].................................................................1078 Failure Code [#T0653].................................................................1079 Failure Code [#T0654].................................................................1080 Failure Code [#T0655].................................................................1081 Failure Code [#T0656].................................................................1082 Failure Code [#T0657].................................................................1085 Failure Code [#T0658].................................................................1086 Failure Code [#T0659].................................................................1087 Failure Code [#T0660].................................................................1088 Failure Code [#T0661].................................................................1089 Failure Code [#T0662].................................................................1090 Failure Code [#T0663].................................................................1091 Failure Code [#T0664].................................................................1093 Failure Code [#T0665].................................................................1094 Failure Code [#T0666].................................................................1096 Failure Code [#T0667].................................................................1098 Failure Code [#T0669].................................................................1100 Failure Code [#T0670].................................................................1101 Failure Code [#T0672].................................................................1102 Failure Code [#T0673].................................................................1104 Failure Code [#T0674].................................................................1106 Failure Code [#T0675].................................................................1108 Failure Code [#T0676].................................................................1110 Failure Code [#T0677].................................................................1111 Failure Code [#T0678].................................................................1112 Failure Code [#T0679].................................................................1113 Failure Code [#T0680].................................................................1115 Failure Code [#T0682].................................................................1116 Failure Code [#T0683].................................................................1118 Failure Code [#T0684].................................................................1120 Failure Code [#T0685].................................................................1121 Failure Code [#T0686].................................................................1122 Failure Code [#T0687].................................................................1123 Failure Code [#T0688].................................................................1124 Failure Code [#T0689].................................................................1125 Failure Code [#T0690].................................................................1126 Failure Code [#T0691].................................................................1127 Failure Code [#T0692].................................................................1128 Failure Code [#T0693].................................................................1129 Failure Code [#T0694].................................................................1130 Failure Code [#T0695].................................................................1132 Failure Code [#T0696].................................................................1134 Failure Code [#T0697].................................................................1136 Failure Code [#T0698].................................................................1137 Failure Code [#T0699].................................................................1138 Failure Code [#T0700].................................................................1141 Failure Code [#T0701].................................................................1144 Failure Code [#T0702].................................................................1147 Failure Code [#T0703].................................................................1148 Failure Code [#T0704].................................................................1149 Failure Code [#T0705].................................................................1150 Failure Code [#T0706].................................................................1153 Failure Code [#T0707].................................................................1156 Failure Code [#T0708].................................................................1159 Failure Code [#T0709].................................................................1160 Failure Code [#T0710].................................................................1161 Failure Code [#T0711].................................................................1162 Failure Code [#T0712].................................................................1163 Failure Code [#T0713].................................................................1164 Failure Code [#T0714].................................................................1165 Failure Code [#T0715].................................................................1166 Failure Code [#T0716].................................................................1167 Failure Code [#T0717].................................................................1168 Failure Code [#T0718].................................................................1169 Failure Code [#T0719].................................................................1170 Failure Code [#T0720].................................................................1171 Failure Code [#T0721].................................................................1173 Failure Code [#T0722].................................................................1174 Failure Code [#T0723].................................................................1175 Failure Code [#T0724].................................................................1177 Failure Code [#T0725].................................................................1179 Failure Code [#T0726].................................................................1181 Failure Code [#T0728].................................................................1183 Failure Code [#T0729].................................................................1185 Failure Code [#T0730].................................................................1187 Failure Code [#T0731].................................................................1190 Failure Code [#T0732].................................................................1192 Failure Code [#T0733].................................................................1193 Failure Code [#T0734].................................................................1196 Failure Code [#T0740].................................................................1199 Failure Code [#T0742].................................................................1200 Failure Code [#T0743].................................................................1203 50 DISASSEMBLY AND ASSEMBLY...................................................................1207 CONTENTS..................................................................................1208 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................1212 HOW TO READ THIS MANUAL...............................................................1212 COATING MATERIALS LIST................................................................1214 ENGINE AND COOLING SYSTEM.................................................................1218 REMOVE AND INSTALL RADIATOR ASSEMBLY..................................................1218 REMOVE RADIATOR ASSEMBLY..........................................................1218 INSTALL RADIATOR ASSEMBLY.........................................................1221 REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY.............................................1223 REMOVE FAN CLUTCH ASSEMBLY........................................................1223 INSTALL FAN CLUTCH ASSEMBLY.......................................................1226 REMOVE AND INSTALL ENGINE.............................................................1227 REMOVE ENGINE.....................................................................1227 INSTALL ENGINE ASSEMBLY...........................................................1233 REMOVE AND INSTALL FUEL COOLER ASSEMBLY...............................................1235 REMOVE FUEL COOLER ASSEMBLY.......................................................1235 INSTALL FUEL COOLER ASSEMBLY......................................................1235 REMOVE AND INSTALL EXHAUST PIPE.......................................................1236 REMOVE EXHAUST PIPE...............................................................1236 INSTALL EXHAUST PIPE..............................................................1236 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY..............................................1237 REMOVE BELLOWS PIPE ASSEMBLY......................................................1237 INSTALL BELLOWS PIPE ASSEMBLY.....................................................1238 REMOVE AND INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC...........................1240 REMOVE NOx DETECTION SENSOR UPSTREAM OF THE DOC...................................1240 INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC..................................1240 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC.................1242 REMOVE KDOC INLET TEMPERATURE SENSOR..............................................1242 INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC........................1242 REMOVE AND INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.........................1244 REMOVE NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.................................1244 INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR................................1245 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR...............1246 REMOVE SCR OUTLET TEMPERATURE SENSOR..............................................1246 INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR......................1247 REMOVE AND INSTALL DOC ASSEMBLY.......................................................1248 REMOVE DOC ASSEMBLY...............................................................1248 INSTALL DOC ASSEMBLY..............................................................1251 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY....................................1253 REMOVE DEF TANK SENSOR FLANGE ASSEMBLY............................................1253 INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...........................................1257 REMOVE AND INSTALL DEF TANK SENSOR....................................................1258 REMOVE DEF TANK SENSOR............................................................1258 INSTALL DEF TANK SENSOR...........................................................1258 REMOVE AND INSTALL DEF TANK STRAINER..................................................1260 REMOVE DEF TANK STRAINER..........................................................1260 INSTALL DEF TANK STRAINER.........................................................1260 REMOVE AND INSTALL DEF INJECTOR.......................................................1261 REMOVE DEF INJECTOR...............................................................1261 INSTALL DEF INJECTOR..............................................................1263 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...............................................1267 REMOVE AIR CLEANER ASSEMBLY.......................................................1267 INSTALL AIR CLEANER ASSEMBLY......................................................1267 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................1268 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY.........................................1268 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................1269 REMOVE AND INSTALL AIR CONDITIONER BELT...............................................1270 REMOVE AIR CONDITIONER BELT.......................................................1270 INSTALL AIR CONDITIONER BELT......................................................1270 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR.........................................1271 REMOVE AIR CONDITIONER COMPRESSOR.................................................1271 INSTALL AIR CONDITIONER COMPRESSOR................................................1273 UNDERCARRIAGE AND FRAME...................................................................1274 REMOVE AND INSTALL ENGINE HOOD........................................................1274 REMOVE ENGINE HOOD................................................................1274 INSTALL ENGINE HOOD...............................................................1275 REMOVE AND INSTALL COUNTERWEIGHT......................................................1276 REMOVE COUNTERWEIGHT..............................................................1276 INSTALL COUNTERWEIGHT.............................................................1276 REMOVE AND INSTALL FRONT AND REAR WHEELS..............................................1278 REMOVE FRONT WHEELS...............................................................1278 INSTALL FRONT WHEELS..............................................................1278 REMOVE REAR WHEELS................................................................1278 INSTALL REAR WHEELS...............................................................1279 POWER TRAIN...............................................................................1280 REMOVE AND INSTALL FRONT AXLE.........................................................1280 REMOVE FRONT AXLE.................................................................1280 INSTALL FRONT AXLE................................................................1281 DISASSEMBLE AND ASSEMBLE FRONT AXLE...................................................1282 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1282 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1285 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1288 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1294 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP.......................................1303 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1305 DISASSEMBLE AND ASSEMBLE AXLE BEAM GROUP..........................................1312 DISASSEMBLE AND ASSEMBLE WHEEL AND DOUBLE U-JOINT GROUP...........................1315 TESTING AFTER ASSEMBLY............................................................1319 REMOVE AND INSTALL REAR AXLE..........................................................1320 REMOVE REAR AXLE..................................................................1320 INSTALL REAR AXLE.................................................................1321 DISASSEMBLE AND ASSEMBLE REAR AXLE....................................................1322 DISASSEMBLE AND ASSEMBLE BRAKE GROUP..............................................1322 DISASSEMBLE AND ASSEMBLE WHEEL HUB AND REDUCTION GEAR.............................1331 DISASSEMBLE AND ASSEMBLE PARKING BRAKE............................................1340 DISASSEMBLE AND ASSEMBLE PARKING BRAKE MECHANICAL CALIPER.........................1343 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1345 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL LOCKING GROUP...............................1353 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL.............................................1357 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1364 TESTING AFTER ASSEMBLY............................................................1371 REMOVE AND INSTALL TRANSMISSION.......................................................1372 REMOVE TRANSMISSION...............................................................1372 INSTALL TRANSMISSION..............................................................1377 DISASSEMBLE AND ASSEMBLE TRANSMISSION.................................................1378 DISASSEMBLE AND ASSEMBLE PLUGS AND FILTERS........................................1378 DISASSEMBLE AND ASSEMBLE CONVERTER AND OIL PUMP...................................1383 DISASSEMBLE AND ASSEMBLE PIPES....................................................1387 DISASSEMBLE AND ASSEMBLE HYDRAULIC CONTROL VALVE..................................1388 DISASSEMBLE AND ASSEMBLE 4WD SOLENOID VALVE.......................................1401 DISASSEMBLE AND ASSEMBLE TRANSMISSION HOUSING.....................................1404 DISASSEMBLE AND ASSEMBLE SHAFTS A - D.............................................1420 DISASSEMBLE AND ASSEMBLE SHAFTS B - C.............................................1437 DISASSEMBLE AND ASSEMBLE SHAFT E..................................................1453 HYDRAULIC SYSTEM..........................................................................1466 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................1466 REMOVE HYDRAULIC PUMP ASSEMBLY....................................................1466 INSTALL HYDRAULIC PUMP ASSEMBLY...................................................1468 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.........................1470 DISASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................1470 ASSEMBLY WORK EQUIPMENT PPC VALVE.................................................1470 WORK EQUIPMENT............................................................................1472 REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY.....................................1472 REMOVE LOADER WORK EQUIPMENT ASSEMBLY.............................................1472 INSTALL LOADER WORK EQUIPMENT ASSEMBLY............................................1474 REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY....................................1476 REMOVE BACKHOE WORK EQUIPMENT ASSEMBLY............................................1476 INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY...........................................1478 REMOVE AND INSTALL BACKHOE BOOM CYLINDER..............................................1479 REMOVE BACKHOE BOOM CYLINDER......................................................1479 INSTALL BACKHOE BOOM CYLINDER.....................................................1481 REMOVE AND INSTALL BACKHOE ARM CYLINDER...............................................1482 REMOVE BACKHOE ARM CYLINDER.......................................................1482 INSTALL BACKHOE ARM CYLINDER......................................................1483 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER....................................1484 REMOVE BACKHOE TELESCOPIC ARM CYLINDER............................................1484 INSTALL BACKHOE TELESCOPIC ARM CYLINDER...........................................1484 REMOVE AND INSTALL OUTRIGGER CYLINDER.................................................1485 REMOVE OUTRIGGER CYLINDER.........................................................1485 INSTALL OUTRIGGER CYLINDER........................................................1486 REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS.......................................1487 REMOVE BACKHOE BOOM SWING CYLINDERS...............................................1487 INSTALL BACKHOE BOOM SWING CYLINDERS..............................................1488 REMOVE AND INSTALL BACKHOE BUCKET CYLINDER............................................1489 REMOVE BACKHOE BUCKET CYLINDER....................................................1489 INSTALL BACKHOE BUCKET CYLINDER...................................................1489 REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER.........................................1491 REMOVE BACKHOE BOOM LOCK CYLINDER.................................................1491 INSTALL BACKHOE BOOM LOCK CYLINDER................................................1491 REMOVE AND INSTALL BACKHOE BOOM.......................................................1492 REMOVE BACKHOE BOOM...............................................................1492 INSTALL BACKHOE BOOM..............................................................1492 REMOVE AND INSTALL BACKHOE ARM ASSEMBLY...............................................1494 REMOVE BACKHOE ARM ASSEMBLY.......................................................1494 INSTALL BACKHOE ARM...............................................................1494 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY....................................1496 REMOVE BACKHOE TELESCOPIC ARM ASSEMBLY............................................1496 INSTALL BACKHOE TELESCOPIC ARM....................................................1496 REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET.........................................1498 REMOVE BACKHOE BOOM SWING BRACKET.................................................1498 INSTALL BACKHOE BOOM SWING BRACKET................................................1498 REMOVE AND INSTALL BACKHOE SLIDING BRACKET............................................1500 REMOVE BACKHOE SLIDING BRACKET....................................................1500 INSTALL BACKHOE SLIDING BRACKET...................................................1501 REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................1502 REMOVE BACKHOE SLIDING BRACKET LOCKING PISTON.....................................1502 INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON....................................1502 CAB AND ITS ATTACHMENTS...................................................................1504 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (MECHANICAL CONTROLS SPECIFICATION)........1504 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1504 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1512 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (HYDRAULIC CONTROLS SPECIFICATION).........1514 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1514 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1522 ELECTRICAL SYSTEM.........................................................................1524 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.........................................1524 REMOVE ENGINE CONTROLLER ASSEMBLY.................................................1524 INSTALL ENGINE CONTROLLER ASSEMBLY................................................1526 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...................................1527 REMOVE TRANSMISSION CONTROLLER ASSEMBLY...........................................1527 INSTALL TRANSMISSION CONTROLLER ASSEMBLY..........................................1529 REMOVE AND INSTALL FRONT PANEL........................................................1530 REMOVE FRONT PANEL................................................................1530 INSTALL FRONT PANEL...............................................................1531 REMOVE AND INSTALL STEERING COLUMN SWITCHES...........................................1532 REMOVE STEERING COLUMN SWITCHES...................................................1532 INSTALL STEERING COLUMN SWITCHES..................................................1533 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY..........................................1534 REMOVE KOMTRAX TERMINAL ASSEMBLY..................................................1534 INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................1534 REMOVE AND INSTALL BACKHOE PPC VALVE..................................................1536 REMOVE BACKHOE PPC VALVE..........................................................1536 INSTALL BACKHOE PPC VALVE.........................................................1537 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES...........................1538 REMOVE BACKHOE PPC VALVE SUPPORT RELEASE CABLES...................................1538 INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES..................................1539 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING........................1540 REMOVE BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING................................1540 INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRINGS..............................1541 60 MAINTENANCE STANDARD.......................................................................1543 CONTENTS..................................................................................1544 ENGINE AND COOLING SYSTEM.................................................................1545 MAINTENANCE STANDARD OF ENGINE MOUNT..................................................1545 MAINTENANCE STANDARD OF COOLING SYSTEM................................................1547 POWER TRAIN...............................................................................1548 MAINTENANCE STANDARD OF TRANSMISSION..................................................1548 MAINTENANCE STANDARD OF FRONT AXLE....................................................1551 MAINTENANCE STANDARD OF REAR AXLE.....................................................1556 HYDRAULIC SYSTEM..........................................................................1561 MAINTENANCE STANDARD OF MAIN PUMP.....................................................1561 MAINTENANCE STANDARD OF CONTROL VALVE (MECHANICAL CONTROLS SPECIFICATION).............1563 MAINTENANCE STANDARD OF CONTROL VALVE (HYDRAULIC CONTROLS SPECIFICATION)..............1573 WORK EQUIPMENT............................................................................1583 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE...............................1583 LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................................1583 LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.................1586 MAINTENANCE STANDARD OF SWING BRACKET.................................................1589 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT.........................................1591 MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT........................................1593 MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS......................................1595 LOADER ARM CYLINDER...............................................................1595 LOADER BUCKET CYLINDER............................................................1595 LOADER BUCKET 4 IN 1 CYLINDER.....................................................1596 BACKHOE BOOM CYLINDER.............................................................1597 BACKHOE ARM CYLINDER..............................................................1597 BACKHOE BUCKET CYLINDER...........................................................1598 BACKHOE BOOM SWING CYLINDER.......................................................1599 BACKHOE TELESCOPIC ARM CYLINDER...................................................1600 OUTRIGGER CYLINDER................................................................1600 90 CIRCUIT DIAGRAMS...........................................................................1603 CONTENTS..................................................................................1604 HOW TO READ THE CODES FOR ELECTRIC CABLE..................................................1605 HYDRAULIC CIRCUIT DIAGRAM.................................................................1609 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.............................................1609 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/2)....................................1613 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/2)....................................1615 ELECTRICAL CIRCUIT DIAGRAM................................................................1617 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM..............................................1617 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/12)..........................................1621 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/12)..........................................1623 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/12)..........................................1625 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/12)..........................................1627 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/12)..........................................1629 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/12)..........................................1631 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/12)..........................................1633 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/12)..........................................1635 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/12)..........................................1637 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/12).........................................1639 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/12).........................................1641 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/12).........................................1643
DESCRIPTION:
KOMATSU WB93R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00300 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams
S.S 21/12/24
