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KOMATSU WB93S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00320 – PDF DOWNLOAD
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KOMATSU WB93S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00320 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WB93S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00320 – PDF DOWNLOAD
Language : English
Pages : 1706
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WB93S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00320 – 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: WB93S-8E0.................................................. 87 SPECIFICATIONS........................................................................ 89 SPECIFICATIONS: WB93S-8E0......................................................... 89 WEIGHT TABLE.......................................................................... 90 WEIGHT TABLE: WB93S-8............................................................. 90 FUEL, COOLANT, LUBRICANTS............................................................. 92 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................. 92 10 STRUCTURE AND FUNCTION..................................................................... 95 CONTENTS.................................................................................. 96 UREA SCR SYSTEM........................................................................... 98 LAYOUT DRAWING OF UREA SCR SYSTEM..................................................... 98 UREA SCR SYSTEM DIAGRAM............................................................... 101 FUNCTION OF UREA SCR SYSTEM........................................................... 103 FUNCTION OF DEF SYSTEM............................................................ 103 INDUCEMENT STRATEGY............................................................... 104 COMPONENT PARTS OF UREA SCR SYSTEM.................................................... 111 DOC AND DEF MIXING TUBE........................................................... 111 DPF/SCR ASSEMBLY.................................................................. 113 DEF TANK.......................................................................... 115 DEF PUMP.......................................................................... 117 DEF INJECTOR...................................................................... 118 DEF HOSE.......................................................................... 119 DEF TANK HEATING VALVE............................................................ 120 HYDRAULIC SYSTEM.......................................................................... 121 LAYOUT DRAWING OF HYDRAULIC SYSTEM.................................................... 121 CLSS.................................................................................. 123 STRUCTURE OF CLSS................................................................. 123 FUNCTION OF CLSS.................................................................. 124 COMPONENT PARTS OF HYDRAULIC SYSTEM................................................... 126 HYDRAULIC TANK.................................................................... 126 MAIN PUMP......................................................................... 128 CONTROL VALVE..................................................................... 141 POWER TRAIN SYSTEM........................................................................ 184 LAYOUT DRAWING OF POWER TRAIN SYSTEM.................................................. 184 OPERATION OF POWER TRAIN SYSTEM....................................................... 186 COMPONENT PARTS OF POWER TRAIN SYSTEM................................................. 187 TRANSMISSION...................................................................... 187 DRIVE SHAFT....................................................................... 194 TRANSMISSION CONTROL VALVE........................................................ 196 AXLE.............................................................................. 197 OPERATION OF STEERING SYSTEM.......................................................... 208 WORK EQUIPMENT SYSTEM..................................................................... 212 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM............................................... 212 LOADER WORK EQUIPMENT PPC VALVE....................................................... 215 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 215 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 217 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 221 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 223 BACKHOE PPC VALVE..................................................................... 228 STRUCTURE OF LH BACKHOE PPC VALVE................................................. 228 STRUCTURE OF RH BACKHOE PPC VALVE................................................. 230 OUTRIGGER PPC VALVE................................................................... 232 STRUCTURE OF OUTRIGGER PPC VALVE.................................................. 232 OPERATION OF OUTRIGGER PPC VALVE.................................................. 233 STEERING UNIT......................................................................... 237 BRAKE PUMP............................................................................ 238 SOLENOID VALVES....................................................................... 239 SOLENOID VALVE GROUP (HYDRAULIC CONTROLS SPECIFICATION)........................... 239 SOLENOID VALVE GROUP (MECHANICAL CONTROLS SPECIFICATION).......................... 240 TELESCOPIC ARM SOLENOID VALVE..................................................... 240 SIDE DIGGING BOOM SOLENOID VALVE.................................................. 241 2-ATTACHMENT SOLENOID VALVE....................................................... 242 STEERING MODE SOLENOID VALVE...................................................... 243 HAMMER SOLENOID VALVE............................................................. 244 PPC CIRCUIT ACCUMULATOR............................................................... 245 SAFETY VALVES......................................................................... 246 LOADER ARM SAFETY VALVE........................................................... 246 LOADER BUCKET SAFETY VALVE........................................................ 247 BACKHOE BOOM SAFETY VALVE......................................................... 248 BACKHOE ARM SAFETY VALVE.......................................................... 249 OUTRIGGER SAFETY VALVE............................................................ 250 WORK EQUIPMENT............................................................................ 251 STRUCTURE OF LOADER WORK EQUIPMENT.................................................... 251 STRUCTURE OF BACKHOE WORK EQUIPMENT................................................... 252 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM.................................. 253 20 STANDARD VALUE TABLE....................................................................... 255 CONTENTS.................................................................................. 256 STANDARD VALUE TABLE FOR ENGINE........................................................... 257 STANDARD VALUE TABLE FOR ENGINE: WB93S-8E0............................................ 257 STANDARD VALUE TABLE FOR MACHINE.......................................................... 260 STANDARD VALUE TABLE FOR MACHINE: WB93S-8E0........................................... 260 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE................................. 280 30 TESTING AND ADJUSTING...................................................................... 287 CONTENTS.................................................................................. 288 ENGINE AND COOLING SYSTEM................................................................. 291 TEST VISUAL CHECK CRANKCASE SYSTEM.................................................... 291 TEST CHECK CYLINDER MECHANICS......................................................... 293 CHECK CYLINDER COMPRESSION........................................................ 293 CHECK CYLINDER PRESSURE LOSS...................................................... 294 TEST CHECK EGR VALVE ACTUATOR......................................................... 295 TEST CHECK EXTERNAL FUEL LEAKAGE ENGINE AREA.......................................... 297 TEST CHECK PRESSURE LIMITING VALVE (PLV) BACKFLOW RATE................................ 299 TEST CHECK TURBO SYSTEM............................................................... 301 TEST CHECK INTAKE AIR SYSTEM.......................................................... 303 TEST CHECK COOLING SYSTEM............................................................. 305 CHECK COOLANT TANK................................................................ 305 CHECK COOLANT TEMPERATURE SENSOR.................................................. 306 READ OUT COOLANT TEMPERATURE SENSOR VALUE......................................... 306 VISUALLY CHECK COOLING SYSTEM..................................................... 307 MECHANICALLY CHECK WATER PUMP..................................................... 307 FAN ACTIVATION CHECK.............................................................. 308 VISCO FAN ACTIVATION CHECK........................................................ 308 ENGINE TEMPERATURE ADJUSTMENT CHECK............................................... 308 CHECK PRESSURE BETWEEN MAIN FILTER AND HIGH PRESSURE PUMP............................. 310 TEST CHECK HIGH PRESSURE PUMP BACKFLOW RATE........................................... 313 TEST CHECK HIGH PRESSURE SYSTEM BACKFLOW RATE......................................... 315 PRESSURE TEST RAIL PRESSURE ADJUSTMENT CHECK.......................................... 317 PRESSURE TEST CHECK RAIL PRESSURE DURING RAIL......................................... 318 PRESSURE TEST CHECK PRESSURE BETWEEN GEAR PUMP AND MAIN FILTER........................ 319 TEST CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR................................. 321 VISUALLY CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR......................... 321 READ OUT INTAKE AIR PRESSURE SENSOR VALUE......................................... 321 PRESSURE TEST CHECK SUCTION PRESSURE BETWEEN TANK AND PRE-FILTER...................... 322 PRESSURE TEST CHECK SUCTION PRESSURE AFTER PRE-FILTER................................. 324 TEST CHECK WATER IN FUEL SENSOR PLAUSIBILITY.......................................... 326 TEST CHECK EXTERNAL FUEL LEAKAGE HIGH PRESSURE SYSTEM................................. 327 TEST CHECK SINGLE INJECTOR BACKFLOW RATE.............................................. 328 TEST INJECTOR CUT OUT ACTIVATION CHECK................................................ 330 TEST ENGINE SPEED..................................................................... 331 PREPARATION FOR TESTING ENGINE SPEED.............................................. 331 TEST ENGINE LOW IDLE SPEED........................................................ 331 TEST ENGINE HIGH IDLE SPEED....................................................... 331 TEST ENGINE LOW IDLE SPEED AT PUMP AT RELIEF...................................... 332 TEST ENGINE HIGH IDLE SPEED WITH TORQUE CONVERTER AT STALL........................ 332 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF AND TORQUE CONVERTER AT STALL..... 332 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)........... 333 TEST EXHAUST GAS COLOR................................................................ 334 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER..................................... 334 TEST EXHAUST GAS COLOR BY SMOKE METER............................................. 334 STEERING SYSTEM........................................................................... 336 CHECK LEAKAGES IN STEERING CYLINDER................................................... 336 TEST STEERING CIRCUIT OIL PRESSURE.................................................... 337 ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE.......................... 338 FRONT AXLE TOE-IN/STEERING ANGLE.................................................. 338 REAR AXLE TOE-IN/STEERING ANGLE................................................... 344 ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE.................. 350 STEERING ANGLE CHECKING AND ADJUSTMENT............................................ 350 BRAKE SYSTEM.............................................................................. 353 TEST BRAKE SYSTEM PRESSURE............................................................ 353 TEST BRAKE SYSTEM LEAKAGE............................................................. 355 TEST BRAKE PISTON STROKE.............................................................. 356 BLEED AIR FROM THE BRAKE CIRCUIT...................................................... 357 TEST AND ADJUST PARKING BRAKE SYSTEM.................................................. 358 TEST PARKING BRAKE................................................................ 358 ADJUST PARKING BRAKE.............................................................. 359 HYDRAULIC SYSTEM.......................................................................... 360 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................ 360 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.................................... 360 RELEASE REMAINING PRESSURE IN LOADER HYDRAULIC CYLINDER CIRCUIT................... 360 RELEASE REMAINING PRESSURE IN BACKHOE HYDRAULIC CYLINDER CIRCUIT.................. 360 TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE............................................ 361 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE........................................... 362 TEST AND ADJUST UNLOAD PRESSURE................................................... 365 TEST AND ADJUST RELIEF PRESSURE................................................... 365 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE) (MECHANICAL CONTROLS SPECIFICATION).... 366 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE) (HYDRAULIC CONTROLS SPECIFICATION)..... 366 ADJUST SECONDARY VALVE............................................................ 366 TEST BACKHOE BOOM OVERLOAD SWITCH................................................. 367 TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE.......................................... 368 TEST CONTROL CIRCUIT OIL PRESSURE................................................. 368 ADJUST CONTROL CIRCUIT OIL PRESSURE............................................... 368 MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE....................................... 369 MEASURE PUMP PC CONTROL OIL PRESSURE.............................................. 369 ADJUST PUMP PC CONTROL OIL PRESSURE............................................... 371 MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE....................................... 373 MEASURE PUMP LS CONTROL OIL PRESSURE.............................................. 373 ADJUST PUMP LS CONTROL OIL PRESSURE............................................... 374 TEST SOLENOID VALVE OUTLET PRESSURE................................................... 375 TEST PPC VALVE OUTLET PRESSURE........................................................ 376 ADJUST WORK EQUIPMENT PPC VALVES PLAY................................................. 378 TEST TRANSMISSION OIL PRESSURE........................................................ 379 TEST.............................................................................. 380 WORK AFTER FINISH TEST............................................................ 381 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT.......................... 382 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER ARM CYLINDER......................... 382 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER BUCKET CYLINDER...................... 382 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BOOM CYLINDER....................... 383 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE ARM CYLINDER........................ 383 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BUCKET CYLINDER..................... 383 TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM SWING CYLINDER......................... 383 BLEED AIR FROM HYDRAULIC SYSTEM....................................................... 384 BLEED AIR FROM HYDRAULIC PUMP..................................................... 384 BLEED AIR FROM CYLINDERS.......................................................... 384 WORK EQUIPMENT............................................................................ 386 OUTRIGGER SENSOR AND SAFETY SYSTEM.................................................... 386 CHECK AND ADJUST OUTRIGGER SENSOR................................................. 386 TEST CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM................................ 388 ADJUST RETURN TO DIG SENSOR........................................................... 389 ADJUST TELESCOPIC ARM GUIDE SLACK..................................................... 390 PREPARATION FOR ADJUSTING GUIDE SLACK............................................. 390 REGISTRATION OF GUIDE SLACK....................................................... 390 ELECTRICAL SYSTEM......................................................................... 392 SET AND OPERATE MACHINE MONITOR....................................................... 392 OPERATOR MODE..................................................................... 394 FAST CHECK FAILURE CODE WHEN NO PROMPT ARE VISIBLE................................ 394 SET USAGE LIMITATION AND CHANGE PASSWORD.......................................... 394 SERVICE MODE...................................................................... 397 OPERATE SERVICE MODE.............................................................. 397 CHECK PRE-DEFINED MONITORING INFORMATION.......................................... 397 ABNORMALITY RECORD MENU........................................................... 404 CHECK MAINTENANCE RECORD.......................................................... 405 MAINTENANCE MODE SETTING.......................................................... 407 SET PHONE NUMBER ENTRY............................................................ 411 DEFAULT SETTING MENU.............................................................. 413 START UP KOMTRAX TERMINAL............................................................. 415 LAMP DISPLAY OF KOMTRAX TERMINAL...................................................... 419 ADJUST FRONT PANEL SETTINGS........................................................... 422 PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................... 423 BATTERY DISCONNECT SWITCH............................................................. 424 TEST DIODES........................................................................... 425 TEST DIODES BY DIGITAL TESTER..................................................... 425 TEST DIODES BY ANALOG TESTER...................................................... 425 40 TROUBLESHOOTING............................................................................ 427 CONTENTS.................................................................................. 428 RELATED INFORMATION TO TROUBLESHOOT....................................................... 436 PRECAUTIONS FOR TROUBLESHOOTING....................................................... 436 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................. 437 GENERAL TROUBLESHOOTING POINTS........................................................ 439 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................ 440 CHECKS BEFORE TROUBLESHOOTING......................................................... 441 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING........................................... 443 WALK-AROUND CHECK................................................................. 443 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.......................................... 445 CHECK FUEL LEVEL AND TYPE......................................................... 445 CHECK WATER SEPARATOR AND DRAIN WATER AND SEDIMENT................................ 445 CHECK AdBlue(R) LEVEL AND TYPE.................................................... 447 REPLACE FUEL PREFILTER............................................................ 447 REPLACE FUEL MAIN FILTER.......................................................... 449 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE........................... 450 CHECK COOLANT LEVEL (EXPANSION TANK).............................................. 451 CHECK AIR CLEANER CLOGGING........................................................ 452 CLEAN OUTER ELEMENT............................................................... 452 REPLACE INNER ELEMENT............................................................. 454 CHECK HYDRAULIC OIL LEVEL......................................................... 455 CHECK HYDRAULIC OIL STRAINER...................................................... 456 REPLACE HYDRAULIC OIL FILTER...................................................... 458 CHECK OIL LEVEL IN TRANSMISSION CASE.............................................. 459 CHECK FRONT AXLE OIL LEVEL........................................................ 460 CHECK REAR AXLE OIL LEVEL......................................................... 460 BLEED AIR FROM SYSTEM............................................................. 461 CHECK ELECTRIC EQUIPMENT.............................................................. 462 CONNECTOR CONTACT IDENTIFICATION...................................................... 466 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................... 508 FUSE LOCATION TABLE................................................................... 514 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)......................................... 518 Failure Code [#T0022]................................................................. 518 Failure Code [#T0023]................................................................. 523 Failure Code [#T0037]................................................................. 528 Failure Code [#T0038]................................................................. 531 Failure Code [#T0039]................................................................. 535 Failure Code [#T0040]................................................................. 539 Failure Code [#T0041]................................................................. 543 Failure Code [#T0042]................................................................. 547 Failure Code [#T0043]................................................................. 550 Failure Code [#T0044]................................................................. 554 Failure Code [#T0045]................................................................. 558 Failure Code [#T0046]................................................................. 562 Failure Code [#T0055]................................................................. 566 Failure Code [#T0056]................................................................. 570 Failure Code [#T0057]................................................................. 571 Failure Code [#T0058]................................................................. 575 Failure Code [#T0061]................................................................. 579 Failure Code [#T0062]................................................................. 582 Failure Code [#T0068]................................................................. 585 Failure Code [#T0069]................................................................. 586 Failure Code [#T0073]................................................................. 588 Failure Code [#T0075]................................................................. 590 Failure Code [#T0077]................................................................. 591 Failure Code [#T0078]................................................................. 592 Failure Code [#T0079]................................................................. 594 Failure Code [#T0080]................................................................. 596 Failure Code [#T0081]................................................................. 598 Failure Code [#T0082]................................................................. 600 Failure Code [#T0083]................................................................. 601 Failure Code [#T0084]................................................................. 602 Failure Code [#T0085]................................................................. 603 Failure Code [#T0090]................................................................. 604 Failure Code [#T0091]................................................................. 607 Failure Code [#T0092]................................................................. 609 Failure Code [#T0093]................................................................. 610 Failure Code [#T0094]................................................................. 612 Failure Code [#T0103]................................................................. 614 Failure Code [#T0105]................................................................. 617 Failure Code [#T0108]................................................................. 620 Failure Code [#T0109]................................................................. 622 Failure Code [#T0110]................................................................. 624 Failure Code [#T0111]................................................................. 626 Failure Code [#T0112]................................................................. 628 Failure Code [#T0113]................................................................. 630 Failure Code [#T0114]................................................................. 632 Failure Code [#T0115]................................................................. 634 Failure Code [#T0116]................................................................. 636 Failure Code [#T0123]................................................................. 638 Failure Code [#T0124]................................................................. 639 Failure Code [#T0125]................................................................. 640 Failure Code [#T0126]................................................................. 641 Failure Code [#T0127]................................................................. 642 Failure Code [#T0128]................................................................. 643 Failure Code [#T0129]................................................................. 644 Failure Code [#T0147]................................................................. 645 Failure Code [#T0148]................................................................. 647 Failure Code [#T0151]................................................................. 649 Failure Code [#T0152]................................................................. 650 Failure Code [#T0168]................................................................. 651 Failure Code [#T0169]................................................................. 652 Failure Code [#T0170]................................................................. 653 Failure Code [#T0173]................................................................. 654 Failure Code [#T0174]................................................................. 655 Failure Code [#T0183]................................................................. 656 Failure Code [#T0185]................................................................. 657 Failure Code [#T0188]................................................................. 658 Failure Code [#T0191]................................................................. 659 Failure Code [#T0192]................................................................. 662 Failure Code [#T0193]................................................................. 663 Failure Code [#T0196]................................................................. 664 Failure Code [#T0198]................................................................. 665 Failure Code [#T0199]................................................................. 666 Failure Code [#T0200]................................................................. 667 Failure Code [#T0201]................................................................. 668 Failure Code [#T0204]................................................................. 669 Failure Code [#T0205]................................................................. 671 Failure Code [#T0207]................................................................. 672 Failure Code [#T0208]................................................................. 674 Failure Code [#T0209]................................................................. 676 Failure Code [#T0210]................................................................. 677 Failure Code [#T0211]................................................................. 678 Failure Code [#T0213]................................................................. 680 Failure Code [#T0215]................................................................. 681 Failure Code [#T0217]................................................................. 684 Failure Code [#T0219]................................................................. 685 Failure Code [#T0220]................................................................. 686 Failure Code [#T0221]................................................................. 687 Failure Code [#T0232]................................................................. 688 Failure Code [#T0236]................................................................. 689 Failure Code [#T0237]................................................................. 691 Failure Code [#T0238]................................................................. 693 Failure Code [#T0239]................................................................. 695 Failure Code [#T0240]................................................................. 697 Failure Code [#T0241]................................................................. 699 Failure Code [#T0242]................................................................. 701 Failure Code [#T0247]................................................................. 704 Failure Code [#T0248]................................................................. 707 Failure Code [#T0249]................................................................. 708 Failure Code [#T0251]................................................................. 711 Failure Code [#T0252]................................................................. 713 Failure Code [#T0254]................................................................. 715 Failure Code [#T0255]................................................................. 718 Failure Code [#T0256]................................................................. 720 Failure Code [#T0257]................................................................. 722 Failure Code [#T0258]................................................................. 723 Failure Code [#T0259]................................................................. 724 Failure Code [#T0260]................................................................. 725 Failure Code [#T0261]................................................................. 726 Failure Code [#T0262]................................................................. 727 Failure Code [#T0263]................................................................. 728 Failure Code [#T0264]................................................................. 729 Failure Code [#T0266]................................................................. 730 Failure Code [#T0267]................................................................. 731 Failure Code [#T0268]................................................................. 732 Failure Code [#T0269]................................................................. 733 Failure Code [#T0270]................................................................. 734 Failure Code [#T0272]................................................................. 735 Failure Code [#T0273]................................................................. 736 Failure Code [#T0274]................................................................. 737 Failure Code [#T0278]................................................................. 738 Failure Code [#T0279]................................................................. 740 Failure Code [#T0280]................................................................. 742 Failure Code [#T0281]................................................................. 743 Failure Code [#T0282]................................................................. 744 Failure Code [#T0283]................................................................. 745 Failure Code [#T0284]................................................................. 746 Failure Code [#T0285]................................................................. 748 Failure Code [#T0292]................................................................. 749 Failure Code [#T0293]................................................................. 751 Failure Code [#T0295]................................................................. 753 Failure Code [#T0303]................................................................. 755 Failure Code [#T0305]................................................................. 757 Failure Code [#T0308]................................................................. 758 Failure Code [#T0310]................................................................. 759 Failure Code [#T0311]................................................................. 760 Failure Code [#T0314]................................................................. 761 Failure Code [#T0318]................................................................. 762 Failure Code [#T0319]................................................................. 763 Failure Code [#T0320]................................................................. 764 Failure Code [#T0321]................................................................. 765 Failure Code [#T0322]................................................................. 767 Failure Code [#T0323]................................................................. 769 Failure Code [#T0324]................................................................. 771 Failure Code [#T0328]................................................................. 773 Failure Code [#T0329]................................................................. 775 Failure Code [#T0338]................................................................. 778 Failure Code [#T0339]................................................................. 780 Failure Code [#T0350]................................................................. 782 Failure Code [#T0356]................................................................. 784 Failure Code [#T0357]................................................................. 787 Failure Code [#T0400]................................................................. 790 Failure Code [#T0401]................................................................. 794 Failure Code [#T0402]................................................................. 798 Failure Code [#T0403]................................................................. 800 Failure Code [#T0404]................................................................. 802 Failure Code [#T0405]................................................................. 804 Failure Code [#T0406]................................................................. 805 Failure Code [#T0407]................................................................. 806 Failure Code [#T0408]................................................................. 808 Failure Code [#T0409]................................................................. 810 Failure Code [#T0410]................................................................. 812 Failure Code [#T0411]................................................................. 814 Failure Code [#T0412]................................................................. 815 Failure Code [#T0413]................................................................. 816 Failure Code [#T0414]................................................................. 818 Failure Code [#T0415]................................................................. 820 Failure Code [#T0416]................................................................. 821 Failure Code [#T0417]................................................................. 823 Failure Code [#T0418]................................................................. 825 Failure Code [#T0419]................................................................. 826 Failure Code [#T0420]................................................................. 829 Failure Code [#T0421]................................................................. 831 Failure Code [#T0422]................................................................. 833 Failure Code [#T0423]................................................................. 835 Failure Code [#T0424]................................................................. 837 Failure Code [#T0425]................................................................. 838 Failure Code [#T0426]................................................................. 840 Failure Code [#T0427]................................................................. 844 Failure Code [#T0428]................................................................. 846 Failure Code [#T0429]................................................................. 850 Failure Code [#T0430]................................................................. 851 Failure Code [#T0431]................................................................. 853 Failure Code [#T0432]................................................................. 855 Failure Code [#T0433]................................................................. 857 Failure Code [#T0434]................................................................. 859 Failure Code [#T0435]................................................................. 861 Failure Code [#T0436]................................................................. 863 Failure Code [#T0439]................................................................. 865 Failure Code [#T0440]................................................................. 867 Failure Code [#T0441]................................................................. 869 Failure Code [#T0442]................................................................. 872 Failure Code [#T0443]................................................................. 874 Failure Code [#T0444]................................................................. 876 Failure Code [#T0445]................................................................. 878 Failure Code [#T0446]................................................................. 879 Failure Code [#T0447]................................................................. 880 Failure Code [#T0448]................................................................. 881 Failure Code [#T0449]................................................................. 883 Failure Code [#T0450]................................................................. 885 Failure Code [#T0451]................................................................. 887 Failure Code [#T0452]................................................................. 889 Failure Code [#T0453]................................................................. 891 Failure Code [#T0454]................................................................. 893 Failure Code [#T0455]................................................................. 895 Failure Code [#T0456]................................................................. 897 Failure Code [#T0457]................................................................. 899 Failure Code [#T0458]................................................................. 901 Failure Code [#T0459]................................................................. 904 Failure Code [#T0460]................................................................. 906 Failure Code [#T0461]................................................................. 908 Failure Code [#T0462]................................................................. 909 Failure Code [#T0463]................................................................. 914 Failure Code [#T0464]................................................................. 915 Failure Code [#T0465]................................................................. 916 Failure Code [#T0466]................................................................. 917 Failure Code [#T0467]................................................................. 920 Failure Code [#T0468]................................................................. 923 Failure Code [#T0469]................................................................. 926 Failure Code [#T0470]................................................................. 929 Failure Code [#T0500]................................................................. 932 Failure Code [#T0501]................................................................. 933 Failure Code [#T0502]................................................................. 934 Failure Code [#T0504]................................................................. 935 Failure Code [#T0508]................................................................. 939 Failure Code [#T0509]................................................................. 941 Failure Code [#T0510]................................................................. 942 Failure Code [#T0511]................................................................. 946 Failure Code [#T0512]................................................................. 950 Failure Code [#T0513]................................................................. 954 Failure Code [#T0517]................................................................. 958 Failure Code [#T0519]................................................................. 959 Failure Code [#T0520]................................................................. 961 Failure Code [#T0521]................................................................. 965 Failure Code [#T0522]................................................................. 969 Failure Code [#T0530]................................................................. 973 Failure Code [#T0531]................................................................. 974 Failure Code [#T0532]................................................................. 975 Failure Code [#T0533]................................................................. 980 Failure Code [#T0534]................................................................. 981 Failure Code [#T0535]................................................................. 986 Failure Code [#T0536]................................................................. 991 Failure Code [#T0537]................................................................. 996 Failure Code [#T0538]................................................................. 997 Failure Code [#T0539]................................................................. 999 Failure Code [#T0540].................................................................1000 Failure Code [#T0541].................................................................1001 Failure Code [#T0542].................................................................1003 Failure Code [#T0543].................................................................1004 Failure Code [#T0544].................................................................1005 Failure Code [#T0545].................................................................1006 Failure Code [#T0546].................................................................1007 Failure Code [#T0547].................................................................1009 Failure Code [#T0550].................................................................1011 Failure Code [#T0551].................................................................1012 Failure Code [#T0555].................................................................1014 Failure Code [#T0556].................................................................1017 Failure Code [#T0557].................................................................1018 Failure Code [#T0558].................................................................1019 Failure Code [#T0565].................................................................1020 Failure Code [#T0566].................................................................1022 Failure Code [#T0567].................................................................1024 Failure Code [#T0568].................................................................1026 Failure Code [#T0573].................................................................1028 Failure Code [#T0574].................................................................1030 Failure Code [#T0575].................................................................1032 Failure Code [#T0576].................................................................1033 Failure Code [#T0577].................................................................1034 Failure Code [#T0578].................................................................1035 Failure Code [#T0579].................................................................1036 Failure Code [#T0580].................................................................1037 Failure Code [#T0581].................................................................1038 Failure Code [#T0582].................................................................1039 Failure Code [#T0583].................................................................1040 Failure Code [#T0584].................................................................1041 Failure Code [#T0585].................................................................1042 Failure Code [#T0586].................................................................1043 Failure Code [#T0587].................................................................1044 Failure Code [#T0588].................................................................1045 Failure Code [#T0589].................................................................1046 Failure Code [#T0590].................................................................1047 Failure Code [#T0591].................................................................1048 Failure Code [#T0592].................................................................1049 Failure Code [#T0593].................................................................1050 Failure Code [#T0594].................................................................1051 Failure Code [#T0595].................................................................1052 Failure Code [#T0596].................................................................1053 Failure Code [#T0597].................................................................1054 Failure Code [#T0598].................................................................1055 Failure Code [#T0599].................................................................1056 Failure Code [#T0600].................................................................1057 Failure Code [#T0601].................................................................1058 Failure Code [#T0602].................................................................1059 Failure Code [#T0603].................................................................1060 Failure Code [#T0604].................................................................1061 Failure Code [#T0605].................................................................1062 Failure Code [#T0606].................................................................1063 Failure Code [#T0607].................................................................1064 Failure Code [#T0608].................................................................1065 Failure Code [#T0609].................................................................1066 Failure Code [#T0610].................................................................1067 Failure Code [#T0611].................................................................1068 Failure Code [#T0612].................................................................1069 Failure Code [#T0613].................................................................1070 Failure Code [#T0614].................................................................1071 Failure Code [#T0615].................................................................1072 Failure Code [#T0616].................................................................1073 Failure Code [#T0617].................................................................1074 Failure Code [#T0618].................................................................1075 Failure Code [#T0619].................................................................1076 Failure Code [#T0620].................................................................1077 Failure Code [#T0621].................................................................1078 Failure Code [#T0622].................................................................1079 Failure Code [#T0623].................................................................1080 Failure Code [#T0624].................................................................1081 Failure Code [#T0625].................................................................1082 Failure Code [#T0626].................................................................1083 Failure Code [#T0627].................................................................1084 Failure Code [#T0628].................................................................1085 Failure Code [#T0630].................................................................1086 Failure Code [#T0631].................................................................1087 Failure Code [#T0632].................................................................1088 Failure Code [#T0633].................................................................1089 Failure Code [#T0634].................................................................1090 Failure Code [#T0635].................................................................1091 Failure Code [#T0636].................................................................1092 Failure Code [#T0637].................................................................1093 Failure Code [#T0638].................................................................1094 Failure Code [#T0639].................................................................1095 Failure Code [#T0640].................................................................1096 Failure Code [#T0641].................................................................1097 Failure Code [#T0642].................................................................1098 Failure Code [#T0643].................................................................1099 Failure Code [#T0644].................................................................1100 Failure Code [#T0645].................................................................1101 Failure Code [#T0646].................................................................1102 Failure Code [#T0647].................................................................1103 Failure Code [#T0648].................................................................1104 Failure Code [#T0649].................................................................1105 Failure Code [#T0650].................................................................1106 Failure Code [#T0651].................................................................1107 Failure Code [#T0652].................................................................1108 Failure Code [#T0653].................................................................1109 Failure Code [#T0654].................................................................1110 Failure Code [#T0655].................................................................1111 Failure Code [#T0656].................................................................1112 Failure Code [#T0657].................................................................1115 Failure Code [#T0658].................................................................1116 Failure Code [#T0659].................................................................1117 Failure Code [#T0660].................................................................1118 Failure Code [#T0661].................................................................1119 Failure Code [#T0662].................................................................1120 Failure Code [#T0663].................................................................1121 Failure Code [#T0664].................................................................1123 Failure Code [#T0665].................................................................1124 Failure Code [#T0666].................................................................1126 Failure Code [#T0667].................................................................1128 Failure Code [#T0669].................................................................1130 Failure Code [#T0670].................................................................1131 Failure Code [#T0672].................................................................1132 Failure Code [#T0673].................................................................1134 Failure Code [#T0674].................................................................1136 Failure Code [#T0675].................................................................1138 Failure Code [#T0676].................................................................1140 Failure Code [#T0677].................................................................1141 Failure Code [#T0678].................................................................1142 Failure Code [#T0679].................................................................1143 Failure Code [#T0680].................................................................1145 Failure Code [#T0682].................................................................1146 Failure Code [#T0683].................................................................1148 Failure Code [#T0684].................................................................1150 Failure Code [#T0685].................................................................1151 Failure Code [#T0686].................................................................1152 Failure Code [#T0687].................................................................1153 Failure Code [#T0688].................................................................1154 Failure Code [#T0689].................................................................1155 Failure Code [#T0690].................................................................1156 Failure Code [#T0691].................................................................1157 Failure Code [#T0692].................................................................1158 Failure Code [#T0693].................................................................1159 Failure Code [#T0694].................................................................1160 Failure Code [#T0695].................................................................1162 Failure Code [#T0696].................................................................1164 Failure Code [#T0697].................................................................1166 Failure Code [#T0698].................................................................1167 Failure Code [#T0699].................................................................1168 Failure Code [#T0700].................................................................1171 Failure Code [#T0701].................................................................1174 Failure Code [#T0702].................................................................1177 Failure Code [#T0703].................................................................1178 Failure Code [#T0704].................................................................1179 Failure Code [#T0705].................................................................1180 Failure Code [#T0706].................................................................1183 Failure Code [#T0707].................................................................1186 Failure Code [#T0708].................................................................1189 Failure Code [#T0709].................................................................1190 Failure Code [#T0710].................................................................1191 Failure Code [#T0711].................................................................1192 Failure Code [#T0712].................................................................1193 Failure Code [#T0713].................................................................1194 Failure Code [#T0714].................................................................1195 Failure Code [#T0715].................................................................1196 Failure Code [#T0716].................................................................1197 Failure Code [#T0717].................................................................1198 Failure Code [#T0718].................................................................1199 Failure Code [#T0719].................................................................1200 Failure Code [#T0720].................................................................1201 Failure Code [#T0721].................................................................1203 Failure Code [#T0722].................................................................1204 Failure Code [#T0723].................................................................1205 Failure Code [#T0724].................................................................1207 Failure Code [#T0725].................................................................1209 Failure Code [#T0726].................................................................1211 Failure Code [#T0728].................................................................1213 Failure Code [#T0729].................................................................1215 Failure Code [#T0730].................................................................1217 Failure Code [#T0731].................................................................1220 Failure Code [#T0732].................................................................1222 Failure Code [#T0733].................................................................1223 Failure Code [#T0734].................................................................1226 Failure Code [#T0740].................................................................1229 Failure Code [#T0742].................................................................1230 Failure Code [#T0743].................................................................1233 FAILURE CODE TABLE........................................................................1236 TRANSMISSION AND STEERING ECU FAILURE CODE TABLE......................................1236 MACHINE ECU FAILURE CODE TABLE........................................................1238 MONITOR ECU FAILURE CODE TABLE........................................................1241 50 DISASSEMBLY AND ASSEMBLY...................................................................1243 CONTENTS..................................................................................1244 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................1248 HOW TO READ THIS MANUAL...............................................................1248 COATING MATERIALS LIST................................................................1250 ENGINE AND COOLING SYSTEM.................................................................1254 REMOVE AND INSTALL RADIATOR ASSEMBLY..................................................1254 REMOVE RADIATOR ASSEMBLY..........................................................1254 INSTALL RADIATOR ASSEMBLY.........................................................1257 REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY.............................................1259 REMOVE FAN CLUTCH ASSEMBLY........................................................1259 INSTALL FAN CLUTCH ASSEMBLY.......................................................1262 REMOVE AND INSTALL ENGINE.............................................................1263 REMOVE ENGINE.....................................................................1263 INSTALL ENGINE ASSEMBLY...........................................................1269 REMOVE AND INSTALL FUEL COOLER ASSEMBLY...............................................1271 REMOVE FUEL COOLER ASSEMBLY.......................................................1271 INSTALL FUEL COOLER ASSEMBLY......................................................1271 REMOVE AND INSTALL EXHAUST PIPE.......................................................1272 REMOVE EXHAUST PIPE...............................................................1272 INSTALL EXHAUST PIPE..............................................................1272 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY..............................................1273 REMOVE BELLOWS PIPE ASSEMBLY......................................................1273 INSTALL BELLOWS PIPE ASSEMBLY.....................................................1274 REMOVE AND INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC...........................1276 REMOVE NOx DETECTION SENSOR UPSTREAM OF THE DOC...................................1276 INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC..................................1276 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC.................1278 REMOVE KDOC INLET TEMPERATURE SENSOR..............................................1278 INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC........................1278 REMOVE AND INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.........................1280 REMOVE NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.................................1280 INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR................................1281 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR...............1282 REMOVE SCR OUTLET TEMPERATURE SENSOR..............................................1282 INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR......................1283 REMOVE AND INSTALL DOC ASSEMBLY.......................................................1284 REMOVE DOC ASSEMBLY...............................................................1284 INSTALL DOC ASSEMBLY..............................................................1287 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY....................................1289 REMOVE DEF TANK SENSOR FLANGE ASSEMBLY............................................1289 INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...........................................1293 REMOVE AND INSTALL DEF TANK SENSOR....................................................1294 REMOVE DEF TANK SENSOR............................................................1294 INSTALL DEF TANK SENSOR...........................................................1294 REMOVE AND INSTALL DEF TANK STRAINER..................................................1296 REMOVE DEF TANK STRAINER..........................................................1296 INSTALL DEF TANK STRAINER.........................................................1296 REMOVE AND INSTALL DEF INJECTOR.......................................................1297 REMOVE DEF INJECTOR...............................................................1297 INSTALL DEF INJECTOR..............................................................1299 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...............................................1303 REMOVE AIR CLEANER ASSEMBLY.......................................................1303 INSTALL AIR CLEANER ASSEMBLY......................................................1303 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................1304 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY.........................................1304 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................1305 REMOVE AND INSTALL AIR CONDITIONER BELT...............................................1306 REMOVE AIR CONDITIONER BELT.......................................................1306 INSTALL AIR CONDITIONER BELT......................................................1306 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR.........................................1307 REMOVE AIR CONDITIONER COMPRESSOR.................................................1307 INSTALL AIR CONDITIONER COMPRESSOR................................................1309 UNDERCARRIAGE AND FRAME...................................................................1310 REMOVE AND INSTALL ENGINE HOOD........................................................1310 REMOVE ENGINE HOOD................................................................1310 INSTALL ENGINE HOOD...............................................................1311 REMOVE AND INSTALL COUNTERWEIGHT......................................................1312 REMOVE COUNTERWEIGHT..............................................................1312 INSTALL COUNTERWEIGHT.............................................................1312 REMOVE AND INSTALL FRONT AND REAR WHEELS..............................................1314 REMOVE FRONT AND REAR WHEELS......................................................1314 INSTALL FRONT AND REAR WHEELS.....................................................1314 POWER TRAIN...............................................................................1315 REMOVE AND INSTALL FRONT AXLE.........................................................1315 REMOVE FRONT AXLE.................................................................1315 INSTALL FRONT AXLE................................................................1316 DISASSEMBLE AND ASSEMBLE FRONT AXLE...................................................1318 DISASSEMBLE AND ASSEMBLE FLANGE GROUP.............................................1318 DISASSEMBLE AND ASSEMBLE TRUNNIONS GROUP..........................................1320 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1325 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1332 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1335 DISASSEMBLE AND ASSEMBLE AXLE BEAM GROUP..........................................1343 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1345 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP (LS)..................................1354 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1356 TESTING AFTER ASSEMBLY............................................................1363 REMOVE AND INSTALL REAR AXLE..........................................................1364 REMOVE REAR AXLE..................................................................1364 INSTALL REAR AXLE.................................................................1365 DISASSEMBLE AND ASSEMBLE REAR AXLE....................................................1367 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1367 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1377 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1380 DISASSEMBLE AND ASSEMBLE FLANGE GROUP.............................................1387 DISASSEMBLE AND ASSEMBLE AXLE BEAM TRUMPET GROUP..................................1389 DISASSEMBLE AND ASSEMBLE BRAKE GROUP..............................................1394 DISASSEMBLE AND ASSEMBLE BRAKE CONTROL GROUP......................................1399 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1408 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP.......................................1416 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1419 TESTING AFTER ASSEMBLY............................................................1426 REMOVE AND INSTALL TRANSMISSION.......................................................1427 REMOVE TRANSMISSION...............................................................1427 INSTALL TRANSMISSION..............................................................1432 DISASSEMBLE AND ASSEMBLE TRANSMISSION.................................................1433 DISASSEMBLE AND ASSEMBLE PLUGS AND FILTERS........................................1433 DISASSEMBLE AND ASSEMBLE CONVERTER AND OIL PUMP...................................1438 DISASSEMBLE AND ASSEMBLE PIPES....................................................1442 DISASSEMBLE AND ASSEMBLE HYDRAULIC CONTROL VALVE..................................1443 DISASSEMBLE AND ASSEMBLE 4WD SOLENOID VALVE.......................................1456 DISASSEMBLE AND ASSEMBLE TRANSMISSION HOUSING.....................................1459 DISASSEMBLE AND ASSEMBLE SHAFTS A - D.............................................1475 DISASSEMBLE AND ASSEMBLE SHAFTS B - C.............................................1492 DISASSEMBLE AND ASSEMBLE SHAFT E..................................................1508 HYDRAULIC SYSTEM..........................................................................1521 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................1521 REMOVE HYDRAULIC PUMP ASSEMBLY....................................................1521 INSTALL HYDRAULIC PUMP ASSEMBLY...................................................1523 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.........................1525 DISASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................1525 ASSEMBLY WORK EQUIPMENT PPC VALVE.................................................1525 WORK EQUIPMENT............................................................................1527 REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY.....................................1527 REMOVE LOADER WORK EQUIPMENT ASSEMBLY.............................................1527 INSTALL LOADER WORK EQUIPMENT ASSEMBLY............................................1529 REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY....................................1531 REMOVE BACKHOE WORK EQUIPMENT ASSEMBLY............................................1531 INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY...........................................1533 REMOVE AND INSTALL BACKHOE BOOM CYLINDER..............................................1534 REMOVE BACKHOE BOOM CYLINDER......................................................1534 INSTALL BACKHOE BOOM CYLINDER.....................................................1536 REMOVE AND INSTALL BACKHOE ARM CYLINDER...............................................1537 REMOVE BACKHOE ARM CYLINDER.......................................................1537 INSTALL BACKHOE ARM CYLINDER......................................................1538 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER....................................1539 REMOVE BACKHOE TELESCOPIC ARM CYLINDER............................................1539 INSTALL BACKHOE TELESCOPIC ARM CYLINDER...........................................1539 REMOVE AND INSTALL OUTRIGGER CYLINDER.................................................1540 REMOVE OUTRIGGER CYLINDER.........................................................1540 INSTALL OUTRIGGER CYLINDER........................................................1541 REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS.......................................1542 REMOVE BACKHOE BOOM SWING CYLINDERS...............................................1542 INSTALL BACKHOE BOOM SWING CYLINDERS..............................................1543 REMOVE AND INSTALL BACKHOE BUCKET CYLINDER............................................1544 REMOVE BACKHOE BUCKET CYLINDER....................................................1544 INSTALL BACKHOE BUCKET CYLINDER...................................................1544 REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER.........................................1546 REMOVE BACKHOE BOOM LOCK CYLINDER.................................................1546 INSTALL BACKHOE BOOM LOCK CYLINDER................................................1546 REMOVE AND INSTALL BACKHOE BOOM.......................................................1547 REMOVE BACKHOE BOOM...............................................................1547 INSTALL BACKHOE BOOM..............................................................1547 REMOVE AND INSTALL BACKHOE ARM ASSEMBLY...............................................1549 REMOVE BACKHOE ARM ASSEMBLY.......................................................1549 INSTALL BACKHOE ARM...............................................................1549 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY....................................1551 REMOVE BACKHOE TELESCOPIC ARM ASSEMBLY............................................1551 INSTALL BACKHOE TELESCOPIC ARM....................................................1551 REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET.........................................1553 REMOVE BACKHOE BOOM SWING BRACKET.................................................1553 INSTALL BACKHOE BOOM SWING BRACKET................................................1553 REMOVE AND INSTALL BACKHOE SLIDING BRACKET............................................1555 REMOVE BACKHOE SLIDING BRACKET....................................................1555 INSTALL BACKHOE SLIDING BRACKET...................................................1556 REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................1557 REMOVE BACKHOE SLIDING BRACKET LOCKING PISTON.....................................1557 INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON....................................1557 CAB AND ITS ATTACHMENTS...................................................................1559 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (MECHANICAL CONTROLS SPECIFICATION)........1559 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1559 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1567 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (HYDRAULIC CONTROLS SPECIFICATION).........1569 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1569 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1577 ELECTRICAL SYSTEM.........................................................................1579 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.........................................1579 REMOVE ENGINE CONTROLLER ASSEMBLY.................................................1579 INSTALL ENGINE CONTROLLER ASSEMBLY................................................1581 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...................................1582 REMOVE TRANSMISSION CONTROLLER ASSEMBLY...........................................1582 INSTALL TRANSMISSION CONTROLLER ASSEMBLY..........................................1584 REMOVE AND INSTALL FRONT PANEL........................................................1585 REMOVE FRONT PANEL................................................................1585 INSTALL FRONT PANEL...............................................................1586 REMOVE AND INSTALL STEERING COLUMN SWITCHES...........................................1587 REMOVE STEERING COLUMN SWITCHES...................................................1587 INSTALL STEERING COLUMN SWITCHES..................................................1588 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY..........................................1589 REMOVE KOMTRAX TERMINAL ASSEMBLY..................................................1589 INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................1589 REMOVE AND INSTALL BACKHOE PPC VALVE..................................................1591 REMOVE BACKHOE PPC VALVE..........................................................1591 INSTALL BACKHOE PPC VALVE.........................................................1592 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES...........................1593 REMOVE BACKHOE PPC VALVE SUPPORT RELEASE CABLES...................................1593 INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES..................................1594 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING........................1595 REMOVE BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING................................1595 INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRINGS..............................1596 60 MAINTENANCE STANDARD.......................................................................1597 CONTENTS..................................................................................1598 ENGINE AND COOLING SYSTEM.................................................................1599 MAINTENANCE STANDARD OF ENGINE MOUNT..................................................1599 MAINTENANCE STANDARD OF COOLING SYSTEM................................................1601 POWER TRAIN...............................................................................1602 MAINTENANCE STANDARD OF TRANSMISSION..................................................1602 MAINTENANCE STANDARD OF FRONT AXLE....................................................1605 MAINTENANCE STANDARD OF REAR AXLE.....................................................1611 HYDRAULIC SYSTEM..........................................................................1621 MAINTENANCE STANDARD OF MAIN PUMP.....................................................1621 MAINTENANCE STANDARD OF CONTROL VALVE (MECHANICAL CONTROLS SPECIFICATION).............1623 MAINTENANCE STANDARD OF CONTROL VALVE (HYDRAULIC CONTROLS SPECIFICATION)..............1633 WORK EQUIPMENT............................................................................1643 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE...............................1643 LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................................1643 LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.................1646 MAINTENANCE STANDARD OF SWING BRACKET.................................................1649 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT.........................................1651 MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT........................................1653 MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS......................................1655 LOADER ARM CYLINDER...............................................................1655 LOADER BUCKET CYLINDER............................................................1655 LOADER BUCKET 4 IN 1 CYLINDER.....................................................1656 BACKHOE BOOM CYLINDER.............................................................1657 BACKHOE ARM CYLINDER..............................................................1657 BACKHOE BUCKET CYLINDER...........................................................1658 BACKHOE BOOM SWING CYLINDER.......................................................1659 BACKHOE TELESCOPIC ARM CYLINDER...................................................1660 OUTRIGGER CYLINDER................................................................1660 90 CIRCUIT DIAGRAMS...........................................................................1663 CONTENTS..................................................................................1664 HOW TO READ THE CODES FOR ELECTRIC CABLE..................................................1665 HYDRAULIC CIRCUIT DIAGRAM.................................................................1669 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.............................................1669 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/2)....................................1673 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/2)....................................1675 ELECTRICAL CIRCUIT DIAGRAM................................................................1677 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM..............................................1677 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/12)..........................................1681 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/12)..........................................1683 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/12)..........................................1685 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/12)..........................................1687 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/12)..........................................1689 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/12)..........................................1691 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/12)..........................................1693 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/12)..........................................1695 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/12)..........................................1697 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/12).........................................1699 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/12).........................................1701 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/12).........................................1703
DESCRIPTION:
KOMATSU WB93S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00320 – 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.
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