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KOMATSU WB97R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00340 – PDF DOWNLOAD
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KOMATSU WB97R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00340 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WB97R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00340 – PDF DOWNLOAD
Language : English
Pages : 1650
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WB97R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00340 – 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: WB97R-8E0.................................................. 87 SPECIFICATIONS........................................................................ 89 SPECIFICATIONS: WB97R-8E0......................................................... 89 WEIGHT TABLE.......................................................................... 91 WEIGHT TABLE: WB97R-8E0........................................................... 91 FUEL, COOLANT, LUBRICANTS............................................................. 93 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................. 93 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........................................................................ 171 LAYOUT DRAWING OF POWER TRAIN SYSTEM.................................................. 171 OPERATION OF POWER TRAIN SYSTEM....................................................... 173 COMPONENT PARTS OF POWER TRAIN SYSTEM................................................. 174 TRANSMISSION...................................................................... 174 DRIVE SHAFT....................................................................... 184 TRANSMISSION CONTROL VALVE........................................................ 187 AXLE.............................................................................. 189 WORK EQUIPMENT SYSTEM..................................................................... 199 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM............................................... 199 LOADER WORK EQUIPMENT PPC VALVE....................................................... 202 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 202 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 204 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 208 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 210 BACKHOE PPC VALVE..................................................................... 215 STRUCTURE OF LH BACKHOE PPC VALVE................................................. 215 STRUCTURE OF RH BACKHOE PPC VALVE................................................. 217 OUTRIGGER PPC VALVE................................................................... 219 STRUCTURE OF OUTRIGGER PPC VALVE.................................................. 219 OPERATION OF OUTRIGGER PPC VALVE.................................................. 220 STEERING UNIT......................................................................... 224 BRAKE PUMP............................................................................ 225 SOLENOID VALVES....................................................................... 226 SOLENOID VALVE GROUP.............................................................. 226 TELESCOPIC ARM SOLENOID VALVE..................................................... 227 SIDE DIGGING BOOM SOLENOID VALVE.................................................. 228 2-ATTACHMENT SOLENOID VALVE....................................................... 229 STEERING MODE SOLENOID VALVE...................................................... 230 HAMMER SOLENOID VALVE............................................................. 231 PPC CIRCUIT ACCUMULATOR............................................................... 232 SAFETY VALVES......................................................................... 233 LOADER ARM SAFETY VALVE........................................................... 233 LOADER BUCKET SAFETY VALVE........................................................ 234 BACKHOE BOOM SAFETY VALVE......................................................... 235 BACKHOE ARM SAFETY VALVE.......................................................... 236 OUTRIGGER SAFETY VALVE............................................................ 237 WORK EQUIPMENT............................................................................ 238 STRUCTURE OF LOADER WORK EQUIPMENT.................................................... 238 STRUCTURE OF BACKHOE WORK EQUIPMENT................................................... 239 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM.................................. 240 20 STANDARD VALUE TABLE....................................................................... 241 CONTENTS.................................................................................. 242 STANDARD VALUE TABLE FOR ENGINE........................................................... 243 STANDARD VALUE TABLE FOR ENGINE: WB97R-8E0............................................ 243 STANDARD VALUE TABLE FOR MACHINE.......................................................... 246 STANDARD VALUE TABLE FOR MACHINE: WB97R-8E0........................................... 246 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE................................. 266 30 TESTING AND ADJUSTING...................................................................... 273 CONTENTS.................................................................................. 274 ENGINE AND COOLING SYSTEM................................................................. 277 TEST VISUAL CHECK CRANKCASE SYSTEM.................................................... 277 TEST CHECK CYLINDER MECHANICS......................................................... 279 CHECK CYLINDER COMPRESSION........................................................ 279 CHECK CYLINDER PRESSURE LOSS...................................................... 280 TEST CHECK EGR VALVE ACTUATOR......................................................... 281 TEST CHECK EXTERNAL FUEL LEAKAGE ENGINE AREA.......................................... 283 TEST CHECK PRESSURE LIMITING VALVE (PLV) BACKFLOW RATE................................ 285 TEST CHECK TURBO SYSTEM............................................................... 287 TEST CHECK INTAKE AIR SYSTEM.......................................................... 289 TEST CHECK COOLING SYSTEM............................................................. 291 CHECK COOLANT TANK................................................................ 291 CHECK COOLANT TEMPERATURE SENSOR.................................................. 292 READ OUT COOLANT TEMPERATURE SENSOR VALUE......................................... 292 VISUALLY CHECK COOLING SYSTEM..................................................... 293 MECHANICALLY CHECK WATER PUMP..................................................... 293 FAN ACTIVATION CHECK.............................................................. 294 VISCO FAN ACTIVATION CHECK........................................................ 294 ENGINE TEMPERATURE ADJUSTMENT CHECK............................................... 294 CHECK PRESSURE BETWEEN MAIN FILTER AND HIGH PRESSURE PUMP............................. 296 TEST CHECK HIGH PRESSURE PUMP BACKFLOW RATE........................................... 299 TEST CHECK HIGH PRESSURE SYSTEM BACKFLOW RATE......................................... 301 PRESSURE TEST RAIL PRESSURE ADJUSTMENT CHECK.......................................... 303 PRESSURE TEST CHECK RAIL PRESSURE DURING RAIL......................................... 304 PRESSURE TEST CHECK PRESSURE BETWEEN GEAR PUMP AND MAIN FILTER........................ 305 TEST CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR................................. 307 VISUALLY CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR......................... 307 READ OUT INTAKE AIR PRESSURE SENSOR VALUE......................................... 307 PRESSURE TEST CHECK SUCTION PRESSURE BETWEEN TANK AND PRE-FILTER...................... 308 PRESSURE TEST CHECK SUCTION PRESSURE AFTER PRE-FILTER................................. 310 TEST CHECK WATER IN FUEL SENSOR PLAUSIBILITY.......................................... 312 TEST CHECK EXTERNAL FUEL LEAKAGE HIGH PRESSURE SYSTEM................................. 313 TEST CHECK SINGLE INJECTOR BACKFLOW RATE.............................................. 314 TEST INJECTOR CUT OUT ACTIVATION CHECK................................................ 316 TEST ENGINE SPEED..................................................................... 317 PREPARATION FOR TESTING ENGINE SPEED.............................................. 317 TEST ENGINE LOW IDLE SPEED........................................................ 317 TEST ENGINE HIGH IDLE SPEED....................................................... 317 TEST ENGINE LOW IDLE SPEED AT PUMP AT RELIEF...................................... 318 TEST ENGINE HIGH IDLE SPEED WITH TORQUE CONVERTER AT STALL........................ 318 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF AND TORQUE CONVERTER AT STALL..... 318 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)........... 319 TEST EXHAUST GAS COLOR................................................................ 320 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER..................................... 320 TEST EXHAUST GAS COLOR BY SMOKE METER............................................. 320 STEERING SYSTEM........................................................................... 322 CHECK LEAKAGES IN STEERING CYLINDER................................................... 322 TEST STEERING CIRCUIT OIL PRESSURE.................................................... 323 ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE.......................... 324 TOE-IN ADJUSTMENT................................................................. 324 ADJUSTMENT WITH REFERENCE STEERING ANGLE.......................................... 326 ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE.................. 327 STEERING ANGLE CHECKING AND ADJUSTMENT............................................ 327 BRAKE SYSTEM.............................................................................. 330 TEST BRAKE SYSTEM PRESSURE............................................................ 330 TEST BRAKE SYSTEM LEAKAGE............................................................. 332 TEST BRAKE PISTON STROKE.............................................................. 333 BLEED AIR FROM THE BRAKE CIRCUIT...................................................... 334 ADJUST BRAKE PEDAL TRAVEL............................................................. 335 TEST AND ADJUST PARKING BRAKE SYSTEM.................................................. 337 TEST PARKING BRAKE................................................................ 337 ADJUST PARKING BRAKE.............................................................. 338 HYDRAULIC SYSTEM.......................................................................... 339 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................ 339 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.................................... 339 RELEASE REMAINING PRESSURE IN LOADER HYDRAULIC CYLINDER CIRCUIT................... 339 RELEASE REMAINING PRESSURE IN BACKHOE HYDRAULIC CYLINDER CIRCUIT.................. 339 TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE............................................ 340 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE........................................... 341 TEST AND ADJUST UNLOAD PRESSURE................................................... 344 TEST AND ADJUST RELIEF PRESSURE................................................... 344 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE)........................................ 345 ADJUST SECONDARY VALVE............................................................ 345 TEST BACKHOE BOOM OVERLOAD SWITCH................................................. 346 TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE.......................................... 347 TEST CONTROL CIRCUIT OIL PRESSURE................................................. 347 ADJUST CONTROL CIRCUIT OIL PRESSURE............................................... 347 MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE....................................... 348 MEASURE PUMP PC CONTROL OIL PRESSURE.............................................. 348 ADJUST PUMP PC CONTROL OIL PRESSURE............................................... 350 MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE....................................... 352 MEASURE PUMP LS CONTROL OIL PRESSURE.............................................. 352 ADJUST PUMP LS CONTROL OIL PRESSURE............................................... 353 TEST SOLENOID VALVE OUTLET PRESSURE................................................... 354 TEST PPC VALVE OUTLET PRESSURE........................................................ 355 ADJUST WORK EQUIPMENT PPC VALVES PLAY................................................. 357 TEST TRANSMISSION OIL PRESSURE........................................................ 358 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT.......................... 360 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER ARM CYLINDER......................... 360 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER BUCKET CYLINDER...................... 360 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BOOM CYLINDER....................... 361 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE ARM CYLINDER........................ 361 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BUCKET CYLINDER..................... 361 TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM SWING CYLINDER......................... 361 BLEED AIR FROM HYDRAULIC SYSTEM....................................................... 362 BLEED AIR FROM HYDRAULIC PUMP..................................................... 362 BLEED AIR FROM CYLINDERS.......................................................... 362 WORK EQUIPMENT............................................................................ 364 OUTRIGGER SENSOR AND SAFETY SYSTEM.................................................... 364 CHECK AND ADJUST OUTRIGGER SENSOR................................................. 364 TEST CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM................................ 366 ADJUST RETURN TO DIG SENSOR........................................................... 367 ADJUST TELESCOPIC ARM GUIDE SLACK..................................................... 368 PREPARATION FOR ADJUSTING GUIDE SLACK............................................. 368 REGISTRATION OF GUIDE SLACK....................................................... 368 ELECTRICAL SYSTEM......................................................................... 370 SET AND OPERATE MACHINE MONITOR....................................................... 370 OPERATOR MODE..................................................................... 372 FAST CHECK FAILURE CODE WHEN NO PROMPT ARE VISIBLE................................ 372 SET USAGE LIMITATION AND CHANGE PASSWORD.......................................... 372 SERVICE MODE...................................................................... 375 OPERATE SERVICE MODE.............................................................. 375 CHECK PRE-DEFINED MONITORING INFORMATION.......................................... 375 ABNORMALITY RECORD MENU........................................................... 382 CHECK MAINTENANCE RECORD.......................................................... 383 MAINTENANCE MODE SETTING.......................................................... 385 SET PHONE NUMBER ENTRY............................................................ 389 DEFAULT SETTING MENU.............................................................. 391 START UP KOMTRAX TERMINAL............................................................. 393 LAMP DISPLAY OF KOMTRAX TERMINAL...................................................... 397 ADJUST FRONT PANEL SETTINGS........................................................... 400 PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................... 401 BATTERY DISCONNECT SWITCH............................................................. 402 TEST DIODES........................................................................... 403 TEST DIODES BY DIGITAL TESTER..................................................... 403 TEST DIODES BY ANALOG TESTER...................................................... 403 40 TROUBLESHOOTING............................................................................ 405 CONTENTS.................................................................................. 406 RELATED INFORMATION TO TROUBLESHOOT....................................................... 414 PRECAUTIONS FOR TROUBLESHOOTING....................................................... 414 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................. 415 GENERAL TROUBLESHOOTING POINTS........................................................ 417 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................ 418 CHECKS BEFORE TROUBLESHOOTING......................................................... 419 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING........................................... 421 WALK-AROUND CHECK................................................................. 421 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.......................................... 423 CHECK FUEL LEVEL AND TYPE......................................................... 423 CHECK WATER SEPARATOR AND DRAIN WATER AND SEDIMENT................................ 423 CHECK AdBlue(R) LEVEL AND TYPE.................................................... 425 REPLACE FUEL PREFILTER............................................................ 425 REPLACE FUEL MAIN FILTER.......................................................... 427 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE........................... 428 CHECK COOLANT LEVEL (EXPANSION TANK).............................................. 429 CHECK AIR CLEANER CLOGGING........................................................ 430 CLEAN OUTER ELEMENT............................................................... 430 REPLACE INNER ELEMENT............................................................. 432 CHECK HYDRAULIC OIL LEVEL......................................................... 433 CHECK HYDRAULIC OIL STRAINER...................................................... 434 REPLACE HYDRAULIC OIL FILTER...................................................... 436 CHECK OIL LEVEL IN TRANSMISSION CASE.............................................. 437 CHECK FRONT AXLE OIL LEVEL........................................................ 438 CHECK REAR AXLE OIL LEVEL......................................................... 438 BLEED AIR FROM SYSTEM............................................................. 439 CHECK ELECTRIC EQUIPMENT.......................................................... 439 CONNECTOR CONTACT IDENTIFICATION...................................................... 444 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................... 486 FUSE LOCATION TABLE................................................................... 492 FAILURE CODE TABLE.................................................................... 496 TRANSMISSION ECU FAILURE CODE TABLE............................................... 496 MACHINE ECU FAILURE CODE TABLE.................................................... 497 MONITOR ECU FAILURE CODE TABLE.................................................... 500 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)......................................... 501 Failure Code [#T0022]................................................................. 501 Failure Code [#T0023]................................................................. 506 Failure Code [#T0037]................................................................. 511 Failure Code [#T0038]................................................................. 514 Failure Code [#T0039]................................................................. 518 Failure Code [#T0040]................................................................. 522 Failure Code [#T0041]................................................................. 526 Failure Code [#T0042]................................................................. 530 Failure Code [#T0043]................................................................. 533 Failure Code [#T0044]................................................................. 537 Failure Code [#T0045]................................................................. 541 Failure Code [#T0046]................................................................. 545 Failure Code [#T0055]................................................................. 549 Failure Code [#T0056]................................................................. 553 Failure Code [#T0057]................................................................. 554 Failure Code [#T0058]................................................................. 558 Failure Code [#T0061]................................................................. 562 Failure Code [#T0062]................................................................. 565 Failure Code [#T0068]................................................................. 568 Failure Code [#T0069]................................................................. 569 Failure Code [#T0073]................................................................. 571 Failure Code [#T0075]................................................................. 573 Failure Code [#T0077]................................................................. 574 Failure Code [#T0078]................................................................. 575 Failure Code [#T0079]................................................................. 577 Failure Code [#T0080]................................................................. 579 Failure Code [#T0081]................................................................. 581 Failure Code [#T0082]................................................................. 583 Failure Code [#T0083]................................................................. 584 Failure Code [#T0084]................................................................. 585 Failure Code [#T0085]................................................................. 586 Failure Code [#T0090]................................................................. 587 Failure Code [#T0091]................................................................. 590 Failure Code [#T0092]................................................................. 592 Failure Code [#T0093]................................................................. 593 Failure Code [#T0094]................................................................. 595 Failure Code [#T0103]................................................................. 597 Failure Code [#T0105]................................................................. 600 Failure Code [#T0108]................................................................. 603 Failure Code [#T0109]................................................................. 605 Failure Code [#T0110]................................................................. 607 Failure Code [#T0111]................................................................. 609 Failure Code [#T0112]................................................................. 611 Failure Code [#T0113]................................................................. 613 Failure Code [#T0114]................................................................. 615 Failure Code [#T0115]................................................................. 617 Failure Code [#T0116]................................................................. 619 Failure Code [#T0123]................................................................. 621 Failure Code [#T0124]................................................................. 622 Failure Code [#T0125]................................................................. 623 Failure Code [#T0126]................................................................. 624 Failure Code [#T0127]................................................................. 625 Failure Code [#T0128]................................................................. 626 Failure Code [#T0129]................................................................. 627 Failure Code [#T0147]................................................................. 628 Failure Code [#T0148]................................................................. 630 Failure Code [#T0151]................................................................. 632 Failure Code [#T0152]................................................................. 633 Failure Code [#T0168]................................................................. 634 Failure Code [#T0169]................................................................. 635 Failure Code [#T0170]................................................................. 636 Failure Code [#T0173]................................................................. 637 Failure Code [#T0174]................................................................. 638 Failure Code [#T0183]................................................................. 639 Failure Code [#T0185]................................................................. 640 Failure Code [#T0188]................................................................. 641 Failure Code [#T0191]................................................................. 642 Failure Code [#T0192]................................................................. 645 Failure Code [#T0193]................................................................. 646 Failure Code [#T0196]................................................................. 647 Failure Code [#T0198]................................................................. 648 Failure Code [#T0199]................................................................. 649 Failure Code [#T0200]................................................................. 650 Failure Code [#T0201]................................................................. 651 Failure Code [#T0204]................................................................. 652 Failure Code [#T0205]................................................................. 654 Failure Code [#T0207]................................................................. 655 Failure Code [#T0208]................................................................. 657 Failure Code [#T0209]................................................................. 659 Failure Code [#T0210]................................................................. 660 Failure Code [#T0211]................................................................. 661 Failure Code [#T0213]................................................................. 663 Failure Code [#T0215]................................................................. 664 Failure Code [#T0217]................................................................. 667 Failure Code [#T0219]................................................................. 668 Failure Code [#T0220]................................................................. 669 Failure Code [#T0221]................................................................. 670 Failure Code [#T0232]................................................................. 671 Failure Code [#T0236]................................................................. 672 Failure Code [#T0237]................................................................. 674 Failure Code [#T0238]................................................................. 676 Failure Code [#T0239]................................................................. 678 Failure Code [#T0240]................................................................. 680 Failure Code [#T0241]................................................................. 682 Failure Code [#T0242]................................................................. 684 Failure Code [#T0247]................................................................. 687 Failure Code [#T0248]................................................................. 690 Failure Code [#T0249]................................................................. 691 Failure Code [#T0251]................................................................. 694 Failure Code [#T0252]................................................................. 696 Failure Code [#T0254]................................................................. 698 Failure Code [#T0255]................................................................. 701 Failure Code [#T0256]................................................................. 703 Failure Code [#T0257]................................................................. 705 Failure Code [#T0258]................................................................. 706 Failure Code [#T0259]................................................................. 707 Failure Code [#T0260]................................................................. 708 Failure Code [#T0261]................................................................. 709 Failure Code [#T0262]................................................................. 710 Failure Code [#T0263]................................................................. 711 Failure Code [#T0264]................................................................. 712 Failure Code [#T0266]................................................................. 713 Failure Code [#T0267]................................................................. 714 Failure Code [#T0268]................................................................. 715 Failure Code [#T0269]................................................................. 716 Failure Code [#T0270]................................................................. 717 Failure Code [#T0272]................................................................. 718 Failure Code [#T0273]................................................................. 719 Failure Code [#T0274]................................................................. 720 Failure Code [#T0278]................................................................. 721 Failure Code [#T0279]................................................................. 723 Failure Code [#T0280]................................................................. 725 Failure Code [#T0281]................................................................. 726 Failure Code [#T0282]................................................................. 727 Failure Code [#T0283]................................................................. 728 Failure Code [#T0284]................................................................. 729 Failure Code [#T0285]................................................................. 731 Failure Code [#T0292]................................................................. 732 Failure Code [#T0293]................................................................. 734 Failure Code [#T0295]................................................................. 736 Failure Code [#T0303]................................................................. 738 Failure Code [#T0305]................................................................. 740 Failure Code [#T0308]................................................................. 741 Failure Code [#T0310]................................................................. 742 Failure Code [#T0311]................................................................. 743 Failure Code [#T0314]................................................................. 744 Failure Code [#T0318]................................................................. 745 Failure Code [#T0319]................................................................. 746 Failure Code [#T0320]................................................................. 747 Failure Code [#T0321]................................................................. 748 Failure Code [#T0322]................................................................. 750 Failure Code [#T0323]................................................................. 752 Failure Code [#T0324]................................................................. 754 Failure Code [#T0328]................................................................. 756 Failure Code [#T0329]................................................................. 758 Failure Code [#T0338]................................................................. 761 Failure Code [#T0339]................................................................. 763 Failure Code [#T0350]................................................................. 765 Failure Code [#T0356]................................................................. 767 Failure Code [#T0357]................................................................. 770 Failure Code [#T0400]................................................................. 773 Failure Code [#T0401]................................................................. 777 Failure Code [#T0402]................................................................. 781 Failure Code [#T0403]................................................................. 783 Failure Code [#T0404]................................................................. 785 Failure Code [#T0405]................................................................. 787 Failure Code [#T0406]................................................................. 788 Failure Code [#T0407]................................................................. 789 Failure Code [#T0408]................................................................. 791 Failure Code [#T0409]................................................................. 793 Failure Code [#T0410]................................................................. 795 Failure Code [#T0411]................................................................. 797 Failure Code [#T0412]................................................................. 798 Failure Code [#T0413]................................................................. 799 Failure Code [#T0414]................................................................. 801 Failure Code [#T0415]................................................................. 803 Failure Code [#T0416]................................................................. 804 Failure Code [#T0417]................................................................. 806 Failure Code [#T0418]................................................................. 808 Failure Code [#T0419]................................................................. 809 Failure Code [#T0420]................................................................. 812 Failure Code [#T0421]................................................................. 814 Failure Code [#T0422]................................................................. 816 Failure Code [#T0423]................................................................. 818 Failure Code [#T0424]................................................................. 820 Failure Code [#T0425]................................................................. 821 Failure Code [#T0426]................................................................. 823 Failure Code [#T0427]................................................................. 827 Failure Code [#T0428]................................................................. 829 Failure Code [#T0429]................................................................. 833 Failure Code [#T0430]................................................................. 834 Failure Code [#T0431]................................................................. 836 Failure Code [#T0432]................................................................. 838 Failure Code [#T0433]................................................................. 840 Failure Code [#T0434]................................................................. 842 Failure Code [#T0435]................................................................. 844 Failure Code [#T0436]................................................................. 846 Failure Code [#T0439]................................................................. 848 Failure Code [#T0440]................................................................. 850 Failure Code [#T0441]................................................................. 852 Failure Code [#T0442]................................................................. 855 Failure Code [#T0443]................................................................. 857 Failure Code [#T0444]................................................................. 859 Failure Code [#T0445]................................................................. 861 Failure Code [#T0446]................................................................. 862 Failure Code [#T0447]................................................................. 863 Failure Code [#T0448]................................................................. 864 Failure Code [#T0449]................................................................. 866 Failure Code [#T0450]................................................................. 868 Failure Code [#T0451]................................................................. 870 Failure Code [#T0452]................................................................. 872 Failure Code [#T0453]................................................................. 874 Failure Code [#T0454]................................................................. 876 Failure Code [#T0455]................................................................. 878 Failure Code [#T0456]................................................................. 880 Failure Code [#T0457]................................................................. 882 Failure Code [#T0458]................................................................. 884 Failure Code [#T0459]................................................................. 887 Failure Code [#T0460]................................................................. 889 Failure Code [#T0461]................................................................. 891 Failure Code [#T0462]................................................................. 892 Failure Code [#T0463]................................................................. 897 Failure Code [#T0464]................................................................. 898 Failure Code [#T0465]................................................................. 899 Failure Code [#T0466]................................................................. 900 Failure Code [#T0467]................................................................. 903 Failure Code [#T0468]................................................................. 906 Failure Code [#T0469]................................................................. 909 Failure Code [#T0470]................................................................. 912 Failure Code [#T0500]................................................................. 915 Failure Code [#T0501]................................................................. 916 Failure Code [#T0502]................................................................. 917 Failure Code [#T0504]................................................................. 918 Failure Code [#T0508]................................................................. 922 Failure Code [#T0509]................................................................. 924 Failure Code [#T0510]................................................................. 925 Failure Code [#T0511]................................................................. 929 Failure Code [#T0512]................................................................. 933 Failure Code [#T0513]................................................................. 937 Failure Code [#T0517]................................................................. 941 Failure Code [#T0519]................................................................. 942 Failure Code [#T0520]................................................................. 944 Failure Code [#T0521]................................................................. 948 Failure Code [#T0522]................................................................. 952 Failure Code [#T0530]................................................................. 956 Failure Code [#T0531]................................................................. 957 Failure Code [#T0532]................................................................. 958 Failure Code [#T0533]................................................................. 963 Failure Code [#T0534]................................................................. 964 Failure Code [#T0535]................................................................. 969 Failure Code [#T0536]................................................................. 974 Failure Code [#T0537]................................................................. 979 Failure Code [#T0538]................................................................. 980 Failure Code [#T0539]................................................................. 982 Failure Code [#T0540]................................................................. 983 Failure Code [#T0541]................................................................. 984 Failure Code [#T0542]................................................................. 986 Failure Code [#T0543]................................................................. 987 Failure Code [#T0544]................................................................. 988 Failure Code [#T0545]................................................................. 989 Failure Code [#T0546]................................................................. 990 Failure Code [#T0547]................................................................. 992 Failure Code [#T0550]................................................................. 994 Failure Code [#T0551]................................................................. 995 Failure Code [#T0555]................................................................. 997 Failure Code [#T0556].................................................................1000 Failure Code [#T0557].................................................................1001 Failure Code [#T0558].................................................................1002 Failure Code [#T0565].................................................................1003 Failure Code [#T0566].................................................................1005 Failure Code [#T0567].................................................................1007 Failure Code [#T0568].................................................................1009 Failure Code [#T0573].................................................................1011 Failure Code [#T0574].................................................................1013 Failure Code [#T0575].................................................................1015 Failure Code [#T0576].................................................................1016 Failure Code [#T0577].................................................................1017 Failure Code [#T0578].................................................................1018 Failure Code [#T0579].................................................................1019 Failure Code [#T0580].................................................................1020 Failure Code [#T0581].................................................................1021 Failure Code [#T0582].................................................................1022 Failure Code [#T0583].................................................................1023 Failure Code [#T0584].................................................................1024 Failure Code [#T0585].................................................................1025 Failure Code [#T0586].................................................................1026 Failure Code [#T0587].................................................................1027 Failure Code [#T0588].................................................................1028 Failure Code [#T0589].................................................................1029 Failure Code [#T0590].................................................................1030 Failure Code [#T0591].................................................................1031 Failure Code [#T0592].................................................................1032 Failure Code [#T0593].................................................................1033 Failure Code [#T0594].................................................................1034 Failure Code [#T0595].................................................................1035 Failure Code [#T0596].................................................................1036 Failure Code [#T0597].................................................................1037 Failure Code [#T0598].................................................................1038 Failure Code [#T0599].................................................................1039 Failure Code [#T0600].................................................................1040 Failure Code [#T0601].................................................................1041 Failure Code [#T0602].................................................................1042 Failure Code [#T0603].................................................................1043 Failure Code [#T0604].................................................................1044 Failure Code [#T0605].................................................................1045 Failure Code [#T0606].................................................................1046 Failure Code [#T0607].................................................................1047 Failure Code [#T0608].................................................................1048 Failure Code [#T0609].................................................................1049 Failure Code [#T0610].................................................................1050 Failure Code [#T0611].................................................................1051 Failure Code [#T0612].................................................................1052 Failure Code [#T0613].................................................................1053 Failure Code [#T0614].................................................................1054 Failure Code [#T0615].................................................................1055 Failure Code [#T0616].................................................................1056 Failure Code [#T0617].................................................................1057 Failure Code [#T0618].................................................................1058 Failure Code [#T0619].................................................................1059 Failure Code [#T0620].................................................................1060 Failure Code [#T0621].................................................................1061 Failure Code [#T0622].................................................................1062 Failure Code [#T0623].................................................................1063 Failure Code [#T0624].................................................................1064 Failure Code [#T0625].................................................................1065 Failure Code [#T0626].................................................................1066 Failure Code [#T0627].................................................................1067 Failure Code [#T0628].................................................................1068 Failure Code [#T0630].................................................................1069 Failure Code [#T0631].................................................................1070 Failure Code [#T0632].................................................................1071 Failure Code [#T0633].................................................................1072 Failure Code [#T0634].................................................................1073 Failure Code [#T0635].................................................................1074 Failure Code [#T0636].................................................................1075 Failure Code [#T0637].................................................................1076 Failure Code [#T0638].................................................................1077 Failure Code [#T0639].................................................................1078 Failure Code [#T0640].................................................................1079 Failure Code [#T0641].................................................................1080 Failure Code [#T0642].................................................................1081 Failure Code [#T0643].................................................................1082 Failure Code [#T0644].................................................................1083 Failure Code [#T0645].................................................................1084 Failure Code [#T0646].................................................................1085 Failure Code [#T0647].................................................................1086 Failure Code [#T0648].................................................................1087 Failure Code [#T0649].................................................................1088 Failure Code [#T0650].................................................................1089 Failure Code [#T0651].................................................................1090 Failure Code [#T0652].................................................................1091 Failure Code [#T0653].................................................................1092 Failure Code [#T0654].................................................................1093 Failure Code [#T0655].................................................................1094 Failure Code [#T0656].................................................................1095 Failure Code [#T0657].................................................................1098 Failure Code [#T0658].................................................................1099 Failure Code [#T0659].................................................................1100 Failure Code [#T0660].................................................................1101 Failure Code [#T0661].................................................................1102 Failure Code [#T0662].................................................................1103 Failure Code [#T0663].................................................................1104 Failure Code [#T0664].................................................................1106 Failure Code [#T0665].................................................................1107 Failure Code [#T0666].................................................................1109 Failure Code [#T0667].................................................................1111 Failure Code [#T0669].................................................................1113 Failure Code [#T0670].................................................................1114 Failure Code [#T0672].................................................................1115 Failure Code [#T0673].................................................................1117 Failure Code [#T0674].................................................................1119 Failure Code [#T0675].................................................................1121 Failure Code [#T0676].................................................................1123 Failure Code [#T0677].................................................................1124 Failure Code [#T0678].................................................................1125 Failure Code [#T0679].................................................................1126 Failure Code [#T0680].................................................................1128 Failure Code [#T0682].................................................................1129 Failure Code [#T0683].................................................................1131 Failure Code [#T0684].................................................................1133 Failure Code [#T0685].................................................................1134 Failure Code [#T0686].................................................................1135 Failure Code [#T0687].................................................................1136 Failure Code [#T0688].................................................................1137 Failure Code [#T0689].................................................................1138 Failure Code [#T0690].................................................................1139 Failure Code [#T0691].................................................................1140 Failure Code [#T0692].................................................................1141 Failure Code [#T0693].................................................................1142 Failure Code [#T0694].................................................................1143 Failure Code [#T0695].................................................................1145 Failure Code [#T0696].................................................................1147 Failure Code [#T0697].................................................................1149 Failure Code [#T0698].................................................................1150 Failure Code [#T0699].................................................................1151 Failure Code [#T0700].................................................................1154 Failure Code [#T0701].................................................................1157 Failure Code [#T0702].................................................................1160 Failure Code [#T0703].................................................................1161 Failure Code [#T0704].................................................................1162 Failure Code [#T0705].................................................................1163 Failure Code [#T0706].................................................................1166 Failure Code [#T0707].................................................................1169 Failure Code [#T0708].................................................................1172 Failure Code [#T0709].................................................................1173 Failure Code [#T0710].................................................................1174 Failure Code [#T0711].................................................................1175 Failure Code [#T0712].................................................................1176 Failure Code [#T0713].................................................................1177 Failure Code [#T0714].................................................................1178 Failure Code [#T0715].................................................................1179 Failure Code [#T0716].................................................................1180 Failure Code [#T0717].................................................................1181 Failure Code [#T0718].................................................................1182 Failure Code [#T0719].................................................................1183 Failure Code [#T0720].................................................................1184 Failure Code [#T0721].................................................................1186 Failure Code [#T0722].................................................................1187 Failure Code [#T0723].................................................................1188 Failure Code [#T0724].................................................................1190 Failure Code [#T0725].................................................................1192 Failure Code [#T0726].................................................................1194 Failure Code [#T0728].................................................................1196 Failure Code [#T0729].................................................................1198 Failure Code [#T0730].................................................................1200 Failure Code [#T0731].................................................................1203 Failure Code [#T0732].................................................................1205 Failure Code [#T0733].................................................................1206 Failure Code [#T0734].................................................................1209 Failure Code [#T0740].................................................................1212 Failure Code [#T0742].................................................................1213 Failure Code [#T0743].................................................................1216 50 DISASSEMBLY AND ASSEMBLY...................................................................1219 CONTENTS..................................................................................1220 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................1224 HOW TO READ THIS MANUAL...............................................................1224 COATING MATERIALS LIST................................................................1226 ENGINE AND COOLING SYSTEM.................................................................1230 REMOVE AND INSTALL RADIATOR ASSEMBLY..................................................1230 REMOVE RADIATOR ASSEMBLY..........................................................1230 INSTALL RADIATOR ASSEMBLY.........................................................1233 REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY.............................................1235 REMOVE FAN CLUTCH ASSEMBLY........................................................1235 INSTALL FAN CLUTCH ASSEMBLY.......................................................1238 REMOVE AND INSTALL ENGINE.............................................................1239 REMOVE ENGINE.....................................................................1239 INSTALL ENGINE ASSEMBLY...........................................................1245 REMOVE AND INSTALL FUEL COOLER ASSEMBLY...............................................1247 REMOVE FUEL COOLER ASSEMBLY.......................................................1247 INSTALL FUEL COOLER ASSEMBLY......................................................1247 REMOVE AND INSTALL EXHAUST PIPE.......................................................1248 REMOVE EXHAUST PIPE...............................................................1248 INSTALL EXHAUST PIPE..............................................................1248 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY..............................................1249 REMOVE BELLOWS PIPE ASSEMBLY......................................................1249 INSTALL BELLOWS PIPE ASSEMBLY.....................................................1250 REMOVE AND INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC...........................1252 REMOVE NOx DETECTION SENSOR UPSTREAM OF THE DOC...................................1252 INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC..................................1252 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC.................1254 REMOVE KDOC INLET TEMPERATURE SENSOR..............................................1254 INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC........................1254 REMOVE AND INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.........................1256 REMOVE NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.................................1256 INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR................................1257 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR...............1258 REMOVE SCR OUTLET TEMPERATURE SENSOR..............................................1258 INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR......................1259 REMOVE AND INSTALL DOC ASSEMBLY.......................................................1260 REMOVE DOC ASSEMBLY...............................................................1260 INSTALL DOC ASSEMBLY..............................................................1263 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY....................................1265 REMOVE DEF TANK SENSOR FLANGE ASSEMBLY............................................1265 INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...........................................1269 REMOVE AND INSTALL DEF TANK SENSOR....................................................1270 REMOVE DEF TANK SENSOR............................................................1270 INSTALL DEF TANK SENSOR...........................................................1270 REMOVE AND INSTALL DEF TANK STRAINER..................................................1272 REMOVE DEF TANK STRAINER..........................................................1272 INSTALL DEF TANK STRAINER.........................................................1272 REMOVE AND INSTALL DEF INJECTOR.......................................................1273 REMOVE DEF INJECTOR...............................................................1273 INSTALL DEF INJECTOR..............................................................1275 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...............................................1279 REMOVE AIR CLEANER ASSEMBLY.......................................................1279 INSTALL AIR CLEANER ASSEMBLY......................................................1279 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................1280 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY.........................................1280 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................1281 REMOVE AND INSTALL AIR CONDITIONER BELT...............................................1282 REMOVE AIR CONDITIONER BELT.......................................................1282 INSTALL AIR CONDITIONER BELT......................................................1282 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR.........................................1283 REMOVE AIR CONDITIONER COMPRESSOR.................................................1283 INSTALL AIR CONDITIONER COMPRESSOR................................................1285 UNDERCARRIAGE AND FRAME...................................................................1286 REMOVE AND INSTALL ENGINE HOOD........................................................1286 REMOVE ENGINE HOOD................................................................1286 INSTALL ENGINE HOOD...............................................................1287 REMOVE AND INSTALL COUNTERWEIGHT......................................................1288 REMOVE COUNTERWEIGHT..............................................................1288 INSTALL COUNTERWEIGHT.............................................................1288 REMOVE AND INSTALL FRONT AND REAR WHEELS..............................................1290 REMOVE FRONT WHEELS...............................................................1290 INSTALL FRONT WHEELS..............................................................1290 REMOVE REAR WHEELS................................................................1290 INSTALL REAR WHEELS...............................................................1291 POWER TRAIN...............................................................................1292 REMOVE AND INSTALL FRONT AXLE.........................................................1292 REMOVE FRONT AXLE.................................................................1292 INSTALL FRONT AXLE................................................................1293 DISASSEMBLE AND ASSEMBLE FRONT AXLE...................................................1294 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1294 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1297 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1300 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1306 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP.......................................1315 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1317 DISASSEMBLE AND ASSEMBLE AXLE BEAM GROUP..........................................1324 DISASSEMBLE AND ASSEMBLE WHEEL AND DOUBLE U-JOINT GROUP...........................1327 TESTING AFTER ASSEMBLY............................................................1331 REMOVE AND INSTALL REAR AXLE..........................................................1332 REMOVE REAR AXLE..................................................................1332 INSTALL REAR AXLE.................................................................1333 DISASSEMBLE AND ASSEMBLE REAR AXLE....................................................1334 DISASSEMBLE AND ASSEMBLE BRAKE GROUP..............................................1334 DISASSEMBLE AND ASSEMBLE WHEEL HUB AND REDUCTION GEAR.............................1343 DISASSEMBLE AND ASSEMBLE PARKING BRAKE............................................1352 DISASSEMBLE AND ASSEMBLE PARKING BRAKE MECHANICAL CALIPER.........................1355 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1357 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL LOCKING GROUP...............................1365 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL.............................................1369 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1376 TESTING AFTER ASSEMBLY............................................................1383 REMOVE AND INSTALL TRANSMISSION.......................................................1384 REMOVE TRANSMISSION...............................................................1384 INSTALL TRANSMISSION..............................................................1389 DISASSEMBLE AND ASSEMBLE TRANSMISSION.................................................1390 DISASSEMBLE AND ASSEMBLE PLUGS, FILTERS AND SENSORS...............................1390 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER AND OIL PUMP............................1396 DISASSEMBLE AND ASSEMBLE HYDRAULIC CONTROL VALVE..................................1400 DISASSEMBLE AND ASSEMBLE HYDRAULIC SYSTEM PIPES...................................1405 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER VALVOLE KIT.............................1409 DISASSEMBLE AND ASSEMBLE TRANSMISSION HOUSING.....................................1411 DISASSEMBLE AND ASSEMBLE SHAFTS A - D.............................................1420 DISASSEMBLE AND ASSEMBLE SHAFT B..................................................1437 DISASSEMBLE AND ASSEMBLE SHAFT C..................................................1450 DISASSEMBLE AND ASSEMBLE SHAFT E..................................................1477 HYDRAULIC SYSTEM..........................................................................1490 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................1490 REMOVE HYDRAULIC PUMP ASSEMBLY....................................................1490 INSTALL HYDRAULIC PUMP ASSEMBLY...................................................1492 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.........................1494 DISASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................1494 ASSEMBLY WORK EQUIPMENT PPC VALVE.................................................1494 WORK EQUIPMENT............................................................................1496 REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY.....................................1496 REMOVE LOADER WORK EQUIPMENT ASSEMBLY.............................................1496 INSTALL LOADER WORK EQUIPMENT ASSEMBLY............................................1498 REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY....................................1500 REMOVE BACKHOE WORK EQUIPMENT ASSEMBLY............................................1500 INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY...........................................1502 REMOVE AND INSTALL BACKHOE BOOM CYLINDER..............................................1503 REMOVE BACKHOE BOOM CYLINDER......................................................1503 INSTALL BACKHOE BOOM CYLINDER.....................................................1505 REMOVE AND INSTALL BACKHOE ARM CYLINDER...............................................1506 REMOVE BACKHOE ARM CYLINDER.......................................................1506 INSTALL BACKHOE ARM CYLINDER......................................................1507 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER....................................1508 REMOVE BACKHOE TELESCOPIC ARM CYLINDER............................................1508 INSTALL BACKHOE TELESCOPIC ARM CYLINDER...........................................1508 REMOVE AND INSTALL OUTRIGGER CYLINDER.................................................1509 REMOVE OUTRIGGER CYLINDER.........................................................1509 INSTALL OUTRIGGER CYLINDER........................................................1510 REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS.......................................1511 REMOVE BACKHOE BOOM SWING CYLINDERS...............................................1511 INSTALL BACKHOE BOOM SWING CYLINDERS..............................................1512 REMOVE AND INSTALL BACKHOE BUCKET CYLINDER............................................1513 REMOVE BACKHOE BUCKET CYLINDER....................................................1513 INSTALL BACKHOE BUCKET CYLINDER...................................................1513 REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER.........................................1515 REMOVE BACKHOE BOOM LOCK CYLINDER.................................................1515 INSTALL BACKHOE BOOM LOCK CYLINDER................................................1515 REMOVE AND INSTALL BACKHOE BOOM.......................................................1516 REMOVE BACKHOE BOOM...............................................................1516 INSTALL BACKHOE BOOM..............................................................1516 REMOVE AND INSTALL BACKHOE ARM ASSEMBLY...............................................1518 REMOVE BACKHOE ARM ASSEMBLY.......................................................1518 INSTALL BACKHOE ARM...............................................................1518 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY....................................1520 REMOVE BACKHOE TELESCOPIC ARM ASSEMBLY............................................1520 INSTALL BACKHOE TELESCOPIC ARM....................................................1520 REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET.........................................1522 REMOVE BACKHOE BOOM SWING BRACKET.................................................1522 INSTALL BACKHOE BOOM SWING BRACKET................................................1522 REMOVE AND INSTALL BACKHOE SLIDING BRACKET............................................1524 REMOVE BACKHOE SLIDING BRACKET....................................................1524 INSTALL BACKHOE SLIDING BRACKET...................................................1525 REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................1526 REMOVE BACKHOE SLIDING BRACKET LOCKING PISTON.....................................1526 INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON....................................1526 CAB AND ITS ATTACHMENTS...................................................................1528 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY............................................1528 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1528 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1536 ELECTRICAL SYSTEM.........................................................................1538 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.........................................1538 REMOVE ENGINE CONTROLLER ASSEMBLY.................................................1538 INSTALL ENGINE CONTROLLER ASSEMBLY................................................1540 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...................................1541 REMOVE TRANSMISSION CONTROLLER ASSEMBLY...........................................1541 INSTALL TRANSMISSION CONTROLLER ASSEMBLY..........................................1543 REMOVE AND INSTALL FRONT PANEL........................................................1544 REMOVE FRONT PANEL................................................................1544 INSTALL FRONT PANEL...............................................................1545 REMOVE AND INSTALL STEERING COLUMN SWITCHES...........................................1546 REMOVE STEERING COLUMN SWITCHES...................................................1546 INSTALL STEERING COLUMN SWITCHES..................................................1547 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY..........................................1548 REMOVE KOMTRAX TERMINAL ASSEMBLY..................................................1548 INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................1548 REMOVE AND INSTALL BACKHOE PPC VALVE..................................................1550 REMOVE BACKHOE PPC VALVE..........................................................1550 INSTALL BACKHOE PPC VALVE.........................................................1551 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES...........................1552 REMOVE BACKHOE PPC VALVE SUPPORT RELEASE CABLES...................................1552 INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES..................................1553 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING........................1554 REMOVE BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING................................1554 INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRINGS..............................1555 60 MAINTENANCE STANDARD.......................................................................1557 CONTENTS..................................................................................1558 ENGINE AND COOLING SYSTEM.................................................................1559 MAINTENANCE STANDARD OF ENGINE MOUNT..................................................1559 MAINTENANCE STANDARD OF COOLING SYSTEM................................................1561 POWER TRAIN...............................................................................1562 MAINTENANCE STANDARD OF TRANSMISSION..................................................1562 MAINTENANCE STANDARD OF FRONT AXLE....................................................1565 MAINTENANCE STANDARD OF REAR AXLE.....................................................1570 HYDRAULIC SYSTEM..........................................................................1575 MAINTENANCE STANDARD OF MAIN PUMP.....................................................1575 MAINTENANCE STANDARD OF CONTROL VALVE.................................................1577 WORK EQUIPMENT............................................................................1587 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE...............................1587 LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................................1587 LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.................1590 MAINTENANCE STANDARD OF SWING BRACKET.................................................1593 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT.........................................1595 MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT........................................1597 MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS......................................1599 LOADER ARM CYLINDER...............................................................1599 LOADER BUCKET CYLINDER............................................................1599 LOADER BUCKET 4 IN 1 CYLINDER.....................................................1600 BACKHOE BOOM CYLINDER.............................................................1601 BACKHOE ARM CYLINDER..............................................................1601 BACKHOE BUCKET CYLINDER...........................................................1602 BACKHOE BOOM SWING CYLINDER.......................................................1603 BACKHOE TELESCOPIC ARM CYLINDER...................................................1604 OUTRIGGER CYLINDER................................................................1604 90 CIRCUIT DIAGRAMS...........................................................................1607 CONTENTS..................................................................................1608 HOW TO READ THE CODES FOR ELECTRIC CABLE..................................................1609 HYDRAULIC CIRCUIT DIAGRAM.................................................................1613 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.............................................1613 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/2)....................................1617 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/2)....................................1619 ELECTRICAL CIRCUIT DIAGRAM................................................................1621 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM..............................................1621 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/12)..........................................1625 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/12)..........................................1627 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/12)..........................................1629 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/12)..........................................1631 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/12)..........................................1633 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/12)..........................................1635 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/12)..........................................1637 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/12)..........................................1639 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/12)..........................................1641 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/12).........................................1643 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/12).........................................1645 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/12).........................................1647
DESCRIPTION:
KOMATSU WB97R-8E0 BACKHOE LOADER SHOP MANUAL WENBM00340 – 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 22/12/24
