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KOMATSU WB97S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00350 – PDF DOWNLOAD
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KOMATSU WB97S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00350 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WB97S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00350 – PDF DOWNLOAD
Language : English
Pages : 1460
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WB97S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00350 – PDF DOWNLOAD
00 INDEX AND FOREWORD......................................................................... 3 INDEX..................................................................................... 4 FOREWORD, SAFETY, BASIC INFORMATION....................................................... 9 HOW TO READ THE SHOP MANUAL........................................................... 9 SAFETY NOTICE FOR OPERATION........................................................... 11 PRECAUTIONS TO PREVENT FIRE........................................................... 19 ACTIONS IF FIRE OCCURS................................................................ 21 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.......................................... 22 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS......................................... 23 PRECAUTIONS FOR DEF................................................................... 24 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.................................... 24 PRECAUTIONS FOR ADDING............................................................ 24 PRECAUTIONS FOR STORING........................................................... 24 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE........................................... 24 THE OTHER PRECAUTIONS............................................................. 24 STORE AdBlue/DEF...................................................................... 25 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.......................................... 26 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS............................... 29 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT......................................... 36 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT........................................ 38 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...................................... 39 PRACTICAL USE OF KOMTRAX.............................................................. 40 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER......................................... 41 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER............. 41 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER............. 42 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER............. 43 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................ 45 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR............................. 49 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR..................... 50 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL................... 52 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH................... 53 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE.............. 55 HOW TO READ ELECTRICAL WIRE CODE...................................................... 56 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD......................................... 60 STANDARD TIGHTENING TORQUE TABLE...................................................... 63 CONVERSION TABLE...................................................................... 70 ABBREVIATION LIST..................................................................... 75 01 SPECIFICATIONS............................................................................. 79 CONTENTS.................................................................................. 80 SPECIFICATIONS............................................................................ 81 SPECIFICATION DRAWING................................................................. 81 SPECIFICATION DRAWING: WB97S-8E0.................................................. 81 SPECIFICATIONS........................................................................ 83 SPECIFICATIONS: WB97S-8E0......................................................... 83 WEIGHT TABLE.......................................................................... 84 WEIGHT TABLE: WB97S-8............................................................. 84 FUEL, COOLANT, LUBRICANTS............................................................. 86 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................. 86 10 STRUCTURE AND FUNCTION..................................................................... 89 CONTENTS.................................................................................. 90 UREA SCR SYSTEM........................................................................... 92 LAYOUT DRAWING OF UREA SCR SYSTEM..................................................... 92 UREA SCR SYSTEM DIAGRAM............................................................... 95 FUNCTION OF UREA SCR SYSTEM........................................................... 97 FUNCTION OF DEF SYSTEM............................................................ 97 INDUCEMENT STRATEGY............................................................... 98 COMPONENT PARTS OF UREA SCR SYSTEM.................................................... 105 DOC AND DEF MIXING TUBE........................................................... 105 DPF/SCR ASSEMBLY.................................................................. 107 DEF TANK.......................................................................... 109 DEF PUMP.......................................................................... 111 DEF INJECTOR...................................................................... 112 DEF HOSE.......................................................................... 113 DEF TANK HEATING VALVE............................................................ 114 HYDRAULIC SYSTEM.......................................................................... 115 LAYOUT DRAWING OF HYDRAULIC SYSTEM.................................................... 115 CLSS.................................................................................. 117 STRUCTURE OF CLSS................................................................. 117 FUNCTION OF CLSS.................................................................. 118 COMPONENT PARTS OF HYDRAULIC SYSTEM................................................... 120 HYDRAULIC TANK.................................................................... 120 MAIN PUMP......................................................................... 122 CONTROL VALVE..................................................................... 135 POWER TRAIN SYSTEM........................................................................ 165 LAYOUT DRAWING OF POWER TRAIN SYSTEM.................................................. 165 OPERATION OF POWER TRAIN SYSTEM....................................................... 167 COMPONENT PARTS OF POWER TRAIN SYSTEM................................................. 168 TRANSMISSION...................................................................... 168 DRIVE SHAFT....................................................................... 178 TRANSMISSION CONTROL VALVE........................................................ 181 AXLE.............................................................................. 183 OPERATION OF STEERING SYSTEM.......................................................... 194 WORK EQUIPMENT SYSTEM..................................................................... 198 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM............................................... 198 LOADER WORK EQUIPMENT PPC VALVE....................................................... 201 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 201 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................... 203 STRUCTURE OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 207 OPERATION OF LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.... 209 BACKHOE PPC VALVE..................................................................... 214 STRUCTURE OF LH BACKHOE PPC VALVE................................................. 214 STRUCTURE OF RH BACKHOE PPC VALVE................................................. 216 OUTRIGGER PPC VALVE................................................................... 218 STRUCTURE OF OUTRIGGER PPC VALVE.................................................. 218 OPERATION OF OUTRIGGER PPC VALVE.................................................. 219 STEERING UNIT......................................................................... 223 BRAKE PUMP............................................................................ 224 SOLENOID VALVES....................................................................... 225 SOLENOID VALVE GROUP.............................................................. 225 TELESCOPIC ARM SOLENOID VALVE..................................................... 226 SIDE DIGGING BOOM SOLENOID VALVE.................................................. 227 2-ATTACHMENT SOLENOID VALVE....................................................... 228 STEERING MODE SOLENOID VALVE...................................................... 229 HAMMER SOLENOID VALVE............................................................. 230 PPC CIRCUIT ACCUMULATOR............................................................... 231 SAFETY VALVES......................................................................... 232 LOADER ARM SAFETY VALVE........................................................... 232 LOADER BUCKET SAFETY VALVE........................................................ 233 BACKHOE BOOM SAFETY VALVE......................................................... 234 BACKHOE ARM SAFETY VALVE.......................................................... 235 OUTRIGGER SAFETY VALVE............................................................ 236 WORK EQUIPMENT............................................................................ 237 STRUCTURE OF LOADER WORK EQUIPMENT.................................................... 237 STRUCTURE OF BACKHOE WORK EQUIPMENT................................................... 238 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM.................................. 239 20 STANDARD VALUE TABLE....................................................................... 241 CONTENTS.................................................................................. 242 STANDARD VALUE TABLE FOR ENGINE........................................................... 243 STANDARD VALUE TABLE FOR ENGINE: WB97S-8E0............................................ 243 STANDARD VALUE TABLE FOR MACHINE.......................................................... 246 STANDARD VALUE TABLE FOR MACHINE: WB97S-8E0........................................... 246 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE................................. 263 30 TESTING AND ADJUSTING...................................................................... 271 CONTENTS.................................................................................. 272 ENGINE AND COOLING SYSTEM................................................................. 275 TEST VISUAL CHECK CRANKCASE SYSTEM.................................................... 275 TEST CHECK CYLINDER MECHANICS......................................................... 277 CHECK CYLINDER COMPRESSION........................................................ 277 CHECK CYLINDER PRESSURE LOSS...................................................... 278 TEST CHECK EGR VALVE ACTUATOR......................................................... 279 TEST CHECK EXTERNAL FUEL LEAKAGE ENGINE AREA.......................................... 281 TEST CHECK PRESSURE LIMITING VALVE (PLV) BACKFLOW RATE................................ 283 TEST CHECK TURBO SYSTEM............................................................... 285 TEST CHECK INTAKE AIR SYSTEM.......................................................... 287 TEST CHECK COOLING SYSTEM............................................................. 289 CHECK COOLANT TANK................................................................ 289 CHECK COOLANT TEMPERATURE SENSOR.................................................. 290 READ OUT COOLANT TEMPERATURE SENSOR VALUE......................................... 290 VISUALLY CHECK COOLING SYSTEM..................................................... 291 MECHANICALLY CHECK WATER PUMP..................................................... 291 FAN ACTIVATION CHECK.............................................................. 292 VISCO FAN ACTIVATION CHECK........................................................ 292 ENGINE TEMPERATURE ADJUSTMENT CHECK............................................... 292 CHECK PRESSURE BETWEEN MAIN FILTER AND HIGH PRESSURE PUMP............................. 294 TEST CHECK HIGH PRESSURE PUMP BACKFLOW RATE........................................... 297 TEST CHECK HIGH PRESSURE SYSTEM BACKFLOW RATE......................................... 299 PRESSURE TEST RAIL PRESSURE ADJUSTMENT CHECK.......................................... 301 PRESSURE TEST CHECK RAIL PRESSURE DURING RAIL......................................... 302 PRESSURE TEST CHECK PRESSURE BETWEEN GEAR PUMP AND MAIN FILTER........................ 303 TEST CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR................................. 305 VISUALLY CHECK INTAKE AIR PRESSURE AND TEMPERATURE SENSOR......................... 305 READ OUT INTAKE AIR PRESSURE SENSOR VALUE......................................... 305 PRESSURE TEST CHECK SUCTION PRESSURE BETWEEN TANK AND PRE-FILTER...................... 306 PRESSURE TEST CHECK SUCTION PRESSURE AFTER PRE-FILTER................................. 308 TEST CHECK WATER IN FUEL SENSOR PLAUSIBILITY.......................................... 310 TEST CHECK EXTERNAL FUEL LEAKAGE HIGH PRESSURE SYSTEM................................. 311 TEST CHECK SINGLE INJECTOR BACKFLOW RATE.............................................. 312 TEST INJECTOR CUT OUT ACTIVATION CHECK................................................ 314 TEST ENGINE SPEED..................................................................... 315 PREPARATION FOR TESTING ENGINE SPEED.............................................. 315 TEST ENGINE LOW IDLE SPEED........................................................ 315 TEST ENGINE HIGH IDLE SPEED....................................................... 315 TEST ENGINE LOW IDLE SPEED AT PUMP AT RELIEF...................................... 316 TEST ENGINE HIGH IDLE SPEED WITH TORQUE CONVERTER AT STALL........................ 316 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF AND TORQUE CONVERTER AT STALL..... 316 TEST ENGINE HIGH IDLE SPEED WITH PUMP AT RELIEF (FUEL CONTROL DIAL SET)........... 317 TEST EXHAUST GAS COLOR................................................................ 318 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER..................................... 318 TEST EXHAUST GAS COLOR BY SMOKE METER............................................. 318 STEERING SYSTEM........................................................................... 320 CHECK LEAKAGES IN STEERING CYLINDER................................................... 320 TEST STEERING CIRCUIT OIL PRESSURE.................................................... 321 ADJUST TOE-IN/STEERING ANGLE WITH AXLES REMOVED FROM MACHINE.......................... 322 FRONT AXLE TOE-IN/STEERING ANGLE.................................................. 322 REAR AXLE TOE-IN/STEERING ANGLE................................................... 328 ADJUST TOE-IN/STEERING ANGLE WITH AXLES WITHOUT REMOVED FROM MACHINE.................. 334 STEERING ANGLE CHECKING AND ADJUSTMENT............................................ 334 BRAKE SYSTEM.............................................................................. 337 TEST BRAKE SYSTEM PRESSURE............................................................ 337 TEST BRAKE SYSTEM LEAKAGE............................................................. 339 TEST BRAKE PISTON STROKE.............................................................. 340 BLEED AIR FROM THE BRAKE CIRCUIT...................................................... 341 TEST AND ADJUST PARKING BRAKE SYSTEM.................................................. 342 TEST PARKING BRAKE................................................................ 342 ADJUST PARKING BRAKE.............................................................. 343 HYDRAULIC SYSTEM.......................................................................... 344 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................ 344 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.................................... 344 RELEASE REMAINING PRESSURE IN LOADER HYDRAULIC CYLINDER CIRCUIT................... 344 RELEASE REMAINING PRESSURE IN BACKHOE HYDRAULIC CYLINDER CIRCUIT.................. 344 TEST AND ADJUST HYDRAULIC CIRCUIT PRESSURE............................................ 345 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE........................................... 346 TEST AND ADJUST UNLOAD PRESSURE................................................... 349 TEST AND ADJUST RELIEF PRESSURE................................................... 349 ADJUST MAIN SAFETY VALVE (LS SAFETY VALVE)........................................ 350 ADJUST SECONDARY VALVE............................................................ 350 TEST BACKHOE BOOM OVERLOAD SWITCH................................................. 351 TEST AND ADJUST CONTROL CIRCUIT OIL PRESSURE.......................................... 352 TEST CONTROL CIRCUIT OIL PRESSURE................................................. 352 ADJUST CONTROL CIRCUIT OIL PRESSURE............................................... 352 MEASURE AND ADJUST PUMP PC CONTROL OIL PRESSURE....................................... 353 MEASURE PUMP PC CONTROL OIL PRESSURE.............................................. 353 ADJUST PUMP PC CONTROL OIL PRESSURE............................................... 355 MEASURE AND ADJUST PUMP LS CONTROL OIL PRESSURE....................................... 357 MEASURE PUMP LS CONTROL OIL PRESSURE.............................................. 357 ADJUST PUMP LS CONTROL OIL PRESSURE............................................... 358 TEST SOLENOID VALVE OUTLET PRESSURE................................................... 359 TEST PPC VALVE OUTLET PRESSURE........................................................ 360 ADJUST WORK EQUIPMENT PPC VALVES PLAY................................................. 362 TEST TRANSMISSION OIL PRESSURE........................................................ 363 TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT.......................... 365 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER ARM CYLINDER......................... 365 TEST PARTS CAUSING HYDRAULIC DRIFT OF LOADER BUCKET CYLINDER...................... 365 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BOOM CYLINDER....................... 366 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE ARM CYLINDER........................ 366 TEST PARTS CAUSING HYDRAULIC DRIFT OF BACKHOE BUCKET CYLINDER..................... 366 TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM SWING CYLINDER......................... 366 BLEED AIR FROM HYDRAULIC SYSTEM....................................................... 367 BLEED AIR FROM HYDRAULIC PUMP..................................................... 367 BLEED AIR FROM CYLINDERS.......................................................... 367 WORK EQUIPMENT............................................................................ 369 OUTRIGGER SENSOR AND SAFETY SYSTEM.................................................... 369 CHECK AND ADJUST OUTRIGGER SENSOR................................................. 369 TEST CORRECT FUNCTIONALITY OUTRIGGER SAFETY SYSTEM................................ 371 ADJUST RETURN TO DIG SENSOR........................................................... 372 ADJUST TELESCOPIC ARM GUIDE SLACK..................................................... 373 PREPARATION FOR ADJUSTING GUIDE SLACK............................................. 373 REGISTRATION OF GUIDE SLACK....................................................... 373 ELECTRICAL SYSTEM......................................................................... 375 SET AND OPERATE MACHINE MONITOR....................................................... 375 OPERATOR MODE..................................................................... 377 FAST CHECK FAILURE CODE WHEN NO PROMPT ARE VISIBLE................................ 377 SET USAGE LIMITATION AND CHANGE PASSWORD.......................................... 377 SERVICE MODE...................................................................... 380 OPERATE SERVICE MODE.............................................................. 380 CHECK PRE-DEFINED MONITORING INFORMATION.......................................... 380 ABNORMALITY RECORD MENU........................................................... 387 CHECK MAINTENANCE RECORD.......................................................... 388 MAINTENANCE MODE SETTING.......................................................... 390 SET PHONE NUMBER ENTRY............................................................ 394 DEFAULT SETTING MENU.............................................................. 396 START UP KOMTRAX TERMINAL............................................................. 398 LAMP DISPLAY OF KOMTRAX TERMINAL...................................................... 402 ADJUST FRONT PANEL SETTINGS........................................................... 405 PREPARATE KOMTRAX TERMINAL FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................... 406 BATTERY DISCONNECT SWITCH............................................................. 407 TEST DIODES........................................................................... 408 TEST DIODES BY DIGITAL TESTER..................................................... 408 TEST DIODES BY ANALOG TESTER...................................................... 408 40 TROUBLESHOOTING............................................................................ 409 CONTENTS.................................................................................. 410 RELATED INFORMATION TO TROUBLESHOOT....................................................... 418 PRECAUTIONS FOR TROUBLESHOOTING....................................................... 418 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................. 419 GENERAL TROUBLESHOOTING POINTS........................................................ 421 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM............................................ 422 CHECKS BEFORE TROUBLESHOOTING......................................................... 423 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING........................................... 425 WALK-AROUND CHECK................................................................. 425 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.......................................... 427 CHECK FUEL LEVEL AND TYPE......................................................... 427 CHECK WATER SEPARATOR AND DRAIN WATER AND SEDIMENT................................ 427 CHECK AdBlue(R) LEVEL AND TYPE.................................................... 429 REPLACE FUEL PREFILTER............................................................ 429 REPLACE FUEL MAIN FILTER.......................................................... 431 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE........................... 432 CHECK COOLANT LEVEL (EXPANSION TANK).............................................. 433 CHECK AIR CLEANER CLOGGING........................................................ 434 CLEAN OUTER ELEMENT............................................................... 434 REPLACE INNER ELEMENT............................................................. 436 CHECK HYDRAULIC OIL LEVEL......................................................... 437 CHECK HYDRAULIC OIL STRAINER...................................................... 438 REPLACE HYDRAULIC OIL FILTER...................................................... 440 CHECK OIL LEVEL IN TRANSMISSION CASE.............................................. 441 CHECK FRONT AXLE OIL LEVEL........................................................ 442 CHECK REAR AXLE OIL LEVEL......................................................... 442 BLEED AIR FROM SYSTEM............................................................. 443 CHECK ELECTRIC EQUIPMENT.......................................................... 443 CONNECTOR CONTACT IDENTIFICATION...................................................... 448 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE............................................... 490 FUSE LOCATION TABLE................................................................... 496 FAILURE CODE TABLE.................................................................... 500 TRANSMISSION AND STEERING ECU FAILURE CODE TABLE.................................. 500 MACHINE ECU FAILURE CODE TABLE.................................................... 502 MONITOR ECU FAILURE CODE TABLE.................................................... 505 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)..................................... 506 Failure Code [#T0022]............................................................. 506 Failure Code [#T0023]............................................................. 510 Failure Code [#T0037]............................................................. 514 Failure Code [#T0038]............................................................. 517 Failure Code [#T0039]............................................................. 520 Failure Code [#T0040]............................................................. 523 Failure Code [#T0041]............................................................. 526 Failure Code [#T0042]............................................................. 529 Failure Code [#T0043]............................................................. 532 Failure Code [#T0044]............................................................. 535 Failure Code [#T0045]............................................................. 538 Failure Code [#T0046]............................................................. 541 Failure Code [#T0055]............................................................. 544 Failure Code [#T0056]............................................................. 548 Failure Code [#T0057]............................................................. 548 Failure Code [#T0058]............................................................. 551 Failure Code [#T0061]............................................................. 554 Failure Code [#T0062]............................................................. 557 Failure Code [#T0068]............................................................. 560 Failure Code [#T0069]............................................................. 561 Failure Code [#T0073]............................................................. 562 Failure Code [#T0075]............................................................. 564 Failure Code [#T0077]............................................................. 565 Failure Code [#T0078]............................................................. 566 Failure Code [#T0079]............................................................. 567 Failure Code [#T0080]............................................................. 568 Failure Code [#T0081]............................................................. 570 Failure Code [#T0082]............................................................. 571 Failure Code [#T0083]............................................................. 571 Failure Code [#T0084]............................................................. 571 Failure Code [#T0085]............................................................. 572 Failure Code [#T0090]............................................................. 572 Failure Code [#T0091]............................................................. 574 Failure Code [#T0092]............................................................. 576 Failure Code [#T0093]............................................................. 576 Failure Code [#T0094]............................................................. 577 Failure Code [#T0103]............................................................. 579 Failure Code [#T0105]............................................................. 582 Failure Code [#T0108]............................................................. 585 Failure Code [#T0109]............................................................. 587 Failure Code [#T0110]............................................................. 589 Failure Code [#T0111]............................................................. 591 Failure Code [#T0112]............................................................. 593 Failure Code [#T0113]............................................................. 595 Failure Code [#T0114]............................................................. 597 Failure Code [#T0115]............................................................. 598 Failure Code [#T0116]............................................................. 600 Failure Code [#T0123]............................................................. 601 Failure Code [#T0124]............................................................. 601 Failure Code [#T0125]............................................................. 601 Failure Code [#T0126]............................................................. 602 Failure Code [#T0127]............................................................. 602 Failure Code [#T0128]............................................................. 603 Failure Code [#T0129]............................................................. 604 Failure Code [#T0147]............................................................. 605 Failure Code [#T0148]............................................................. 606 Failure Code [#T0151]............................................................. 608 Failure Code [#T0152]............................................................. 608 Failure Code [#T0168]............................................................. 608 Failure Code [#T0169]............................................................. 609 Failure Code [#T0170]............................................................. 609 Failure Code [#T0173]............................................................. 609 Failure Code [#T0174]............................................................. 610 Failure Code [#T0183]............................................................. 610 Failure Code [#T0185]............................................................. 610 Failure Code [#T0188]............................................................. 610 Failure Code [#T0191]............................................................. 611 Failure Code [#T0192]............................................................. 613 Failure Code [#T0193]............................................................. 614 Failure Code [#T0196]............................................................. 614 Failure Code [#T0198]............................................................. 615 Failure Code [#T0199]............................................................. 615 Failure Code [#T0200]............................................................. 616 Failure Code [#T0201]............................................................. 617 Failure Code [#T0204]............................................................. 618 Failure Code [#T0205]............................................................. 619 Failure Code [#T0207]............................................................. 620 Failure Code [#T0208]............................................................. 621 Failure Code [#T0209]............................................................. 623 Failure Code [#T0210]............................................................. 623 Failure Code [#T0211]............................................................. 623 Failure Code [#T0213]............................................................. 625 Failure Code [#T0215]............................................................. 626 Failure Code [#T0217]............................................................. 629 Failure Code [#T0219]............................................................. 630 Failure Code [#T0220]............................................................. 631 Failure Code [#T0221]............................................................. 632 Failure Code [#T0232]............................................................. 633 Failure Code [#T0236]............................................................. 634 Failure Code [#T0237]............................................................. 635 Failure Code [#T0238]............................................................. 636 Failure Code [#T0239]............................................................. 638 Failure Code [#T0240]............................................................. 639 Failure Code [#T0241]............................................................. 641 Failure Code [#T0242]............................................................. 642 Failure Code [#T0247]............................................................. 645 Failure Code [#T0248]............................................................. 648 Failure Code [#T0249]............................................................. 648 Failure Code [#T0251]............................................................. 650 Failure Code [#T0252]............................................................. 652 Failure Code [#T0254]............................................................. 654 Failure Code [#T0255]............................................................. 656 Failure Code [#T0256]............................................................. 658 Failure Code [#T0257]............................................................. 660 Failure Code [#T0258]............................................................. 660 Failure Code [#T0259]............................................................. 661 Failure Code [#T0260]............................................................. 661 Failure Code [#T0261]............................................................. 662 Failure Code [#T0262]............................................................. 662 Failure Code [#T0263]............................................................. 662 Failure Code [#T0264]............................................................. 663 Failure Code [#T0266]............................................................. 663 Failure Code [#T0267]............................................................. 663 Failure Code [#T0268]............................................................. 664 Failure Code [#T0269]............................................................. 664 Failure Code [#T0270]............................................................. 664 Failure Code [#T0272]............................................................. 664 Failure Code [#T0273]............................................................. 665 Failure Code [#T0274]............................................................. 666 Failure Code [#T0278]............................................................. 666 Failure Code [#T0279]............................................................. 667 Failure Code [#T0280]............................................................. 669 Failure Code [#T0281]............................................................. 670 Failure Code [#T0282]............................................................. 671 Failure Code [#T0283]............................................................. 672 Failure Code [#T0284]............................................................. 673 Failure Code [#T0285]............................................................. 674 Failure Code [#T0292]............................................................. 675 Failure Code [#T0293]............................................................. 676 Failure Code [#T0295]............................................................. 678 Failure Code [#T0303]............................................................. 680 Failure Code [#T0305]............................................................. 681 Failure Code [#T0308]............................................................. 682 Failure Code [#T0310]............................................................. 683 Failure Code [#T0311]............................................................. 684 Failure Code [#T0314]............................................................. 685 Failure Code [#T0318]............................................................. 686 Failure Code [#T0319]............................................................. 687 Failure Code [#T0320]............................................................. 688 Failure Code [#T0321]............................................................. 689 Failure Code [#T0322]............................................................. 690 Failure Code [#T0323]............................................................. 691 Failure Code [#T0324]............................................................. 692 Failure Code [#T0328]............................................................. 694 Failure Code [#T0329]............................................................. 695 Failure Code [#T0338]............................................................. 697 Failure Code [#T0339]............................................................. 699 Failure Code [#T0350]............................................................. 700 Failure Code [#T0356]............................................................. 702 Failure Code [#T0357]............................................................. 705 Failure Code [#T0400]............................................................. 708 Failure Code [#T0401]............................................................. 711 Failure Code [#T0402]............................................................. 714 Failure Code [#T0403]............................................................. 716 Failure Code [#T0404]............................................................. 718 Failure Code [#T0405]............................................................. 719 Failure Code [#T0406]............................................................. 720 Failure Code [#T0407]............................................................. 721 Failure Code [#T0408]............................................................. 723 Failure Code [#T0409]............................................................. 725 Failure Code [#T0410]............................................................. 726 Failure Code [#T0411]............................................................. 728 Failure Code [#T0412]............................................................. 729 Failure Code [#T0413]............................................................. 730 Failure Code [#T0414]............................................................. 731 Failure Code [#T0415]............................................................. 733 Failure Code [#T0416]............................................................. 733 Failure Code [#T0417]............................................................. 734 Failure Code [#T0418]............................................................. 736 Failure Code [#T0419]............................................................. 737 Failure Code [#T0420]............................................................. 739 Failure Code [#T0421]............................................................. 740 Failure Code [#T0422]............................................................. 742 Failure Code [#T0423]............................................................. 743 Failure Code [#T0424]............................................................. 745 Failure Code [#T0425]............................................................. 745 Failure Code [#T0426]............................................................. 747 Failure Code [#T0427]............................................................. 750 Failure Code [#T0428]............................................................. 751 Failure Code [#T0429]............................................................. 754 Failure Code [#T0430]............................................................. 754 Failure Code [#T0431]............................................................. 755 Failure Code [#T0432]............................................................. 756 Failure Code [#T0433]............................................................. 758 Failure Code [#T0434]............................................................. 760 Failure Code [#T0435]............................................................. 761 Failure Code [#T0436]............................................................. 763 Failure Code [#T0439]............................................................. 765 Failure Code [#T0440]............................................................. 766 Failure Code [#T0441]............................................................. 768 Failure Code [#T0442]............................................................. 771 Failure Code [#T0443]............................................................. 772 Failure Code [#T0444]............................................................. 773 Failure Code [#T0445]............................................................. 775 Failure Code [#T0446]............................................................. 775 Failure Code [#T0447]............................................................. 775 Failure Code [#T0448]............................................................. 776 Failure Code [#T0449]............................................................. 777 Failure Code [#T0450]............................................................. 778 Failure Code [#T0451]............................................................. 780 Failure Code [#T0452]............................................................. 782 Failure Code [#T0453]............................................................. 784 Failure Code [#T0454]............................................................. 786 Failure Code [#T0455]............................................................. 788 Failure Code [#T0456]............................................................. 790 Failure Code [#T0457]............................................................. 792 Failure Code [#T0458]............................................................. 793 Failure Code [#T0459]............................................................. 797 Failure Code [#T0460]............................................................. 798 Failure Code [#T0461]............................................................. 799 Failure Code [#T0462]............................................................. 799 Failure Code [#T0463]............................................................. 803 Failure Code [#T0464]............................................................. 803 Failure Code [#T0465]............................................................. 803 Failure Code [#T0466]............................................................. 804 Failure Code [#T0467]............................................................. 806 Failure Code [#T0468]............................................................. 808 Failure Code [#T0469]............................................................. 811 Failure Code [#T0470]............................................................. 814 Failure Code [#T0500]............................................................. 816 Failure Code [#T0501]............................................................. 817 Failure Code [#T0502]............................................................. 818 Failure Code [#T0504]............................................................. 819 Failure Code [#T0508]............................................................. 822 Failure Code [#T0509]............................................................. 824 Failure Code [#T0510]............................................................. 824 Failure Code [#T0511]............................................................. 828 Failure Code [#T0512]............................................................. 831 Failure Code [#T0513]............................................................. 834 Failure Code [#T0517]............................................................. 838 Failure Code [#T0519]............................................................. 838 Failure Code [#T0520]............................................................. 840 Failure Code [#T0521]............................................................. 843 Failure Code [#T0522]............................................................. 846 Failure Code [#T0530]............................................................. 849 Failure Code [#T0531]............................................................. 849 Failure Code [#T0532]............................................................. 850 Failure Code [#T0533]............................................................. 854 Failure Code [#T0534]............................................................. 854 Failure Code [#T0535]............................................................. 859 Failure Code [#T0536]............................................................. 863 Failure Code [#T0537]............................................................. 867 Failure Code [#T0538]............................................................. 867 Failure Code [#T0539]............................................................. 869 Failure Code [#T0540]............................................................. 870 Failure Code [#T0541]............................................................. 870 Failure Code [#T0542]............................................................. 872 Failure Code [#T0543]............................................................. 872 Failure Code [#T0544]............................................................. 873 Failure Code [#T0545]............................................................. 873 Failure Code [#T0546]............................................................. 873 Failure Code [#T0547]............................................................. 875 Failure Code [#T0550]............................................................. 877 Failure Code [#T0551]............................................................. 878 Failure Code [#T0555]............................................................. 880 Failure Code [#T0556]............................................................. 882 Failure Code [#T0557]............................................................. 882 Failure Code [#T0558]............................................................. 883 Failure Code [#T0565]............................................................. 883 Failure Code [#T0566]............................................................. 884 Failure Code [#T0567]............................................................. 886 Failure Code [#T0568]............................................................. 887 Failure Code [#T0573]............................................................. 888 Failure Code [#T0574]............................................................. 889 Failure Code [#T0575]............................................................. 890 Failure Code [#T0576]............................................................. 891 Failure Code [#T0577]............................................................. 891 Failure Code [#T0578]............................................................. 892 Failure Code [#T0579]............................................................. 892 Failure Code [#T0580]............................................................. 892 Failure Code [#T0581]............................................................. 893 Failure Code [#T0582]............................................................. 893 Failure Code [#T0583]............................................................. 893 Failure Code [#T0584]............................................................. 893 Failure Code [#T0585]............................................................. 893 Failure Code [#T0586]............................................................. 894 Failure Code [#T0587]............................................................. 894 Failure Code [#T0588]............................................................. 894 Failure Code [#T0589]............................................................. 895 Failure Code [#T0590]............................................................. 895 Failure Code [#T0591]............................................................. 895 Failure Code [#T0592]............................................................. 896 Failure Code [#T0593]............................................................. 896 Failure Code [#T0594]............................................................. 896 Failure Code [#T0595]............................................................. 897 Failure Code [#T0596]............................................................. 897 Failure Code [#T0597]............................................................. 897 Failure Code [#T0598]............................................................. 898 Failure Code [#T0599]............................................................. 898 Failure Code [#T0600]............................................................. 898 Failure Code [#T0601]............................................................. 899 Failure Code [#T0602]............................................................. 899 Failure Code [#T0603]............................................................. 899 Failure Code [#T0604]............................................................. 900 Failure Code [#T0605]............................................................. 900 Failure Code [#T0606]............................................................. 900 Failure Code [#T0607]............................................................. 901 Failure Code [#T0608]............................................................. 901 Failure Code [#T0609]............................................................. 901 Failure Code [#T0610]............................................................. 902 Failure Code [#T0611]............................................................. 903 Failure Code [#T0612]............................................................. 903 Failure Code [#T0613]............................................................. 904 Failure Code [#T0614]............................................................. 904 Failure Code [#T0615]............................................................. 905 Failure Code [#T0616]............................................................. 905 Failure Code [#T0617]............................................................. 905 Failure Code [#T0618]............................................................. 906 Failure Code [#T0619]............................................................. 906 Failure Code [#T0620]............................................................. 906 Failure Code [#T0621]............................................................. 907 Failure Code [#T0622]............................................................. 907 Failure Code [#T0623]............................................................. 907 Failure Code [#T0624]............................................................. 908 Failure Code [#T0625]............................................................. 908 Failure Code [#T0626]............................................................. 908 Failure Code [#T0627]............................................................. 909 Failure Code [#T0628]............................................................. 909 Failure Code [#T0630]............................................................. 909 Failure Code [#T0631]............................................................. 910 Failure Code [#T0632]............................................................. 910 Failure Code [#T0633]............................................................. 910 Failure Code [#T0634]............................................................. 911 Failure Code [#T0635]............................................................. 911 Failure Code [#T0636]............................................................. 911 Failure Code [#T0637]............................................................. 912 Failure Code [#T0638]............................................................. 912 Failure Code [#T0639]............................................................. 912 Failure Code [#T0640]............................................................. 913 Failure Code [#T0641]............................................................. 914 Failure Code [#T0642]............................................................. 914 Failure Code [#T0643]............................................................. 914 Failure Code [#T0644]............................................................. 915 Failure Code [#T0645]............................................................. 915 Failure Code [#T0646]............................................................. 915 Failure Code [#T0647]............................................................. 916 Failure Code [#T0648]............................................................. 916 Failure Code [#T0649]............................................................. 916 Failure Code [#T0650]............................................................. 917 Failure Code [#T0651]............................................................. 917 Failure Code [#T0652]............................................................. 917 Failure Code [#T0653]............................................................. 918 Failure Code [#T0654]............................................................. 918 Failure Code [#T0655]............................................................. 918 Failure Code [#T0656]............................................................. 918 Failure Code [#T0657]............................................................. 920 Failure Code [#T0658]............................................................. 921 Failure Code [#T0659]............................................................. 921 Failure Code [#T0660]............................................................. 921 Failure Code [#T0661]............................................................. 922 Failure Code [#T0662]............................................................. 922 Failure Code [#T0663]............................................................. 922 Failure Code [#T0664]............................................................. 924 Failure Code [#T0665]............................................................. 924 Failure Code [#T0666]............................................................. 926 Failure Code [#T0667]............................................................. 927 Failure Code [#T0669]............................................................. 929 Failure Code [#T0670]............................................................. 930 Failure Code [#T0672]............................................................. 931 Failure Code [#T0673]............................................................. 932 Failure Code [#T0674]............................................................. 934 Failure Code [#T0675]............................................................. 936 Failure Code [#T0676]............................................................. 937 Failure Code [#T0677]............................................................. 938 Failure Code [#T0678]............................................................. 939 Failure Code [#T0679]............................................................. 940 Failure Code [#T0680]............................................................. 941 Failure Code [#T0682]............................................................. 941 Failure Code [#T0683]............................................................. 943 Failure Code [#T0684]............................................................. 944 Failure Code [#T0685]............................................................. 945 Failure Code [#T0686]............................................................. 945 Failure Code [#T0687]............................................................. 946 Failure Code [#T0688]............................................................. 946 Failure Code [#T0689]............................................................. 946 Failure Code [#T0690]............................................................. 947 Failure Code [#T0691]............................................................. 947 Failure Code [#T0692]............................................................. 947 Failure Code [#T0693]............................................................. 948 Failure Code [#T0694]............................................................. 949 Failure Code [#T0695]............................................................. 951 Failure Code [#T0696]............................................................. 952 Failure Code [#T0697]............................................................. 953 Failure Code [#T0698]............................................................. 954 Failure Code [#T0699]............................................................. 954 Failure Code [#T0700]............................................................. 957 Failure Code [#T0701]............................................................. 960 Failure Code [#T0702]............................................................. 962 Failure Code [#T0703]............................................................. 962 Failure Code [#T0704]............................................................. 963 Failure Code [#T0705]............................................................. 963 Failure Code [#T0706]............................................................. 966 Failure Code [#T0707]............................................................. 968 Failure Code [#T0708]............................................................. 971 Failure Code [#T0709]............................................................. 972 Failure Code [#T0710]............................................................. 973 Failure Code [#T0711]............................................................. 973 Failure Code [#T0712]............................................................. 973 Failure Code [#T0713]............................................................. 973 Failure Code [#T0714]............................................................. 974 Failure Code [#T0715]............................................................. 974 Failure Code [#T0716]............................................................. 975 Failure Code [#T0717]............................................................. 975 Failure Code [#T0718]............................................................. 976 Failure Code [#T0719]............................................................. 976 Failure Code [#T0720]............................................................. 976 Failure Code [#T0721]............................................................. 978 Failure Code [#T0722]............................................................. 979 Failure Code [#T0723]............................................................. 980 Failure Code [#T0724]............................................................. 981 Failure Code [#T0725]............................................................. 983 Failure Code [#T0726]............................................................. 984 Failure Code [#T0728]............................................................. 986 Failure Code [#T0729]............................................................. 987 Failure Code [#T0730]............................................................. 989 Failure Code [#T0731]............................................................. 992 Failure Code [#T0732]............................................................. 993 Failure Code [#T0733]............................................................. 993 Failure Code [#T0734]............................................................. 995 Failure Code [#T0740]............................................................. 998 Failure Code [#T0742]............................................................. 999 Failure Code [#T0743].............................................................1001 50 DISASSEMBLY AND ASSEMBLY...................................................................1005 CONTENTS..................................................................................1006 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...........................................1010 HOW TO READ THIS MANUAL...............................................................1010 COATING MATERIALS LIST................................................................1012 ENGINE AND COOLING SYSTEM.................................................................1016 REMOVE AND INSTALL RADIATOR ASSEMBLY..................................................1016 REMOVE RADIATOR ASSEMBLY..........................................................1016 INSTALL RADIATOR ASSEMBLY.........................................................1019 REMOVE AND INSTALL OF FAN CLUTCH ASSEMBLY.............................................1021 REMOVE FAN CLUTCH ASSEMBLY........................................................1021 INSTALL FAN CLUTCH ASSEMBLY.......................................................1024 REMOVE AND INSTALL ENGINE.............................................................1025 REMOVE ENGINE.....................................................................1025 INSTALL ENGINE ASSEMBLY...........................................................1031 REMOVE AND INSTALL FUEL COOLER ASSEMBLY...............................................1033 REMOVE FUEL COOLER ASSEMBLY.......................................................1033 INSTALL FUEL COOLER ASSEMBLY......................................................1033 REMOVE AND INSTALL EXHAUST PIPE.......................................................1034 REMOVE EXHAUST PIPE...............................................................1034 INSTALL EXHAUST PIPE..............................................................1034 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY..............................................1035 REMOVE BELLOWS PIPE ASSEMBLY......................................................1035 INSTALL BELLOWS PIPE ASSEMBLY.....................................................1036 REMOVE AND INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC...........................1038 REMOVE NOx DETECTION SENSOR UPSTREAM OF THE DOC...................................1038 INSTALL NOx DETECTION SENSOR UPSTREAM OF THE DOC..................................1038 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC.................1040 REMOVE KDOC INLET TEMPERATURE SENSOR..............................................1040 INSTALL EXHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE DOC........................1040 REMOVE AND INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.........................1042 REMOVE NOx DETECTION SENSOR DOWNSTREAM OF THE SCR.................................1042 INSTALL NOx DETECTION SENSOR DOWNSTREAM OF THE SCR................................1043 REMOVE AND INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR...............1044 REMOVE SCR OUTLET TEMPERATURE SENSOR..............................................1044 INSTALL EXHAUST GAS TEMPERATURE SENSOR DOWNSTREAM OF THE SCR......................1045 REMOVE AND INSTALL DOC ASSEMBLY.......................................................1046 REMOVE DOC ASSEMBLY...............................................................1046 INSTALL DOC ASSEMBLY..............................................................1049 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY....................................1051 REMOVE DEF TANK SENSOR FLANGE ASSEMBLY............................................1051 INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...........................................1055 REMOVE AND INSTALL DEF TANK SENSOR....................................................1056 REMOVE DEF TANK SENSOR............................................................1056 INSTALL DEF TANK SENSOR...........................................................1056 REMOVE AND INSTALL DEF TANK STRAINER..................................................1058 REMOVE DEF TANK STRAINER..........................................................1058 INSTALL DEF TANK STRAINER.........................................................1058 REMOVE AND INSTALL DEF INJECTOR.......................................................1059 REMOVE DEF INJECTOR...............................................................1059 INSTALL DEF INJECTOR..............................................................1061 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...............................................1065 REMOVE AIR CLEANER ASSEMBLY.......................................................1065 INSTALL AIR CLEANER ASSEMBLY......................................................1065 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................1066 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY.........................................1066 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................1067 REMOVE AND INSTALL AIR CONDITIONER BELT...............................................1068 REMOVE AIR CONDITIONER BELT.......................................................1068 INSTALL AIR CONDITIONER BELT......................................................1068 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR.........................................1069 REMOVE AIR CONDITIONER COMPRESSOR.................................................1069 INSTALL AIR CONDITIONER COMPRESSOR................................................1071 UNDERCARRIAGE AND FRAME...................................................................1072 REMOVE AND INSTALL ENGINE HOOD........................................................1072 REMOVE ENGINE HOOD................................................................1072 INSTALL ENGINE HOOD...............................................................1073 REMOVE AND INSTALL COUNTERWEIGHT......................................................1074 REMOVE COUNTERWEIGHT..............................................................1074 INSTALL COUNTERWEIGHT.............................................................1074 REMOVE AND INSTALL FRONT AND REAR WHEELS..............................................1076 REMOVE FRONT AND REAR WHEELS......................................................1076 INSTALL FRONT AND REAR WHEELS.....................................................1076 POWER TRAIN...............................................................................1077 REMOVE AND INSTALL FRONT AXLE.........................................................1077 REMOVE FRONT AXLE.................................................................1077 INSTALL FRONT AXLE................................................................1078 DISASSEMBLE AND ASSEMBLE FRONT AXLE...................................................1080 DISASSEMBLE AND ASSEMBLE FLANGE GROUP.............................................1080 DISASSEMBLE AND ASSEMBLE TRUNNIONS GROUP..........................................1082 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1087 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1094 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1097 DISASSEMBLE AND ASSEMBLE AXLE BEAM GROUP..........................................1105 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1107 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP (LS)..................................1116 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1118 TESTING AFTER ASSEMBLY............................................................1125 REMOVE AND INSTALL REAR AXLE..........................................................1126 REMOVE REAR AXLE..................................................................1126 INSTALL REAR AXLE.................................................................1127 DISASSEMBLE AND ASSEMBLE REAR AXLE....................................................1129 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER GROUP..................................1129 DISASSEMBLE AND ASSEMBLE EPICYCLIC REDUCTION GEAR GROUP...........................1139 DISASSEMBLE AND ASSEMBLE WHEEL HUB GROUP..........................................1142 DISASSEMBLE AND ASSEMBLE FLANGE GROUP.............................................1149 DISASSEMBLE AND ASSEMBLE AXLE BEAM TRUMPET GROUP..................................1151 DISASSEMBLE AND ASSEMBLE BRAKE GROUP..............................................1156 DISASSEMBLE AND ASSEMBLE BRAKE CONTROL GROUP......................................1161 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL SUPPORT GROUP...............................1170 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL GROUP.......................................1178 DISASSEMBLE AND ASSEMBLE PINION GROUP.............................................1181 TESTING AFTER ASSEMBLY............................................................1188 REMOVE AND INSTALL TRANSMISSION.......................................................1189 REMOVE TRANSMISSION...............................................................1189 INSTALL TRANSMISSION..............................................................1194 DISASSEMBLE AND ASSEMBLE TRANSMISSION.................................................1195 DISASSEMBLE AND ASSEMBLE PLUGS, FILTERS AND SENSORS...............................1195 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER AND OIL PUMP............................1201 DISASSEMBLE AND ASSEMBLE HYDRAULIC CONTROL VALVE..................................1205 DISASSEMBLE AND ASSEMBLE HYDRAULIC SYSTEM PIPES...................................1210 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER VALVOLE KIT.............................1214 DISASSEMBLE AND ASSEMBLE TRANSMISSION HOUSING.....................................1216 DISASSEMBLE AND ASSEMBLE SHAFTS A - D.............................................1225 DISASSEMBLE AND ASSEMBLE SHAFT B..................................................1242 DISASSEMBLE AND ASSEMBLE SHAFT C..................................................1255 DISASSEMBLE AND ASSEMBLE SHAFT E..................................................1282 HYDRAULIC SYSTEM..........................................................................1295 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY............................................1295 REMOVE HYDRAULIC PUMP ASSEMBLY....................................................1295 INSTALL HYDRAULIC PUMP ASSEMBLY...................................................1297 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.........................1299 DISASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................1299 ASSEMBLY WORK EQUIPMENT PPC VALVE.................................................1299 WORK EQUIPMENT............................................................................1301 REMOVE AND INSTALL LOADER WORK EQUIPMENT ASSEMBLY.....................................1301 REMOVE LOADER WORK EQUIPMENT ASSEMBLY.............................................1301 INSTALL LOADER WORK EQUIPMENT ASSEMBLY............................................1303 REMOVE AND INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY....................................1305 REMOVE BACKHOE WORK EQUIPMENT ASSEMBLY............................................1305 INSTALL BACKHOE WORK EQUIPMENT ASSEMBLY...........................................1307 REMOVE AND INSTALL BACKHOE BOOM CYLINDER..............................................1308 REMOVE BACKHOE BOOM CYLINDER......................................................1308 INSTALL BACKHOE BOOM CYLINDER.....................................................1310 REMOVE AND INSTALL BACKHOE ARM CYLINDER...............................................1311 REMOVE BACKHOE ARM CYLINDER.......................................................1311 INSTALL BACKHOE ARM CYLINDER......................................................1312 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM CYLINDER....................................1313 REMOVE BACKHOE TELESCOPIC ARM CYLINDER............................................1313 INSTALL BACKHOE TELESCOPIC ARM CYLINDER...........................................1313 REMOVE AND INSTALL OUTRIGGER CYLINDER.................................................1314 REMOVE OUTRIGGER CYLINDER.........................................................1314 INSTALL OUTRIGGER CYLINDER........................................................1315 REMOVE AND INSTALL BACKHOE BOOM SWING CYLINDERS.......................................1316 REMOVE BACKHOE BOOM SWING CYLINDERS...............................................1316 INSTALL BACKHOE BOOM SWING CYLINDERS..............................................1317 REMOVE AND INSTALL BACKHOE BUCKET CYLINDER............................................1318 REMOVE BACKHOE BUCKET CYLINDER....................................................1318 INSTALL BACKHOE BUCKET CYLINDER...................................................1318 REMOVE AND INSTALL BACKHOE BOOM LOCK CYLINDER.........................................1320 REMOVE BACKHOE BOOM LOCK CYLINDER.................................................1320 INSTALL BACKHOE BOOM LOCK CYLINDER................................................1320 REMOVE AND INSTALL BACKHOE BOOM.......................................................1321 REMOVE BACKHOE BOOM...............................................................1321 INSTALL BACKHOE BOOM..............................................................1321 REMOVE AND INSTALL BACKHOE ARM ASSEMBLY...............................................1323 REMOVE BACKHOE ARM ASSEMBLY.......................................................1323 INSTALL BACKHOE ARM...............................................................1323 REMOVE AND INSTALL BACKHOE TELESCOPIC ARM ASSEMBLY....................................1325 REMOVE BACKHOE TELESCOPIC ARM ASSEMBLY............................................1325 INSTALL BACKHOE TELESCOPIC ARM....................................................1325 REMOVE AND INSTALL BACKHOE BOOM SWING BRACKET.........................................1327 REMOVE BACKHOE BOOM SWING BRACKET.................................................1327 INSTALL BACKHOE BOOM SWING BRACKET................................................1327 REMOVE AND INSTALL BACKHOE SLIDING BRACKET............................................1329 REMOVE BACKHOE SLIDING BRACKET....................................................1329 INSTALL BACKHOE SLIDING BRACKET...................................................1330 REMOVE AND INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON.............................1331 REMOVE BACKHOE SLIDING BRACKET LOCKING PISTON.....................................1331 INSTALL BACKHOE SLIDING BRACKET LOCKING PISTON....................................1331 CAB AND ITS ATTACHMENTS...................................................................1333 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY............................................1333 REMOVE OPERATOR'S CAB ASSEMBLY....................................................1333 INSTALL OPERATOR'S CAB ASSEMBLY...................................................1341 ELECTRICAL SYSTEM.........................................................................1343 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.........................................1343 REMOVE ENGINE CONTROLLER ASSEMBLY.................................................1343 INSTALL ENGINE CONTROLLER ASSEMBLY................................................1345 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...................................1346 REMOVE TRANSMISSION CONTROLLER ASSEMBLY...........................................1346 INSTALL TRANSMISSION CONTROLLER ASSEMBLY..........................................1348 REMOVE AND INSTALL FRONT PANEL........................................................1349 REMOVE FRONT PANEL................................................................1349 INSTALL FRONT PANEL...............................................................1350 REMOVE AND INSTALL STEERING COLUMN SWITCHES...........................................1351 REMOVE STEERING COLUMN SWITCHES...................................................1351 INSTALL STEERING COLUMN SWITCHES..................................................1352 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY..........................................1353 REMOVE KOMTRAX TERMINAL ASSEMBLY..................................................1353 INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................1353 REMOVE AND INSTALL BACKHOE PPC VALVE..................................................1355 REMOVE BACKHOE PPC VALVE..........................................................1355 INSTALL BACKHOE PPC VALVE.........................................................1356 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES...........................1357 REMOVE BACKHOE PPC VALVE SUPPORT RELEASE CABLES...................................1357 INSTALL BACKHOE PPC VALVE SUPPORT RELEASE CABLES..................................1358 REMOVE AND INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING........................1359 REMOVE BACKHOE PPC VALVE SUPPORT RETURN GAS SPRING................................1359 INSTALL BACKHOE PPC VALVE SUPPORT RETURN GAS SPRINGS..............................1360 60 MAINTENANCE STANDARD.......................................................................1361 CONTENTS..................................................................................1362 ENGINE AND COOLING SYSTEM.................................................................1363 MAINTENANCE STANDARD OF ENGINE MOUNT..................................................1363 MAINTENANCE STANDARD OF COOLING SYSTEM................................................1365 POWER TRAIN...............................................................................1366 MAINTENANCE STANDARD OF TRANSMISSION..................................................1366 MAINTENANCE STANDARD OF FRONT AXLE....................................................1369 MAINTENANCE STANDARD OF REAR AXLE.....................................................1375 HYDRAULIC SYSTEM..........................................................................1385 MAINTENANCE STANDARD OF MAIN PUMP.....................................................1385 MAINTENANCE STANDARD OF CONTROL VALVE.................................................1387 WORK EQUIPMENT............................................................................1397 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT PPC VALVE...............................1397 LOADER WORK EQUIPMENT PPC VALVE - STANDARD VERSION................................1397 LOADER WORK EQUIPMENT PPC VALVE - FLOAT AND RETURN TO DIG VERSION.................1400 MAINTENANCE STANDARD OF SWING BRACKET.................................................1403 MAINTENANCE STANDARD OF LOADER WORK EQUIPMENT.........................................1405 MAINTENANCE STANDARD OF BACKHOE WORK EQUIPMENT........................................1407 MAINTENANCE STANDARD OF WORK EQUIPMENT CYLINDERS......................................1409 LOADER ARM CYLINDER...............................................................1409 LOADER BUCKET CYLINDER............................................................1409 LOADER BUCKET 4 IN 1 CYLINDER.....................................................1410 BACKHOE BOOM CYLINDER.............................................................1411 BACKHOE ARM CYLINDER..............................................................1411 BACKHOE BUCKET CYLINDER...........................................................1412 BACKHOE BOOM SWING CYLINDER.......................................................1413 BACKHOE TELESCOPIC ARM CYLINDER...................................................1414 OUTRIGGER CYLINDER................................................................1414 90 CIRCUIT DIAGRAMS...........................................................................1417 CONTENTS..................................................................................1418 HOW TO READ THE CODES FOR ELECTRIC CABLE..................................................1419 HYDRAULIC CIRCUIT DIAGRAM.................................................................1423 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.............................................1423 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/2)....................................1427 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/2)....................................1429 ELECTRICAL CIRCUIT DIAGRAM................................................................1431 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM..............................................1431 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/12)..........................................1435 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/12)..........................................1437 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/12)..........................................1439 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/12)..........................................1441 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/12)..........................................1443 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/12)..........................................1445 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/12)..........................................1447 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/12)..........................................1449 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/12)..........................................1451 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/12).........................................1453 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/12).........................................1455 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/12).........................................1457
DESCRIPTION:
KOMATSU WB97S-8E0 BACKHOE LOADER SHOP MANUAL WENBM00350 – 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
