Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual CEBM019111 – PDF DOWNLOAD

Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual CEBM019111 – PDF DOWNLOAD

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Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual CEBM019111 – PDF DOWNLOAD

Language : English
Pages : 1266
Downloadable : Yes
File Type : PDF
Size: 77.6 MB

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Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual CEBM019111 – PDF DOWNLOAD

SERIAL NUMBERS

D51EX-22 B10001 and up
D51PX-22 B10001 and up
ENGINE 6D107E-1

GENERAL;

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
OTHER
This section has the foldout drawings for the machine.

FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
412. Repair Limit And Allowable Value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer’s requirement.
5. Clearance Limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts
cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference Limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.

TABLE OF CONTENTS:

Komatsu D51EX-22 D51PX-22 Crawler Dozer Shop Manual CEBM019111 – PDF DOWNLOAD

D51EX-22 SM Title Page rev11 pdf 0
CONTENTS 2
00 FOREWORD 0
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 13
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
PUSH PULL COUPLER 18
TYPE 1 18
DISCONNECTION 18
CONNECTION 18
TYPE 2 19
DISCONNECTION 19
CONNECTION 19
TYPE 3 20
DISCONNECTION 20
CONNECTION 20
EXPLANATION OF MAINTENANCE STANDARD TERMS 21
STANDARD TIGHTENING TORQUE 23
BOLTS AND NUTS 23
TIGHTENING TORQUE OF HOSE NUTS 24
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 24
TIGHTENING TORQUE FOR FLARED NUTS 24
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 25
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 25
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 25
ELECTRIC WIRE CODE 26
CLASSIFICATION BY THICKNESS 26
CLASSIFICATION BY COLOR AND CODE 26
HOW TO READ ELECTRIC WIRE CODE 27
CONVERSION TABLES 30
METHOD OF USING THE CONVERSION TABLE 30
COATING MATERIALS 36
01 GENERAL 39
SPECIFICATION DRAWING 40
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB 40
SPECIFICATION 41
WEIGHT TABLE 45
TABLE OF FUEL, COOLANT AND LUBRICANTS 48
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS 50
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD 51
ENGINE AND COOLING SYSTEM 53
ENGINE RELATED PARTS 53
COOLING SYSTEM 55
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP) 58
COOLING FAN MOTOR 59
OIL COOLER BYPASS VALVE 65
CHARGE SAFETY VALVE 68
POWER TRAIN 70
POWER TRAIN 70
POWER TRAIN SYSTEM 71
DAMPER 72
FINAL DRIVE 73
PATH OF POWER TRANSMISSION 76
UNDER CARRIAGE AND FRAME 77
MAIN FRAME 77
TRACK FRAME AND RECOIL SPRING 78
SUSPENSION 80
IDLER 83
TRACK ROLLER 85
CARRIER ROLLER 89
TRACK SHOE 95
HYDRAULIC SYSTEM 1 (HST) 100
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 100
HST PUMP 101
SAFETY-SUCTION VALVE 109
TOWING VALVE 112
HST MOTOR 113
MOTOR CONTROL VALVE 125
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE 125
SOLENOID VALVE 127
EPC VALVE 128
CHARGE PUMP 132
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT) 134
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) 134
UNLOAD VALVE 138
PRESSURE COMPENSATION VALVE 144
LS BYPASS VALVE 145
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM 146
WORK EQUIPMENT AND FAN PUMP 147
SERVO VALVE 152
CONTROL VALVE 154
QUICK DROP VALVE 166
BLADE PPC VALVE 168
RIPPER/WINCH PPC VALVE 174
HYDRAULIC TANK, FILTER 178
ACCUMULATOR 179
WORK EQUIPMENT 180
WORK EQUIPMENT 180
CUTTING EDGE AND END BIT 185
RIPPER 186
WORK EQUIPMENT CYLINDER 187
LIFT CYLINDER 187
TILT CYLINDER 187
ANGLE CYLINDER 188
RIPPER CYLINDER 188
PISTON VALVE FOR ANGLE CYLINDER 190
CAB AND ITS ATTACHMENTS 191
ROPS CAB 191
STEERING AND BRAKE CONTROL 192
WORK EQUIPMENT CONTROL 194
CAB DAMPER MOUNT 196
AIR CONDITIONER 197
AIR CONDITIONER AND FLOOR HEATER 197
AIR CONDITIONER PIPING 198
ELECTRICAL SYSTEM 199
MONITOR SYSTEM 199
ENGINE CONTROL 201
ENGINE CONTROL SYSTEM 202
COOLING CONTROL SYSTEM 204
HST CONTROL SYSTEM 206
GEAR SHIFT CONTROL SYSTEM 207
GEAR SHIFTING BY OPERATOR 207
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS 208
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED 210
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM 211
PARKING BRAKE CONTROL SYSTEM 212
KOMTRAX SYSTEM 214
SYSTEM COMPONENTS 216
MONITOR PANEL 216
ENGINE CONTROLLER 220
HST CONTROLLER 222
ELECTRIC LEVER (FOR TRAVEL) 224
KOMTRAX TERMINAL 226
SENSORS 227
BRAKE OIL PRESSURE SENSOR 228
HYDRAULIC OIL TEMPERATURE SENSOR 229
HST CIRCUIT OIL PRESSURE SENSOR 230
AIR CLEANER CLOGGING SENSOR 231
DECELERATOR PEDAL POTENTIOMETER 232
BRAKE PEDAL POTENTIOMETER 232
FUEL CONTROL DIAL 233
FUEL LEVEL SENSOR 234
CHARGE FILTER CLOGGING SENSOR 235
COOLANT TEMPERATURE SENSOR 235
ENGINE OIL PRESSURE SWITCH 236
ENGINE ROTATION SENSOR 236
BOOST PRESSURE AND TEMPERATURE SENSOR 237
WIF SENSOR 237
HST MOTOR SPEED SENSOR 238
20 STANDARD VALUE TABLES 239
STANDARD VALUE TABLE FOR ENGINE 240
STANDARD VALUE TABLE FOR CHASSIS 241
PERFORMANCE MEASURING POSTURE AND METHOD 246
30 TESTING AND ADJUSTING 249
LIST OF TOOLS 251
ENGINE 254
ENGINE SPEED 254
AIR INTAKE BOOST PRESSURE 255
EXHAUST TEMPERATURE 256
EXHAUST GAS COLOR 258
VALVE CLEARANCE 259
COMPRESSION PRESSURE 262
BLOW-BY PRESSURE 264
ENGINE OIL PRESSURE 265
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 266
FUEL SYSTEM 267
HANDLING FUEL SYSTEM PARTS 267
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 267
BLEEDING AIR FROM FUEL CIRCUIT 268
FUEL PRESSURE 270
FUEL RETURN RATE AND LEAKAGE 272
FUEL CIRCUIT FOR LEAKAGE 275
FAN (WORK EQUIPMENT) PUMP PRESSURE 276
FAN SPEED 276
FAN SPEED SENSOR 277
DECELERATOR PEDAL 279
HST OIL PRESSURE 281
MOTOR CONTROL VALVE OUTLET PRESSURE 286
TRAVEL DEVIATION 289
PARKING BRAKE LEVER 290
BRAKE PERFORMANCE 292
BRAKE PEDAL LINKAGE 293
EMERGENCY RELEASE OF PARKING BRAKE 295
IDLER CLEARANCE 298
TRACK SHOE TENSION 300
WORK EQUIPMENT 301
OIL PRESSURE 301
WORK EQUIPMENT PPC VALVE 303
OIL PRESSURE 303
PPC circuit connection diagram 304
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 1 305
LOCK LEVER ADJUSTMENT 306
CYLINDER LEAKAGE 307
HYDRAULIC CIRCUIT 309
RELEASING RESIDUAL PRESSURE 309
BLEEDING AIR 310
BLADE CENTER BALL ADJUSTMENT 311
BLADE PITCH BALL ADJUSTMENT 311
DIODES 312
PROCEDURE FOR TESTING 312
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS 314
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM 375
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED 377
ITEMS TO BE ADJUSTED 377
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT 378
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT 381
PM-CLINIC 383
PM-CLINIC SERVICE 383
PM-CLINIC INSPECTION SHEET (1/2) 386
PM-CLINIC INSPECTION SHEET (2/2) 387
PM-CLINIC UNDERCARRIAGE CHECK SHEET 388
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) 389
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) 390
PM-CLINIC UNDERCARRIAGE CHECK SHEET 391
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) 392
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) 393
40 TROUBLESHOOTING 395
TROUBLESHOOTING (GENERAL) 395
POINTS TO REMEMBER WHEN TROUBLESHOOTING 396
SEQUENCE OF EVENTS IN TROUBLESHOOTING 398
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 399
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT 399
HANDLING ELECTRONIC CONTROL UNIT 404
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 405
ELECTRIC WIRE CODE 406
CLASSIFICATION BY THICKNESS 406
CLASSIFICATION BY COLOR AND CODE 406
HOW TO READ ELECTRIC WIRE CODE 407
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 409
CHECKS BEFORE TROUBLESHOOTING 411
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS 412
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS 413
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 416
T-ADAPTER TABLE 440
MODE CHART 444
TROUBLESHOOTING (BY ERROR CODE) 447
TROUBLESHOOTING BY ERROR CODE 453
INFORMATION IN TROUBLESHOOTING TABLE 460
ERROR CODE [6091NX] 462
HST CHARGE FILTER ELEMENT CLOGGING 462
ERROR CODE [AA10NX] 464
AIR CLEANER CLOGGING 464
ERROR CODE [AB00MA] 466
ALTERNATOR MALFUNCTION 466
ERROR CODE [B@BAZG] 467
ENGINE OIL LOWERING OF OIL PRESSURE 467
ERROR CODE [B@BCNS] 468
COOLANT OVERHEAT 468
ERROR CODE [B@CRNS] 469
HST OIL OVERHEATING 469
ERROR CODE [B@CRZG] 470
HST OIL LOWERING OF OIL PRESSURE 470
ERROR CODE [CA111] 471
ABNORMALITY IN ENGINE CONTROLLER 471
ERROR CODE [CA115] 472
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL 472
ERROR CODE [CA122] 474
CHARGE PRESSURE SENSOR TOO HIGH 474
ERROR CODE [CA123] 476
CHARGE PRESSURE SENSOR TOO LOW 476
ERROR CODE [CA131] 478
DECELERATOR PEDAL SENSOR TOO HIGH 478
ERROR CODE [CA132] 480
DECELERATOR PEDAL SENSOR TOO LOW 480
ERROR CODE [CA144] 482
COOLANT TEMPERATURE SENSOR TOO HIGH 482
ERROR CODE [CA145] 484
COOLANT TEMPERATURE SENSOR TOO LOW 484
ERROR CODE [CA153] 486
CHARGE TEMPERATURE SENSOR TOO HIGH 486
ERROR CODE [CA154] 488
CHARGE TEMPERATURE SENSOR TOO low 488
ERROR CODE [CA187] 490
SENSOR POWER SORCE EXCESSIVELY LOW 490
ERROR CODE [CA221] 492
ATMOSPHERIC PRESSURE SENSOR TOO HIGH 492
ERROR CODE [CA222] 494
ATMOSPHERIC PRESSURE SENSOR TOO LOW 494
ERROR CODE [CA227] 496
SENSOR POWER SORCE EXCESSIVELY HIGH 496
ERROR CODE [CA234] 498
ENGINE OVERSPEED 498
ERROR CODE [CA238] 499
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR 499
ERROR CODE [CA271] 500
IMV/PCV1 SHORT CIRCUITED 500
ERROR CODE [CA272] 502
IMV/PCV1 OPEN 502
ERROR CODE [CA322] 504
NO 1 INJECTOR SHOWING OPEN OR SHORT 504
ERROR CODE [CA323] 506
NO 5 INJECTOR SHOWING OPEN OR SHORT 506
ERROR CODE [CA324] 508
NO 3 INJECTOR SHOWING OPEN OR SHORT 508
ERROR CODE [CA325] 510
NO 6 INJECTOR SHOWING OPEN OR SHORT 510
ERROR CODE [CA331] 512
NO 2 INJECTOR SHOWING OPEN OR SHORT 512
ERROR CODE [CA332] 514
NO 4 INJECTOR SHOWING OPEN OR SHORT 514
ERROR CODE [CA342] 516
ENGINE CONTROLLER DATA MATCHING ERROR 516
ERROR CODE [CA352] 517
SENSOR POWER SOURCE TOO LOW 517
ERROR CODE [CA386] 518
SENSOR POWER SOURCE TOO HIGH 518
ERROR CODE [CA428] 520
WATER IN FUEL SENSOR VOLTAGE TOO HIGH 520
ERROR CODE [CA429] 522
WATER IN FUEL SENSOR VOLTAGE TOO LOW 522
ERROR CODE [CA435] 524
ABNORMAL ENGINE OIL PRESSURE SWITCH 524
ERROR CODE [CA441] 526
POWER SOURCE VOLTAGE IS TOO LOW 526
ERROR CODE [CA442] 528
POWER SOURCE VOLTAGE TOO HIGH 528
ERROR CODE [CA449] 530
COMMON RAIL PRESSURE TOO HIGH 530
ERROR CODE [CA451] 532
COMMON RAIL PRESSURE TOO HIGH 532
ERROR CODE [CA452] 534
COMMON RAIL PRESSURE TOO LOW 534
ERROR CODE [CA488] 536
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED 536
ERROR CODE [CA553] 537
COMMON RAIL PRESSURE TOO HIGH 537
ERROR CODE [CA559] 538
LOSS OF PRESSURE FEED FROM SUPPLY PUMP 538
ERROR CODE [CA689] 540
ABNORMAL ENGINE NE SPEED SENSOR 540
ERROR CODE [CA731] 542
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE 542
ERROR CODE [CA757] 544
LOSS OF ALL ENGINE CONTROLLER DATA 544
ERROR CODE [CA778] 546
ABNORMAL ENGINE BKUP SPEED SENSOR 546
ERROR CODE [CA1633] 548
ABNORMAL KOMNET 548
ERROR CODE [CA2185] 550
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH 550
ERROR CODE [CA2186] 551
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW 551
ERROR CODE [CA2249] 552
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) 552
ERROR CODE [CA2311] 554
ABNORMAL IMV SOLENOID 554
ERROR CODE [CA2555] 556
AIR INTAKE HEATER RELAY DISCONNECTION 556
ERROR CODE [CA2556] 558
AIR INTAKE HEATER RELAY SHORT CIRCUIT 558
ERROR CODE [D130KA] 560
NEUTRAL SAFETY RELAY DISCONNECTION 560
ERROR CODE [D130KB] 562
NEUTRAL SAFETY RELAY SHORT CIRCUIT 562
ERROR CODE [DAFRKR] 564
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER 564
ERROR CODE [DAFRMC] 566
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER 566
ERROR CODE [DAJ000] 568
HST CONTROLLER MEMORY ERROR 568
ERROR CODE [DAJ0KK] 570
HST CONTROLLER LOWERING OF SOURCE VOLTAGE 570
ERROR CODE [DAJ0KQ] 572
HST CONTROLLER MACHINE CODE ERROR 572
ERROR CODE [DAJ0KT] 573
HST CONTROLLER MEMORY ERROR 573
ERROR CODE [DAJ5KK] 574
HST CONTROLLER POWER SUPPLY LOWING 574
ERROR CODE [DAJ6KK] 576
HST POWER SUPPLY LOWING 576
ERROR CODE [DAJRKR] 578
CAN COMMUNICATION HST CONTROLLER DEFECTIVE 578
ERROR CODE [DB2RKR] 580
CAN COMMUNICATION HST CONTROLLER DEFECTIVE 580
ERROR CODE [DD12KA] 582
SHIFT UP SWITCH DISCONNECTION 582
ERROR CODE [DD12KB] 584
SHIFT UP SWITCH SHORT CIRCUIT 584
ERROR CODE [DD13KA] 586
SHIFT DOWN SWITCH DISCONNECTION 586
ERROR CODE [DD13KB] 588
SHIFT DOWN SWITCH SHORT CIRCUIT 588
ERROR CODE [DD14KB] 590
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT 590
ERROR CODE [DD1NL4] 592
FAN ROTATION SELECTOR SWITCH DISAGREEMENT 592
ERROR CODE [DDDCKB] 594
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT 594
ERROR CODE [DDP6KA] 596
BRAKE OIL PRESSURE SENSOR DISCONNECTION 596
ERROR CODE [DDP6KB] 598
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT 598
ERROR CODE [DDP6MA] 600
BRAKE OIL PRESSURE SENSOR MALFUNCTION 600
ERROR CODE [DDQ2KA] 602
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION 602
ERROR CODE [DDT0L4] 604
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS 604
ERROR CODE [DDU1FS] 606
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING 606
ERROR CODE [DDU1KA] 608
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION 608
ERROR CODE [DDU1KY] 610
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE 610
ERROR CODE [DGS1KA] 612
HST OIL TEMPERATURE SENSOR DISCONNECTION 612
ERROR CODE [DGS1KX] 614
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE 614
ERROR CODE [DHH5KA] 615
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION 615
ERROR CODE [DHH5KB] 617
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT 617
ERROR CODE [DHH6KA] 619
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION 619
ERROR CODE [DHH6KB] 621
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT 621
ERROR CODE [DK10KA] 623
FUEL DIAL SENSOR DISCONNECTION 623
ERROR CODE [DK10KB] 625
FUEL DIAL SENSOR SHORT CIRCUIT 625
ERROR CODE [DK30KA] 627
STEERING ANGLE SENSOR 1 DISCONNECTION 627
ERROR CODE [DK30KB] 629
STEERING ANGLE SENSOR 1 SHORT CIRCUIT 629
ERROR CODE [DK30KX] 631
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE 631
ERROR CODE [DK30KZ] 632
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT 632
ERROR CODE [DK30L8] 633
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS 633
ERROR CODE [DK31KA] 635
STEERING ANGLE SENSOR DISCONNECTION 635
ERROR CODE [DK31KB] 637
STEERING ANGLE SENSOR 2 SHORT CIRCUIT 637
ERROR CODE [DK40KA] 639
BRAKE PEDAL SENSOR DISCONNECTION 639
ERROR CODE [DK40KB] 641
BRAKE PEDAL SENSOR SHORT CIRCUIT 641
ERROR CODE [DK55KX] 643
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE 643
ERROR CODE [DK55KZ] 644
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT 644
ERROR CODE [DK55L8] 645
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS 645
ERROR CODE [DK56KA] 647
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION 647
ERROR CODE [DK56KB] 649
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT 649
ERROR CODE [DK57KA] 651
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION 651
ERROR CODE [DK57KB] 653
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT 653
ERROR CODE [DLM0KX] 655
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE 655
ERROR CODE [DLM1KA] 657
LEFT HST MOTOR SPEED SENSOR DISCONNECTION 657
ERROR CODE [DLM1KB] 659
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT 659
ERROR CODE [DLM1MA] 661
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION 661
ERROR CODE [DLM2KA] 663
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION 663
ERROR CODE [DLM2KB] 665
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT 665
ERROR CODE [DLM2MA] 667
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION 667
ERROR CODE [DLM3KA] 669
FAN SPEED SENSOR DISCONNECTION 669
ERROR CODE [DLM3KB] 671
FAN SPEED SENSOR: SHORT CIRCUIT 671
ERROR CODE [DN21FS] 673
BRAKE PEDAL AND PROXIMITY SWITCH FIXING 673
ERROR CODE [DV00KB] 675
CAUTION BUZZER SHORT CIRCUIT 675
ERROR CODE [DV20KB] 676
BACK ALARM BUZZER SHORT CIRCUIT 676
ERROR CODE [DW4BKA] 677
PARKING BRAKE SOLENOID VALVE DISCONNECTION 677
ERROR CODE [DW4BKB] 679
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT 679
ERROR CODE [DW4BKY] 681
PARKING BRAKE SOLENOID VALVE SHORTED 681
ERROR CODE [DW7BKA] 682
FAN REVERSE SOLENOID VALVE DISCONNECTION 682
ERROR CODE [DW7BKB] 682
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT 683
ERROR CODE [DW7BKY] 684
FAN REVERSE SOLENOID VALVE SHORTED 684
ERROR CODE [DW7EKA] 685
SLOW BRAKE SOLENOID VALVE DISCONNECTION 685
ERROR CODE [DW7EKB] 689
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT 689
ERROR CODE [DW7EKY] 691
SLOW BRAKE SOLENOID VALVE SHORTED 691
ERROR CODE [DWN5KA] 693
FAN EPC SOLENOID VALVE DISCONNECTION 693
ERROR CODE [DWN5KB] 695
FAN EPC SOLENOID VALVE SHORT CIRCUIT 695
ERROR CODE [DWN5KY] 697
FAN EPC SOLENOID VALVE SHORTED 697
ERROR CODE [DXA4KA] 699
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION 699
ERROR CODE [DXA4KB] 701
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT 701
ERROR CODE [DXA4KY] 702
LF HST PUMP EPC SOLENOID VALVE SHORTED 702
ERROR CODE [DXA5KA] 703
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION 703
ERROR CODE [DXA5KB] 705
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT 705
ERROR CODE [DXA5KY] 706
LR HST PUMP EPC SOLENOID VALVE SHORTED 706
ERROR CODE [DXA6KA] 707
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION 707
ERROR CODE [DXA6KB] 709
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT 709
ERROR CODE [DXA6KY] 710
RF HST PUMP EPC SOLENOID VALVE SHORTED 710
ERROR CODE [DXA7KA] 711
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION 711
ERROR CODE [DXA7KB] 712
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT 712
ERROR CODE [DXA7KY] 713
RR HST PUMP EPC SOLENOID VALVE SHORTED 713
ERROR CODE [DXK1KA] 714
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION 714
ERROR CODE [DXK1KB] 715
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT 715
ERROR CODE [DXK1KY] 716
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED 716
ERROR CODE [DXK2KA] 717
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION 717
ERROR CODE [DXK2KB] 718
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT 718
ERROR CODE [DXK2KY] 719
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED 719
TROUBLESHOOTING (E-MODE) 723
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE) 725
CONNECTION TABLE OF FUSE BOX 725
INFORMATION IN TROUBLESHOOTING TABLE 727
E-1 728
STARTING MOTOR DOES NOT ROTATE 728
E-2 732
ENGINE IS NOT PRE-HEATED 732
E-3 736
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT 736
E-4 738
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING 738
E-5 740
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING 740
E-6 744
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION 744
E-7 746
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 746
E-8 747
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 747
E-9 748
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY 748
E-10 750
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY 750
E-11 750
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY 750
E-12 751
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF 751
E-13 752
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP 752
E-14 754
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION 754
E-15 756
SHIFT MODE SWITCH DOES NOT FUNCTION 756
E-16 758
BUZZER CANCEL SWITCH DOES NOT FUNCTION 758
E-17 760
INFORMATION SWITCH DOES NOT FUNCTION 760
E-18 762
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET 762
E-19 764
BACKUP ALARM DOES NOT SOUND 764
E-20 765
THE HORN DOES NOT SOUND OR DOES NOT STOP 765
E-21 766
WORK EQUIPMENT DOES NOT MOVE 766
E-22 768
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP 768
E-23 772
FOOT HEATER DOES NOT OPERATE 772
E-24 776
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION] 776
E-25 781
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION] 781
E-26 794
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 794
TROUBLESHOOTING (H-MODE) 797
INFORMATION IN TROUBLESHOOTING TABLE 798
H-1 799
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE 799
H-2 801
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE 801
H-3 802
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE 802
H-4 803
SPEED OR POWER OF TRAVEL IS LOW 803
H-5 804
GEAR IS NOT SHIFTED 804
H-6 805
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl 805
H-7 806
MACHINE DEVIATES LARGELY DURING TRAVEL 806
H-8 807
HYDRAULIC DRIFT OF TRAVEL IS LARGE 807
H-9 808
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl 808
H-10 809
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR 809
H-11 810
WORK EQUIPMENT DOSE NOT OPERATE AT ALL 810
H-12 811
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW 811
H-13 812
SPEED OR POWER OF LIFTING BLADE IS LOW 812
H-14 813
SPEED OR POWER OF TILTING BLADE IS LOW 813
H-15 814
SPEED OR POWER OF ANGLING BLADE IS LOW 814
H-16 815
TIME LAG IN LIFTING BLADE IS LARGE 815
H-17 816
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE 816
H-18 817
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE 817
H-19 818
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND CONTROL VALVE 818
H-20 819
HST OIL TEMPERATURE RISES TOO HIGH 819
H-21 820
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM) 820
TROUBLESHOOTING (S-MODE) 821
METHOD OF USING TROUBLESHOOTING CHARTS 822
(S-1) ENGINE STARTING PERFORMANCE IS POOR 826
(S-2) ENGINE DOES NOT CRANK 827
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK 828
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START 829
(S-3) ENGINE DOES NOT RUN SMOOTHLY 830
(S-4) ENGINE STOPS DURING OPERATIONS 831
(S-5) ENGINE SPEED HUNTS 832
(S-6) ENGINE LACKS POWER 833
(S-7) EXHAUST SMOKE IS BLACK 835
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 836
(S-9) OIL BECOMES CONTAMINATED QUICKLY 837
(S-10) FUEL CONSUMPTION IS EXCESSIVE 838
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR 839
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP 840
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) 841
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) 842
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING 843
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING 844
50 DISASSEMBLY AND ASSEMBLY 845
HOW TO USE THIS MANUAL 848
REMOVAL AND INSTALLATION OF COMPONENTS 848
Special Tools 848
OVERHAUL OF COMPONENTS 849
Special Tools 849
Disassembly Procedures 849
Assembly Procedures 849
PRECAUTIONS WHEN CARRYING OUT AN OPERATION 850
SPECIAL TOOL LIST 852
SKETCH OF SPECIAL TOOLS 859
CONNECTOR REPAIR PROCEDURES 874
CONTACT TERMINAL REMOVAL (HD30 TYPE) 874
STRIPPING INSULATION 875
CRIMPING CONTACT TERMINAL (HD30 TYPE) 876
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 877
CONTACT TERMINAL REMOVAL (DT TYPE) 878
STRIPPING INSULATION 879
CRIMPING CONTACT TERMINAL (DT TYPE) 880
INSERTION OF CONTACT TERMINAL (DT TYPE) 881
NOSE GUARD (HOOD) 883
REMOVAL 883
OPENING FRONT GRILL 883
REMOVING SIDE PANELS 884
DISCONNECTING HOOD-RELATED COMPONENTS 884
REMOVAL OF HOOD 885
INSTALLATION 887
MUFFLER AND EXHAUST STACK 889
REMOVAL 889
INSTALLATION 890
CAB 891
REMOVAL 891
FLOOR ACCESS PLATE 894
LIFTING CAB OFF MACHINE 897
INSTALLATION 900
MONITOR PANEL AND HST CONTROLLER 905
REMOVAL 905
INSTALLATION 907
KOMTRAX CONTROLLER 908
REMOVAL 908
INSTALLATION 908
SEAT 909
REMOVAL 909
INSTALLATION 909
AIR CONDITIONER/HEATER 910
DISASSEMBLY OF AIR CONDITIONER 910
REMOVING CONDENSER 911
BLOWER MOTORS AND EVAPORATOR 913
ASSEMBLY OF AIR CONDITIONER 914
FOOT HEATER 915
REMOVAL 915
INSTALLATION 916
FOOT HEATER OVERHAUL PROCEDURES 917
OVERHAUL PROCEDURES 917
ASSEMBLY PROCEDURES 919
ENGINE AND HST PUMP 921
REMOVAL 921
BELLY PANS 921
DRAINING THE COOLING SYSTEM 921
DRAINING THE HYDRAULIC SYSTEM 922
DISCONNECTING COMPONENTS 923
LIFTING ENGINE AND HST PUMP ASSEMBLY 929
INSTALLATION 931
INSTALL ENGINE AND HST PUMP ASSEMBLY 931
REMOVAL FROM ENGINE 933
INSTALLATION TO ENGINE 936
DRIVE DAMPENER 937
REMOVAL 937
INSTALLATION 938
HST PUMP OVERHAUL PROCEDURES 939
DISASSEMBLY PROCEDURES 939
REMOVAL OF ACCESSORIES 939
REMOVAL OF REAR PUMP 940
REMOVAL OF END CAP 940
DISASSEMBLY OF CYLINDER BLOCK AND PISTONS 941
DISASSEMBLY OF ROCKER CAM 942
REMOVAL OF FRONT SHAFT 943
DISASSEMBLY OF SHAFT 944
DISASSEMBLY OF FRONT COVER 945
DISASSEMBLY FRONT SERVO PISTON 946
DISASSEMBLY OF END CAP 947
DISASSEMBLY OF REAR PUMP 947
DISASSEMBLY OF REAR SHAFT 947
ASSEMBLY PROCEDURES 948
INSTALLATION OF REAR SERVO PISTON 949
INSTALLATION OF REAR COVER 951
INSTALLATION OF REAR SHAFT 952
ASSEMBLY OF REAR ROCKER CAM 953
INSTALLATION OF REAR CYLINDER BLOCK AND PISTON 954
ASSEMBLY OF END CAP 955
ASSEMBLY OF FRONT COVER 957
INSTALLATION OF FRONT OIL SEAL 957
INSTALLATION OF END CAP 957
INSTALLATION OF REAR PUMP 958
INSTALLATION OF ACCESSORIES 959
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES 960
DISASSEMBLY PROCEDURES 960
PUMP 960
(PC VALVE) 961
(LS VALVE) 961
REMOVAL OF END CAP 962
DISASSEMBLY OF CYLINDER BLOCK AND PISTON 962
DISASSEMBLY OF SHAFT ASSEMBLY 963
DISASSEMBLY OF ROCKER CAM 965
REMOVAL OF BALLS AND PISTON 965
ASSEMBLY PROCEDURES 967
INSTALLATION OF PUMP CASE 967
INSTALLATION OF ROCKER CAM 967
ASSEMBLY AND INSTALLATION OF SHAFT 968
INSTALLATION OF OIL SEAL 969
INSTALLATION OF CYLINDER BLOCK AND PISTON 970
INSTALLATION OF END CAP 971
ASSEMBLY OF SERVO VALVE 971
INSTALLATION OF SERVO VALVE ASSEMBLY 973
REMOVAL 974
INSTALL 975
CHARGE PUMP OVERHAUL PROCEDURES 976
TOOLS REQUIRED 976
DISASSEMBLY PROCEDURES 976
INSPECT PARTS FOR WEAR 980
ASSEMBLY PROCEDURES 982
GENERAL NOTES 982
PLACING PUMP BACK INTO SERVICE 987
DIESEL ENGINE OVERHAUL PROCEDURES 988
DISASSEMBLY OF EXTERNAL COMPONENTS 988
PREPARATION WORK 988
STARTING MOTOR 989
ENGINE SLING BRACKET ON REAR SIDE 989
FAN PULLEY 989
VIBRATION DAMPER AND CRANKSHAFT PULLEY 989
BELT TENSIONER 990
FAN HUB 990
ALTERNATOR 990
THERMOSTAT 991
WATER PUMP 991
TURBOCHARGER AND EXHAUST MANIFOLD 991
FUEL FILTER ASSEMBLY 992
WIRING HARNESS ASSEMBLY 992
FUEL PIPING AND COMMON RAIL 993
DISASSEMBLY OF ENGINE TOP END 994
INTAKE MANIFOLD 994
VALVE COVER HOUSING 994
ROCKER ARM ASSEMBLY AND CROSSHEAD 995
PUSH RODS 995
FUEL INJECTORS 995
CYLINDER HEAD 996
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP 998
OIL COOLER 998
ENGINE CONTROLLER 998
FUEL SUPPLY PUMP 999
DISASSEMBLY OF ENGINE LOWER END 1000
FLYWHEEL 1000
REAR OIL SEAL 1000
FLYWHEEL HOUSING 1001
OIL PAN 1001
FRONT COVER 1001
OIL PUMP 1002
CAMSHAFT 1002
GEAR HOUSING 1003
PISTONS AND CONNECTING RODS 1003
CRANKSHAFT 1004
PISTON COOLING NOZZLES 1006
TAPPETS 1006
CYLINDER BLOCK 1006
ASSEMBLY OF ENGINE LOWER END 1007
PREPARATION WORK 1007
TAPPETS 1007
PISTON COOLING NOZZLE 1007
CRANKSHAFT 1008
MAIN CAP MOUNTING BOLTS 1009
PISTON AND CONNECTING ROD ASSEMBLY 1010
GEAR HOUSING 1014
CAMSHAFT 1015
FLYWHEEL HOUSING 1016
REAR OIL SEAL 1017
FLYWHEEL 1018
OIL PUMP 1019
FRONT COVER 1020
OIL PAN 1021
VIBRATION DAMPER 1022
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP 1023
FUEL SUPPLY PUMP 1023
ENGINE CONTROLLER 1023
OIL COOLER 1023
CYLINDER HEAD 1025
FUEL INJECTORS 1027
PUSH RODS 1028
ROCKER ARM ASSEMBLY 1028
ADJUSTING VALVE CLEARANCE 1028
VALVE COVER HOUSING 1029
AIR INTAKE MANIFOLD COVER 1030
ASSEMBLY OF EXTERNAL COMPONENTS 1032
PREPARATION WORK 1032
HARNESS ASSEMBLY 1032
FUEL FILTER ASSEMBLY 1032
EXHAUST MANIFOLD AND TURBOCHARGER 1032
WATER PUMP 1033
THERMOSTAT 1033
ALTERNATOR 1034
FAN HUB 1034
BELT TENSIONER 1035
FAN PULLEY 1035
ENGINE SLING BRACKET ON REAR SIDE 1035
STARTER MOTOR 1035
REFILLING WITH OIL 1036
TRACK SYSTEM 1038
SPREADING THE TRACK 1038
(CONVENTIONAL TYPE TRACK SHOE) 1038
Whole disassembly 1062
Whole assembly 1065
1 When recycling for lubricated track 1065
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE) 1061
Special tools 1061
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE) 1075
Special tools 1075
Disassembly 1075
Assembly 1077
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE) 1083
Special tools 1083
Disassembly 1084
Assembly 1088
TRACK FRAME 1091
REMOVAL OF TRACK FRAME 1091
REMOVING TRACKS 1091
TRACK FRAME REMOVAL PREPARATIONS 1094
LIFTING TRACK FRAME FROM MACHINE 1096
FRONT TRACK IDLER 1100
REMOVING FRONT IDLER 1100
PULLING IDLER FROM TRACK FRAME 1101
INSTALLING FRONT IDLER 1103
TRACK ROLLER 1104
REMOVAL 1104
INSTALLATION 1104
TRACK ROLLER OVERHAUL PROCEDURES 1105
DISASSEMBLY 1105
ASSEMBLY 1106
CARRIER ROLLER OVERHAUL PROCEDURES 1110
DISASSEMBLY 1110
ASSEMBLY 1111
FINAL DRIVE 1112
FINAL DRIVE REMOVAL 1112
INSTALLING THE FINAL DRIVE 1116
FINAL DRIVE OVERHAUL PROCEDURES 1118
DISASSEMBLY PROCEDURES 1118
DRAINING OIL 1118
COVER 1119
RING GEAR 1119
NO 1 PLANETARY CARRIER ASSEMBLY 1120
NO 1 SUN GEAR 1120
NO 2 SUN GEAR 1120
NO 2 PLANETARY CARRIER ASSEMBLY 1121
HUB ASSEMBLY 1122
NO 2 PLANETARY CARRIER (HST MOTOR ASSEMBLY) 1123
ASSEMBLY OF FINAL DRIVE 1124
NO 2 PLANETARY CARRIER (HST MOTOR ASSEMBLY) 1124
ASSEMBLY OF HUB 1124
NO 2 PLANETARY CARRIER ASSEMBLY 1127
NO 2 SUN GEAR 1128
NO 1 SUN GEAR 1128
NO 1 PLANETARY CARRIER ASSEMBLY 1128
RING GEAR 1129
COVER 1130
REFILLING WITH OIL 1130
TRAVEL MOTOR OVERHAUL PROCEDURES 1132
DISASSEMBLY PROCEDURES 1132
TRAVEL MOTOR 1132
REMOVAL OF END COVER 1132
DISASSEMBLY OF END COVER 1133
REMOVAL OF RELIEF VALVE 1133
DISASSEMBLY OF SHUTTLE VALVE 1134
REMOVAL OF CYLINDER BLOCK 1134
REMOVAL OF PISTONS 1134
DISASSEMBLY OF BRAKE AND PISTON 1135
REMOVAL AND DISASSEMBLY OF DRIVE SHAFT 1135
REMOVAL OF OIL SEAL 1136
ASSEMBLY PROCEDURES 1137
INSTALLATION OF MOTOR CASE 1137
Install of oil seal 1137
ASSEMBLY OF DRIVE SHAFT 1143
ASSEMBLY OF PISTONS 1144
INSTALLATION OF DRIVE SHAFT ASSEMBLY 1144
INSTALLATION OF DISCS AND PLATES 1145
INSTALLATION OF BRAKE PISTON 1145
ASSEMBLY OF END COVER 1145
ASSEMBLY OF SHUTTLE VALVE 1146
ASSEMBLY OF MAIN PISTON 1146
INSTALLATION OF MAIN VALVE 1147
INSTALLATION OF VALVE PLATE 1147
NSTALLATION OF END COVER 1148
CHECK OF SHAFT ROTATION TORQUE 1149
FAN MOTOR 1150
REMOVAL PROCEDURES 1150
DISCONNECTING THE GRILL FROM THE FAN 1150
DISCONNECTING HYDRAULIC FAN MOTOR 1151
REMOVING THE FAN GUARD 1152
REMOVING THE FAN MOTOR 1153
INSTALLATION PROCEDURES 1154
FAN MOTOR OVERHAUL PROCEDURES 1156
DISASSEMBLY PROCEDURES 1156
REMOVAL OF END COVER 1156
DISASSEMBLY OF END COVER 1156
DISASSEMBLY OF PILOT VALVE 1157
CYLINDER BLOCK, SHAFT AND PISTON 1158
DISASSEMBLY OF CYLINDER BLOCK AND PISTON 1158
DISASSEMBLY OF SHAFT 1159
DISASSEMBLY OF MOTOR CASE 1159
ASSEMBLY PROCEDURES 1160
INSTALLATION OF MOTOR CASE 1160
ASSEMBLY AND INSTALLATION OF SHAFT 1160
ASSEMBLY OF CYLINDER BLOCK AND PISTON 1161
INSTALLATION OF CYLINDER BLOCK AND PISTON 1162
INSTALLATION OF OIL SEAL 1163
ASSEMBLY OF END COVER 1163
INSTALLATION OF END COVER 1165
CHECK OF SHAFT ROTATION TORQUE 1166
DB 12 VALVE 1168
REMOVAL 1168
INSTALLATION 1171
COOLING PACKAGE 1172
REMOVING THE GRILL AND COOLING FAN ASSEMBLY 1172
REMOVING THE GRILL FRAME 1172
REMOVING THE COOLING FAN ASSEMBLY 1179
REMOVING THE COOLING PACKAGE 1183
REMOVING THE FAN SHROUD 1183
REMOVING THE RADIATOR 1186
REMOVING THE OIL COOLER 1188
REMOVING THE AIR CHARGE COOLER 1189
INSTALLING THE COOLING PACKAGE 1191
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY 1192
FUEL TANK 1196
REMOVING THE FUEL TANK 1196
PREPARATIONS FOR REMOVAL 1196
LIFTING THE FUEL TANK OFF THE MACHINE 1199
INSTALLING THE FUEL TANK 1200
HYDRAULIC TANK 1201
REMOVING THE HYDRAULIC TANK 1201
PREPARATIONS FOR REMOVAL 1201
LIFTING THE HYDRAULIC TANK OFF THE MACHINE 1205
INSTALLING THE HYDRAULIC TANK 1207
WORK EQUIPMENT 1208
REMOVING OR INSTALLING PINS 1208
FRONT BLADE, TILT AND ANGLE CYLINDERS 1209
REMOVAL 1209
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY 1214
PITCH ROD 1214
CENTER BALL 1215
INSTALLATION 1215
“C” FRAME 1216
REMOVAL 1216
INSTALLATION 1218
LIFT CYLINDERS 1219
REMOVAL 1219
INSTALLATION 1220
CYLINDER OVERHAUL PROCEDURES 1221
DISASSEMBLY PROCEDURES 1221
PISTON AND ROD 1221
PISTON AND HEAD ASSEMBLY 1222
DISASSEMBLY OF GLAND NUT 1222
ASSEMBLY PROCEDURES 1222
GLAND NUT ASSEMBLY AND PISTON ASSEMBLY 1222
DISASSEMBLY OF PISTON 1223
PISTON ROD ASSEMBLY 1224
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY 1040
(PLUS TYPE TRACK SHOE) 1040
Expansion normal 1040
Installation 1040
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE) 1041
Special tools 1041
Whole disassembly 1041
Whole assembly 1046
90 OTHERS 1225
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM 1227
CONNECTOR LIST 1227
CONNECTOR LOCATION VIEW 1231
CAB ELECTRICAL ACCESSORIES 1245
AIR CONDITIONER AND HEATER UNIT 1247
HYDRAULIC SYSTEM 1249
VIEW (1 OF 2) 1249
VIEW (2 OF 2) 1251
ELECTRICAL DIAGRAMS 0
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5) 1253
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 ) 1255
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5) 1257
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5) 1259
KOMTRAX AND CONNECTORS (VIEW 5 OF 5) 1261
CONVENTIONAL iB WIRING DIAGRAM (1 OF 2) 1263
CONVENTIONAL iB WIRING DIAGRAM (2 OF 2) 1265

IMAGES PREVIEW OF THE MANUAL: