Komatsu XT430-2, XT430L-2, XT445L-2, XT450L-2 Crawler Feller Buncher Shop Manual - CEBM025401

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Crawler Feller Buncher XT430-2, XT430L-2, XT445L-2, XT450L-2 has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu XT430-2 Crawler Feller Buncher
Serial Numbers : A1001 and up

Komatsu XT430L-2 Crawler Feller Buncher
Serial Numbers : A2001 and up

Komatsu XT445L-2 Crawler Feller Buncher
Serial Numbers : A3001 and up

Komatsu XT450L-2 Crawler Feller Buncher
Serial Numbers : A4001 and up


TABLE OF CONTENTS :

00 SAFETY
01 GENERAL
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARDS
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
60 AIR CONDITIONER
90 DIAGRAMS AND SCHEMATICS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM025401
Total Pages : 449


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

More Info : https://www.sitelux.com

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XT430-2,XT430L-2,XT445L-2,XT450L-2 CEBM025401
00 - FOREWORD
CONTENTS
SAFETY
Safety Notice
Important Safety Notice
General Precautions
Preparations For Work
Precautions During Work
GENERAL
HOW TO READ THE SHOP MANUAL
Volumes
Distribution And Updating
Filing Method
Revised Edition Mark
Revisions
Symbols
HOISTING INSTRUCTIONS
Hoisting
Wire Ropes
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
Points To Remember When Handling Electric Equipment
Points To Remember When Handling Hydraulic Equipment
PUSH PULL COUPLER
Type 1
Disconnection
Connection
Type 2
Disconnection
Connection
Type 3
Disconnection
Connection
EXPLANATION OF MAINTENANCE STANDARD TERMS
STANDARD TIGHTENING TORQUE
Bolts And Nuts
GENERAL INSTRUCTIONS
Introduction
Cleaning
Replacement
Hoses and Tubes
Inspection
Installation
Hydraulic Pumps
Replacement
Pressure Testing
Hydraulic Fitting Torque Values
JIC 37˚ Flare Torque Values
37˚ Flare, Tube To Fitting Assembly
SAE Straight Thread O-Ring Fitting (Adjustable) To Port Assembly
Seal-Lok Straight and Adjustable Fitting (Steel)
Flare and Flareless Port Ends
SAE Straight Thread O-Ring Fitting (Non-Adjustable)
Fitting To Port Assembly
Port Assembly For SAE Straight Thread Plugs
4-Bolt Split Flange Assembly, Fitting To Port SAE
Code 61 (3000 psi) and Code 62 (6000 psi)
Pipe Thread Port Assembly, Fitting To Port
Standard Bolt Torque Chart (Inches)
CONVERSION TABLES
Method Of Using The Conversion Table
COATING MATERIALS

01 - GENERAL
SPECIFICATIONS
Dimensions
BOOM SWEEP DIAGRAMS
SPECIFICATIONS
XT430-2, XT430L-2
XT445L-2
XT450L-2
Engine
Fuel Quality Requirements
Engine Oil Performance Information
Hydraulic and Engine Oil Selection, Lubricating Oils, and Grease
New Engine “Break-in” Oils
Coolant Quality Requirements
Coolant and Water for Dilution
Hydraulic Oil Information
Hydraulic Oil Type
Hydraulic Oil Viscosity
Hydraulic Oil Viscosity Selection
ISO Code Rating
General Hydraulic Oil Specification
Minimum Technical Hydraulic Oil Requirements
Track Final Drive Oil Information
Hydraulic System
General
Pump Transmission:
Implement Pump
Track Drive Pump (2)
Track Drive Charge Pump
Return Oil Filtration
Hydraulic Tank
Implement Control Valve
Typical Hydraulic Valve Set-up
Hydraulic Valve Configuration: Processor 2
Hydraulic Valve Configuration: Processor 3
Hydraulic Valve Configuration: Processor 4
Hydraulic Valve Configuration: Processor 5
Hydraulic Valve Configuration: Intermittent Disc Saw
Hydraulic Valve Configuration: Disc Saw
Hydraulic Valve Configuration: Combination 233 Bar Saw w/Lateral Tilt or Disc Saw
Hydraulic Valve Configuration: 233 Bar Saw w/Lateral Tilt Option
VOAC K220 Valve, Typical
VOAC L90LS Valve, Typical
Lubricant and Fill Capacities
XT430-2, XT430L-2
XT445L-2
XT450L-2
XT430-2, XT430L-2 Undercarriage
XT445L-2, XT450L-2 Undercarriage
Upper Structure
Cylinders
Operator’s Environment
LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
Manually Lowering Work Equipment - Procedure

10 - STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
Track Frame And Recoil Spring, XT430L-2
Idler, XT430L-2
Track Roller, Carrier Roller, XT430L-2
Track Shoe, XT430L-2
Single Shoe, XT430L-2
Double Shoe, XT430L-2
Track Frame And Recoil Spring, XT445L-2
Idler, XT445L-2
Track Roller, Carrier Roller, XT445L-2
Track Shoe, XT445L-2
Single Shoe, Heavy Duty Shoe, XT445L-2

30 - TESTING AND ADJUSTING
FIRE SUPPRESSION SYSTEM (OPTIONAL)
Ansul™ Fire Suppression Controls (Optional)
Ansul Fire Suppression Daily Inspections
Ansul Fire Suppression Monthly Inspections
Maintenance
HYDRAULIC PRESSURE SETTINGS
Hydraulic Pressure Gauges
Charge Relief Adjustment
Main Track Pump Relief Adjustment
Track Pump Null Adjustments
Implement Pump Stand-by Adjustment
Implement Pump PCO Adjustment
Auxiliary Pump Stand-by Adjustment (Common & Separate)
Auxiliary Pump PCO Adjustment (Common & Separate)
Main Control Valve Differential Pressure Adjustment
Main Control Valve LS Max Pressure Setting (PLM)
Main Control Valve Port Reliefs
Main Control Valve Feed Reducer Pressure
System Pilot Pressure
Main Control Valve Section Components
Maximum Case Drain Flows

40 - TROUBLESHOOTING
RELAY & FUSE LOCATIONS
Relay Location and Identification
Mini Fuse Bank A Location and Identification
Mini Fuse Bank A Location
Mini Fuse Bank B Location and Identification
Mini Fuse Bank B Location
Maxi Fuse Bank C Location and Identification
Maxi Fuse Bank D Location and Identification
GENERAL INFORMATION
Points to Remember
Sequence of Events
Handling Electric Equipment and Hydraulic Components
Connectors for Tier 3 Engines
Checks Before Troubleshooting
GENERAL HYDRAULIC PROBLEMS
MACHINE OVERHEAT PROBLEMS
IMPLEMENT FUNCTION PROBLEMS
TRACK DRIVE PROBLEMS
ENGINE PROBLEMS
ELECTRICAL PROBLEMS
AIR CONDITIONER / HEATER PROBLEMS
DISC SAW CIRCUIT PROBLEMS

50 - DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
Removal And Installation Of Assemblies
Special Tools
Removal
Installation
Disassembly And Assembly Of Assemblies
Special Tools
Disassembly
Assembly
SPECIAL TOOLS LIST
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion Of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion Of Contact Terminal (DT Type)
PRECAUTIONS DURING OPERATION
Precautions when Performing Removal Work
Precautions when Performing Installation Work
Precautions when Completing The Operations
Other Precautions
ARM
Stick Arm
Removal
Installation
BOOM
Removal
Installation
Tool Tilt Cylinder
Removal
Installation
Stick Cylinder
Removal
Installation
Boom Cylinder
Removal
Installation
HYDRAULIC SYSTEM
Hydraulic Oil Tank
Draining
Removal and Disassembly
Cleaning
Assembly
Installation
Filling the Hydraulic Tank
Auxiliary Oil Cooler
Removal (Hydraulic Driven Fan)
Hydraulic Tank Vacuum Pump
Removal
Installation
Machine Start-Up After Hydraulic Component Replacement
Vent Air From Hydraulic System
Hydraulic System Start-Up for Machines Without A Vacuum Pump
Hydraulic System Start-Up for Machines With A Vacuum Pump
Rotary Manifold
Removal
Inspection
Installation
Swing Motor
Removal
Installation
Swing Motor Anti-Cavitation Valve
Removal
Installation
Swing Motor Gearbox Brake
Disassembly
Assembly
Swing Motor/Gearbox Assembly, XT430-2
Removal
Installation
SWING BEARING
Removal
Installation
Fill and Check Swing Pinion Grease Level
Turntable Casting
Removal
Installation
Intermediate Leveler
Removal
Installation
Auxiliary Pump
45 cc Auxiliary Pump Removal
45 cc Auxiliary Pump Installation
71 cc Auxiliary Pump Removal
71 cc Auxiliary Pump Installation
Implement Pump
Removal
Installation
Auxiliary Oil Cooler Fan Pump
Removal
Installation
Charge Pump
Removal
Charge Pump Installation
Right Side Drive Pump
Removal
Installation
Left Side Drive Pump
Removal
Installation
FINAL DRIVE ASSEMBLY
Removal
Disassembly
Disassembly of Number 1 Carrier
Assembly of Number 1 Carrier
Disassembly of Number 2 Carrier
Assembly of Number 2 Carrier
Assembly
Installation
MAIN CONTROL VALVE
Removal
Installation
FILL PUMP
Removal
Installation
CHARGE MANIFOLD HEATER
Removal
Installation
CHARGE FILTER MANIFOLD
Removal
Installation
PILOT PRESSURE MANIFOLD
Removal and Installation
RETURN OIL MANIFOLD (LOGIC BLOCK)
SAW STOP VALVE
Removal and Installation
ENGINE FLEXPLATE
Remove Hydraulic Pumps
Separate Transmission From Engine
Flexplate Removal
Flexplate Installation
Transmission Installation
Install Hydraulic Pumps
ENGINE
Removal
Installation Preparation
Installation
TRACK SYSTEM
Track Tension
Check Track Tension
Increasing Track Tension
Decreasing Track Tension
Track Shoe Removal and Installation
Track Removal and Installation
Idler Wheel, Recoil Spring and Track Adjuster Assembly
Idler Wheel and Recoil Spring Removal
Idler Wheel and Recoil Spring Installation
Idler Assembly: XT430-2, XT430L-2
Disassembly
Assembly
Recoil Spring: XT430-2, XT430L-2
Disassembly
Assembly
Idler Assembly: XT445L-2, XT450L-2
Disassembly
Assembly
Recoil Spring: XT445L-2, XT450L-2
Disassembly
Assembly
Track Roller
Removal
Installation
Final Drive Sprocket
Removal
Installation
Track Tension
Check Track Tension
Track Slider
Removal
Installation
Carrier Roller (Optional)
Removal
Installation
Track Frame
Removal
Installation
LEVELING COMPONENTS
Leveling Cylinder Removal
Leveling Cylinder Installation
CAB
Removal
Installation

60 - AIR CONDITIONER
AIR CONDITIONER/HEATER
Charging Air Conditioning System
Technician Training and Certification
Air Conditioner/Heater Access

90 - DIAGRAMS AND SCHEMATICS
90 DIAGRAMS AND SCHEMATICS
Track Drive Circuit: 83381 Rev. A.
IMPLEMENT HYDRAULIC SCHEMATICS
Combination BarSaw and Disc Saw: 83382-B
Disc Saw: 83383-B
Dual Flow Processor #2: 83385-B
Combined Flow Processor #3: 83386-B
Combined Flow Processor #4: 83387-B
Intermittent Disc Saw: 83388-B
Bar Saw: 83389-B
Dual Flow Processor #5: 85801-A
Electrical Maxi Head Computer 380/385: 00860148; Sheet 1 of 2
Electrical Maxi Head Computer 380/385: 00860148; Sheet 2 of 2
Electrical 380/385: 00860154; Sheet 1 of 2
Electrical 380/385: 00860154; Sheet 2 of 2
Hydraulic 380/385: 00860150
IQAN Control-J1939: 28356; Sheet 1 of 6
IQAN Control-J1939: 28356; Sheet 2 of 6
IQAN Control-J1939: 28356; Sheet 3 of 6
IQAN Control-J1939: 28356; Sheet 4 of 6
QAN Control-J1939: 28356; Sheet 5 of 6
IQAN Control-J1939: 28356; Sheet 6 of 6
1/18 Main Electrical Center, Fuse Legend: 28606-E; Sheet 1 of 2
1/18 Main Electrical Center, Fuse Legend: 28606-E; Sheet 2 of 2
1/18 Dash Panel: 28411-A
5/18 Upper Cab Harness: 28413-A
6/18 Radio Adapter - Kenwood KDC-MP: 28414-B
7/18 Rear Upper Light Harness: 28415-A
8/18 Lower Cab Sub Harness (shift coil): 28416-A
11/18 Lower Cab Harness: 28417-A
12/18 FOPS Light Harness: 28418-A
15/18 Engine Harness: 28703-B
16/18 Visor Light Harness: 28422-B
18/18 Maxi Interface Harness: 28605-A
Vac/Vent Sub Harness: 27309
Rolly II Installation Kit, Fuse/Relay: 28701 Rev A
Cummins QSC Engine Schematic: 83093-A

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