CEBM029702

Shop
Manual

XT430-3
XT430L-3
XT445L-3
XT460L-3
CRAWLER FELLER BUNCHER
SERIAL NUMBERS XT430-3 A1101 and up
XT430L-3 A2101 and up
XT445L-3 A3101 and up
XT460L-3 A5101 and up
ENGINE QSC 8.3 Tier 3
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2017 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2017
FOREWORD
12

MEMORANDUM

00-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD CONTENTS
12
CONTENTS 00

00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . 10-1


30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

60 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1


90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-3
FOREWORD SAFETY
12
SAFETY 00

Safety Notice 00

Important Safety Notice 00

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols are used to mark safety precautions in this manual. The cautions 
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.

General Precautions 00
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
WARNING! Mistakes in operation are while working.
extremely dangerous. Read
the OPERATION &  Preparations For Work 00

MAINTENANCE MANUAL
1. Before adding oil or making repairs, park the machine
carefully BEFORE operating
on hard, level ground, and block the wheels or tracks to
the machine.
prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any
1. Before performing any greasing or repairs, read all the
other work equipment to the ground. If this is not 
precautions given on the decals which are fixed to the
possible, insert the safety pin or use blocks to prevent
machine.
the work equipment from falling. In addition, be sure to
2. When performing any operation, always wear safety
lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or
them.
clothes with buttons missing.
3. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts with machine with blocks, jacks or stands before starting
a hammer. work.
• Always wear safety glasses when grinding parts 4. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder perform the work. When perform- machine. Never jump on or off the machine. If it is
ing welding work, always wear welding gloves, apron, impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work. stand to provide safe footing.

WARNING! Never modify, weld, cut, or drill Precautions During Work 00

on any part of a ROPS 

structure. Doing so may 1. When removing oil filler cap, drain plug, or hydraulic
weaken the structure which pressure measuring plugs, loosen them slowly to 
could lead to possible failure in prevent oil from spurting out. Before disconnecting or
a rollover situation removing components of the oil, cooling, or air circuits,
first completely remove pressure from the circuit.
4. When performing any operation with two or more  2. The coolant and oil in the circuits is hot when the engine
workers, always agree on operating procedures before is stopped, so be careful not to get burned. Wait for the
starting. Always inform your fellow workers before oil and coolant to cool down before performing any
starting any step of the operation. Before starting work, work on the oil or cooling circuits.
hang UNDER REPAIR signs on the controls in the  3. Before starting work, remove the leads from the battery.
operator's compartment. ALWAYS remove lead from the negative (-) terminal
5. Keep all tools in good condition and learn the correct first.
way to use them.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and

00-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD SAFETY

12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.

5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in 
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.

9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed 
correctly.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any 
measurements.

14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.

15. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit.
A. Disconnection

WARNING! Collect the air conditioner refrigerant gas (R134a).

If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly,
when collecting or adding it, you must be qualified for handling the refrigerant and put on
protective goggles.

B. Connection

i. When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter
them.

ii. When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.

iii. Check that each O-ring is not damaged or deteriorated.

iv. When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-5
FOREWORD SAFETY
★ Example of O-ring (Fitted to every joint of hoses and tubes)
★ For tightening torque, see the precautions for installation in each sec-
tion of "Disassembly and Assembly".

16. When jump starting the machine, only use a machine of similar size and voltage. Never use an arc welder or other electri-
cal generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.

00-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL

12
GENERAL 00

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 judgments. 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.

01 GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.

10 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 judgment standards
when inspecting disassembled parts.

20 STANDARD VALUE TABLE

This section explains the standard values for new machine and judgment criteria for testing, adjusting and 
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.

30 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.

40 TROUBLESHOOTING

Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

50 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.

60 AIR CONDITIONER

This section explains the structure and function of each air conditioning component. In addition, it has the testing and
adjusting, troubleshooting, disassembly, assembly and corrections of the air conditioning system.

90 DIAGRAMS AND SCHEMATICS

This section has the foldout drawings for the machine.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-7
FOREWORD HOW TO READ THE SHOP MANUAL

12
HOW TO READ THE SHOP MANUAL 00

Volumes 00 Revisions 00

Shop manuals are issued as a guide to performing repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.

Chassis volume: Issued for every machine model Symbols 00

Engine volume: Issued for each engine series

So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models following symbols.

These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment Special safety precautions are
be available. Safety necessary when performing the
work.
Distribution And Updating 00

Special technical precautions or

other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems. 
Filing Method 00
Caution necessary when 
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number: Places that require special 
Example: Tightening
attention for tightening torque
torque
during assembly.
10 - 3
Places to be coated with 
Coat
Item number (10. Structure and Function) adhesives and lubricants etc.

Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a Places where oil or water must
hyphen (-) and numbered after the page number. File as Drain be drained, and quantity to be
in the example. drained.
Example:
10-4
10-4-1
Added pages
10-4-2

10-5

Revised Edition Mark 00

When a manual is revised, an edition mark (…) is

recorded on the bottom outside corner of the pages.

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FOREWORD HOISTING INSTRUCTIONS

12
HOISTING INSTRUCTIONS 00

Hoisting 00
can result. Hooks have maximum strength at the middle
portion.

WARNING! Heavy parts (25 kg or more)

must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the 
symbol.

• If a part cannot be smoothly removed from the machine by

hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the
relative parts. 3. Do not sling a heavy load with one rope alone, but sling
2. Check for existence of another part causing interface with two or more ropes symmetrically wound on to the
with the part to be removed. load.

Wire Ropes 00 WARNING! Slinging with one rope may

cause turning of the load 
1. Use adequate ropes depending on the weight of parts to during hoisting, untwisting of
be hoisted, referring to the table below: the rope, or slipping of the
rope from its original winding
Wire ropes position on the load, which
(Standard “Z” or “S” twist ropes without galvanizing) can result in a dangerous
Rope diameter Allowable load accident

mm kN tons 4. Do not sling a heavy load with ropes forming a wide

hanging angle from the hook. When hoisting a load with
10 9.8 1.0 two or more ropes, the force subjected to each rope will
11.2 13.7 1.4 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when 
12.5 15.7 1.6 hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
14 21.6 2.2 hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6 to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150°.

22.4 54.9 5.6

30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of
the breaking strength of the rope used. Sling wire ropes
from the middle portion of the hook.
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-9
FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS

12
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC 
COMPONENTS 00

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct operation, maintenance and inspection, troubleshooting, and repairs must be performed. This section deals particularly
with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives 
sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil).

Points To Remember When Handling Electric Equipment 00

1. Handling wiring harnesses and connectors.

• Wiring harnesses consist of wiring connecting one component
to another component, connectors used for connecting and 
disconnecting one wire from another wire, and protectors or
tubes used for protecting the wiring.
• Compared with other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be affected by the
direct effects of rain, water, heat, or vibration. Furthermore, 
during inspection and repair operations, they are frequently
removed and installed again, so they are likely to suffer 
deformation or damage.
• For this reason, it is necessary to be extremely careful when
handling wiring harnesses.
2. Main failures occurring in wiring harness.
A. Defective contact of connectors (defective contact between male
and female).

• Problems with defective contact are likely to occur because

the male connector is not properly inserted into the female
connector, or because one or both connectors are deformed
or the position is not correctly aligned, or there is corrosion
or oxidation of the contact surfaces.

B. Defective crimping or soldering of connectors.

• The pins of the male and female connectors are in contact at

the crimped terminal or soldered portion, but if there is
excessive force brought to bear on the wiring, the plating at
the joint will peel and cause improper connection or 
breakage.

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
C. Disconnections in wiring.

• If the wiring is held and the connectors are pulled apart, or

components are lifted with a crane with the wiring still 
connected, or a heavy object hits the wiring, the crimping of
the connector may separate, or the soldering may be 
damaged, or the wiring may be broken.

D. High-pressure water entering connector.

• The connector is designed to make it difficult for water to

enter (drip-proof structure), but if high-pressure water is
sprayed directly on the connector, water may enter the 
connector, depending on the direction of the water jet.
• Accordingly, take care not splash water over the connector.
The connector is designed to prevent water from entering,
but at the same time, if water does enter, it is difficult for it
to be drained.
• Therefore, if water should get into the connector, the pins
will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate
action before passing electricity through it.

E. Oil or dirt stuck to connector.

• If oil or grease are stuck to the connector and an oil film is

formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, so there will be
defective contact. If there is oil or grease stuck to the con-
nector, wipe it off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is oil or water in the compressed air, the 
contacts will become even dirtier, so completely
remove the oil and water from the compressed air
before cleaning with compressed air.

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
3. Removing, installing, and drying connectors and wiring harnesses
A. Disconnecting connectors.

• Hold the connectors when disconnecting. 

When disconnecting the connectors, hold the connectors.
For connectors held by a screw, completely loosen the
screw, then hold the male and female connectors in each
hand and pull apart. For connectors which have a lock
stopper, press the stopper down with your thumb and pull
the connectors apart.
★ Never pull with one hand.

B. When removing from clips

• Both of the connector and clip have stoppers, which are

engaged with each other when the connector is installed.

• When removing a connector from a clip, pull connector in a

parallel direction to the clip for removing stoppers.
★ If the connector is twisted up and down or to the left or
right, the housing may break.

C. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to 
prevent any dust, dirt, oil, or water from entering into the 
connector portion.

★ If the machine is left disassembled for a long time, it is 

particularly easy for improper contact to occur, so always
cover the connector.

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
4. Connecting connectors
A. Check the connector visually.

• Check that there is no oil, dirt, or water stuck to the 

connector pins (mating portion). Check that there is no 
deformation, defective contact, corrosion, or damage to the
connector pins. Check that there is no damage or breakage
to the outside of the connector.

• If there is any oil, water, or dirt stuck to the connector, wipe

it off with a dry cloth. If any water has got inside the 
connector, warm the inside of the wiring with a dryer, but
be careful not to make it too hot as this will cause short 
circuits.
• If there is any damage or breakage, replace the connector.

B. Fix the connector securely.

• Align the position of the connector correctly, and then insert

it securely. For connectors with lock stopper, push in the
connector until the stopper clicks into position.

C. Correct any protrusion of the boot and any misalignment of the

wiring harness.

• For connectors fitted with boots, correct any protrusion of 

the boot. In addition, if the wiring harness is misaligned, 
or the clamp is out of position, adjust it to its correct 
position.

★ If the connector cannot be corrected easily, remove the

clamp and adjust the position.
★ If the connector clamp has been removed, be sure to
return it to its original position. Check also that there
are no loose clamps.

D. Connecting DT connectors

• Since the DT 8-pin and 12-pin heavy duty wire connectors

have two latches respectively, push them in until they click
two times.

1. Male connector
2. Female connector
★ Normal locking state (Horizontal): a, b, d
★ Incomplete locking state (Diagonal): c

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
E. Drying wiring harness

• If there is any oil or dirt on the wiring harness, wipe it off

with a dry cloth. Avoid washing it in water or using steam.
If the connector must be washed in water, do not use 
high-pressure water or steam directly on the wiring harness.
If water gets directly on the connector, do as follows.
• Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with compressed air,
there is the risk that oil in the air may cause defective
contact, so remove all oil and water from the 
compressed air before blowing with air.

• Dry the inside of the connector with a dryer.

• If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but regulate the
time that the hot air is used in order not to make the
connector or related parts too hot, as this will cause
deformation or damage to the connector.

• Perform a continuity test on the connector.

• After drying, leave the wiring harness disconnected and
perform a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, blow it with
contact restorer and reassemble.

5. Handling controller
A. The controller contains a microcomputer and electronic control
circuits. These control all of the electronic circuits on the
machine, so be extremely careful when handling the controller.

B. Do not place objects on top of the controller.

C. Cover the control connectors with tape or a vinyl bag. Never

touch the connector contacts with your hand.

D. During rainy weather, do not leave the controller in a place

where it is exposed to rain.

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
E. Do not place the controller on oil, water, or soil, or in any hot
place, even for a short time. (Place it on a suitable dry stand).

F. Precautions when performing arc welding.

• When performing arc welding on the body, disconnect all

wiring harness connectors connected to the controller. Fit
an arc welding ground close to the welding point.

6. Points to remember when troubleshooting electric circuits.

A. Always turn the power OFF before disconnecting or 
connecting connectors.

B. Before performing troubleshooting, check that all the related

connectors are properly inserted.

• Disconnect and connect the related connectors several

times to check.
C. Always connect any disconnected connectors before going on to
the next step.

• If the power is turned ON with the connectors still 

disconnected, unnecessary abnormality displays will be
generated.
D. When performing troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the
related wiring and connectors several times and check that there is no change in the reading of the tester.

• If there is any change, there is probably a defective contact in that circuit.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-15
FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS

12
Points To Remember When Handling Hydraulic Equipment 00

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.

1. Be careful of the operating environment.

• Avoid adding hydraulic oil, replacing filters, or repairing the
machine in rain or high winds, or places where there is a lot of
dust.

2. Disassembly and maintenance work in the field

• If disassembly or maintenance work is performed on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be performed in a
specially prepared dust proof workshop, and the performance
should be checked with special test equipment.

3. Sealing openings
• After any piping or equipment is removed, the openings should
be sealed with caps, tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the surrounding area
being made dirty by leaking oil so never do this. Do not simply
drain oil out onto the ground, but collect it and ask the customer
to dispose of it, or take it back with you for disposal.

4. Do not let any dirt or dust get in during refilling operations

• Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it
clean, and also use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more effective
method.

5. Change hydraulic oil when the temperature is high

• When hydraulic oil or other oil is warm, it flows easily. In addi-
tion, sludge can also easily be drained out from the circuit
together with the oil, so it is best to change oil when it is still
warm. When changing the oil, as much as possible of the old
hydraulic oil must be drained out. (Drain the oil from the hydraulic tank, also drain the oil from the filter and from the
drain plug in the circuit.) If any old oil is left, contaminants and sludge in it will mix with the new oil and will shorten
the life of the hydraulic oil.

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FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
6. Flushing operations
• After disassembling and assembling the equipment, or changing
the oil, use flushing oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit. Normally, flushing is 
performed twice: primary flushing is performed with flushing
oil, and secondary flushing is performed with the specified
hydraulic oil.

7. Cleaning operations
• After repairing the hydraulic equipment (pump, control valve,
etc.), or when running the machine, perform oil cleaning to
remove the sludge or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the ultra fine
(about 3 microns) particles that the filter built in the hydraulic
equipment cannot remove, so it is an extremely effective device.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-17
FOREWORD PUSH PULL COUPLER

12
PUSH PULL COUPLER 00

WARNING! Before performing the following work, release

the residual pressure from the hydraulic tank
by opening the tank vent.

WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Prepare
an oil receiving container.

Type 1 00

Disconnection 00

1. Release the residual pressure from the hydraulic tank by opening the
tank vent.
2. Hold adapter (1) and push hose joint (2) into mating adapter (3).
★ The adapter can be pushed in about 3.5 mm (0.138").
★ Do not hold the rubber cap portion (4).
3. After hose joint (2) is pushed into adapter (3), press rubber cap 
portion (4) against the adapter until it clicks.

4. Hold hose adapter (1) or hose (5) and pull it out.

★ Since some hydraulic oil flows out, prepare an oil receiving 
container.

Connection 00

1. Hold hose adapter (1) or hose (5) and insert it into mating adapter
(3), aligning them with each other.
★ Do not hold rubber cap portion (4).
2. After inserting the hose into the mating adapter, pull it back to check
its connecting condition.
★ When the hose is pulled back, the rubber cap portion moves
toward the hose about 3.5 mm (0.138"). This does not indicate
an abnormality.

00-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD PUSH PULL COUPLER

Type 2 00

Disconnection 00

1. Hold mouthpiece of the tightening portion and push body (2) straight
in until sliding prevention ring (1) contacts surface "a" of hexagonal
portion at the male end.

2. Hold in the condition in Step 1, and turn lever (4) clockwise to the
right.

3. Hold in the condition in Steps 1 and 2, and pull out body (2) to 
disconnect.

Connection 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-19
FOREWORD PUSH PULL COUPLER

12
Type 3 00

Disconnection 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.

2. Hold in the condition in Step 1, and push until cover (3) contacts 
surface a of the hexagonal portion at the male end.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

Connection 00

1. Hold the connector of the tightening portion and push body (2) in
straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

00-20 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS

12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00

• The maintenance standard values necessary for judgment of 

products and parts are described by the following terms.

1. Standard Size And Tolerance

• To be accurate, the finishing size of parts is a little different
from one to another.
• To specify a finishing size of a part, a temporary standard size
is set and an allowable difference from that size is indicated.
• The above size set temporarily is called the “standard size” and
the range of difference from the standard size is called the 
“tolerance”.
• The tolerance with the symbols of + or – is indicated on the
right side of the standard size.

Example:
Standard size Tolerance
-0.022
120
-0.126

★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and
different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

2. Standard Clearance And Standard Value

• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.

3. Standard Interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard 
interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-21
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS

12
4. 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 it 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.

00-22 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD STANDARD TIGHTENING TORQUE

12
STANDARD TIGHTENING TORQUE 00

Bolts And Nuts 00

• Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench)
★ The following table corresponds to the bolts in Figure A.
Thread diameter of bolt Width across flats Tightening torque
mm mm N•m lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35

★ The following table corresponds to the bolts in Figure B.

Thread diameter of bolt Width across flats Tightening torque
mm mm N•m lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52

Figure A Figure B

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-23
FOREWORD GENERAL INSTRUCTIONS

12
GENERAL INSTRUCTIONS 00

Introduction 00

Appropriate service methods and proper repair procedures are essential for safe and reliable operation of track machines and
safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work
with tested, effective techniques. Following them will assure reliability.
There are many variations in procedures, techniques, tools, and parts for servicing vehicles, as well as work skills. This manual
cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to
depart from the instructions in this manual must first consider personal safety and then vehicle integrity.

Cleaning 00

Clean the exterior of all parts before repairing. Dirt and abrasive dust reduce the efficient work life of the part and lead to
costly replacement.
Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user. Certain types of
fluids damage rubber parts and/or cause skin irritation.
The following precautions must be observed to ensure hydraulic cleanliness.
1. Flush hose and tube assemblies with a solvent compatible with hose assemblies. Blow out excess solvent with shop air.
2. Cap or plug hydraulic fittings and protect threads until installation.
3. Cap or plug hoses and tube assemblies until installation.
4. Flush hydraulic reservoir and fuel tank with a suitable solvent to remove any foreign debris.
5. Protect system components from airborne contaminants. 
Plug all cylinder, valve, reservoir, tank, and pump openings until installation.
6. Use clean, filtered hydraulic oil only.
7. Hydraulic oil cleanliness level must be a minimum of ISO 17/14.

Replacement 00

1. Replace O-rings, seals, and gaskets whenever they are disturbed. Never mix new and old seals or O-rings regardless of
condition.
2. Always lubricate seals and O-rings with hydraulic oil before assembly.
3. Use hydraulic thread sealant on all JIC fittings. Example: Loctite® 545.
4. Use pipe sealant on all pipe threads. Example: Loctite® 565.
5. Replace all used elastic locknuts with new locknuts.

Hoses and Tubes 00

Inspection 00

1. If the hose end connections are damaged, always replace hoses and tubes. Damaged, dented, crushed, or leaking hose fit-
tings, tubes, and hoses restrict oil flow and operation of the parts being served.
2. Be sure the hoses and tubes are in good condition. If in doubt, replace them.

Installation 00

1. When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tight-
ening the hose connections. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent
chafing.
2. If a hose is replaced on a moving part, be sure it does not scrap or rub on the moving part.
3. Free moving, unsupported hoses must never touch each other or related work surfaces. This causes chafing which reduces
hose life.

00-24 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL INSTRUCTIONS
12
Hydraulic Pumps 00

Replacement 00

Only replace hydraulic pumps with Komatsu recommended pumps. Do not attempt to rebuild hydraulic pumps.

Pressure Testing 00

Prior to pressure testing, be sure all hoses are in good condition and all fittings are tight.
Use a pressure gauge with a range that is high enough to measure the specified pressure.
Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-25
FOREWORD GENERAL INSTRUCTIONS
12
Hydraulic Fitting Torque Values 00

JIC 37° Flare Torque Values 00

1. Apply Loctite® 545 Thread Sealant on all JIC hydraulic fittings before installation.
2. Align tube and fitting.
3. Tighten nut to torque given below.

ASSEMBLY SWIVEL NUT OR

TUBE
SAE THREAD TORQUE HOSE
CONNECTION
SIZE SIZE CONNECTION
LB-IN LB-FT F.F.F.T.
F.F.F.T.

2 5/16 -24 40 ±5 3 ±1

3 3/8 -24 70 ±5 6 ±1

4 7/16 -20 140 ±10 12 ±1 2 2

5 1/2 -20 180 ±15 15 ±1 2 2

6 9/16 -16 250 ± 5 21 ±1 1 1/2 1 1/4

8 3/4 -16 550 ±25 45 ±2 1 1/2 1 1/2

10 7/16 -14 700 ±50 60 ±5 1 1/2 1

12 1 1/16 -12 1000 ±50 85 ±5 1 1/4 1

14 1 5/16 -12 1250 ±50 105 ±5 1 1

16 1 5/16 -12 1450 ±50 120 ±5 1 1

20 1 5/8 -12 2000 ±100 170 ±10 1 1

24 1 7/8 -12 2400 ±150 200 ±15 1 1

32 2 1/2 -12 3200 ±200 270 ±20 1 1

WIDTH TIGHTENING TORQUE

THREAD
ACCROSS
DIAMETER TARGET VALUE SERVICE LIMIT
FLATS
a (mm)
b (mm) N•m lbf ft N•m lbf ft

14 19 29.4 21.7 27 to 39 20.3 to 28.9

18 24 78.5 57.3 39 to 98 43.4 to 72.3

22 27 117.7 86.8 88.3 to 137.3 63.1 to 101.3

24 32 147.1 108.5 117.7 to 176.3 86.8 to 130.2

30 36 215.7 139.1 176.3 to 245.2 130.2 to 180.8

33 41 255.0 188.1 213.7 to 284.4 139.1 to 209.8

00-26 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL INSTRUCTIONS
12
37° Flare, Tube To Fitting Assembly 00

The plating combination is very important when using the torque method of assembly. Different plating combinations produce
widely varying friction coefficients, resulting in a large variation in clamping force for the same torque. Use the flats method
outlined below when working with different platings.

Figure 1.

1. Locate line to mating fitting and ensure the flare seats comfortably on the nose of the fitting (Figure 1).
2. Finger tighten nut down on fitting. If there is unexpected difficulty, or for larger sizes, use a wrench to tighten nut down
snugly (Figure 1).
3. Mark off nut (Figure 1) and turn to the appropriate F.F.F.T. (Flats From Finger Tight), using the chart on the previous
page.
4. After tightening, extend a line from the nut to body (optional) for future tightening of the same connection (Figure 1).

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-27
FOREWORD GENERAL INSTRUCTIONS
12
SAE Straight Thread O-Ring Fitting (Adjustable) To Port Assembly 00

1. Install O-ring on port end of fitting (if necessary).

2. Inspect both mating parts for burrs, nicks, scratches or any foreign particles.
3. Lubricate O-ring with light oil.

4. Back off locknut as far as possible. Ensure back-up washer is not loose and is pushed up as far as possible. See Step 1 in
figure above.
5. Screw fitting by hand into port finger tight until back-up washer contacts face of the port. Then, unscrew by required
amount to position fitting, but not more than one full turn. See Step 2 in figure above.
6. Use a wrench to hold fitting in desired position and then tighten locknut to torque level shown in the following charts. See
Step 3 in figure above.

00-28 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL INSTRUCTIONS
12
Seal-Lok Straight and Adjustable Fitting (Steel) 00

SAE PORT ASSEMBLY TORQUE

FITTING
THREAD
SIZE
SIZE lbf ft lbf ft

4 7/16 -20 190 ±10 16 ±1.0

6 9/16 -18 420 ±15 35 ± .0

8 3/4 -16 720 ±25 60 ±2.0

10 7/8 -14 1260 ±50 105 ±5.0

12 1 1/16 -12 1680 ±75 140 ±6.0

16 1 5/16 -12 2520 ±100 210 ±8.0

20 1 5/8 -12 3100 ±150 260 ±12.0

24 1 7/8 -12 3800 ±150 315 ±12.0

★ Use upper limits of torque ranges for stainless steel fittings.

★ Lubricant is strongly recommended for threads and contact surfaces of stainless steel assemblies.
Flare and Flareless Port Ends 00

SAE PORT ASSEMBLY TORQUE

FITTING
THREAD
SIZE
SIZE lbf ft lbf ft

2 5/16 -24 65 ±5 5.5 ±0.5

3 3/8 -24 130 ±10 11 ±1.0

4 7/16 -20 170 ±10 14 ±1.0

5 1/2 -20 260 ±15 22 ±1.0

6 9/16 -18 320 ±20 27 ±2.0

8 3/4 -16 500 ±25 42 ±2.0

10 7/8 -14 720 ±30 60 ±2.5

12 1 1/16 -12 960 ±50 80 ±5.0

14 1 3/16 -12 1260 ±75 105 ±6.0

16 1 5/16 12 1380 ±75 115 ±6.0

20 1 5/8 -12 2700 ±150 225 ±12.0

24 1 7/8 -12 3000 ±150 250 ±12.0

32 2 1/2 -12 3900 ±200 325 ±15.0

★ Use upper limits of torque ranges for stainless steel fittings.

★ Lubricant is strongly recommended for threads and contact surfaces of stainless steel assemblies.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-29
FOREWORD GENERAL INSTRUCTIONS
12
SAE Straight Thread O-Ring Fitting (Non-Adjustable) 00

Fitting To Port Assembly 00

1. Install SAE O-ring on port end of fitting (if necessary).

2. Make sure both threads and sealing surfaces are free of burrs, nicks,
and scratches, or any foreign material.
3. Lubricate O-ring with light coating of oil.
4. Turn fitting in full length until finger tight.
5. Tighten to given torque for the size from the following charts.

SAE PORT ASSEMBLY TORQUE

FITTING
THREAD
SIZE
SIZE lbf ft lbf ft

2 5/16 -24 90 ±5 7.5 ±0.5

3 3/8 -24 170 ±10 14 ±1.0

4 7/16 -20 220 ±15 18 ±1.0

5 1/2 -20 260 ±15 22 ±1.0

6 9/16 -18 320 ±20 27 ±2.0

8 3/4 -16 570 ±25 48 ±2.0

10 7/8 -14 1060 ±50 90 ±5.0

12 1 1/16 -12 1300 ±50 110 ±5.0

14 1 3/16 -12 1750 ±75 145 ±6.0

16 1 5/16 -12 1920 ±25 160 ±6.0

20 1 5/8 -12 2700 ±150 225 ±12.0

24 1 7/8 -12 3000 ±150 250 ±12.0

32 2 1/2 -12 3900 ±150 325 ±15

★ Use upper limits of torque ranges for stainless steel fittings.

★ Values in chart are for lubricated assemblies.
★ Lubricant is strongly recommended for threads and contact surfaces of stainless steel assemblies.

00-30 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL INSTRUCTIONS
12
Port Assembly For SAE Straight Thread Plugs 00

HOLLOW HEX HEAD HEX HEAD PLUG

SAE PORT PLUG (HP5ON) (P5ON)
FITTING
THREAD ASSEMBLY TORQUE ASSEMBLY TORQUE
SIZE
SIZE
lbf ft lbf ft lbf ft lbf ft

2 5/16 -24 35 ±5 3.5 ±0.5 90 ±5 7.5 ±0.5

3 3/8 -24 60 ±5 5 ±0.5 170 ±10 14 ±1

4 7/16 -20 135 ±10 11 ±1 220 ±15 18 ±1

5 1/2 -20 180 ±10 15 ±1 260 ±15 22 ±1

6 9/16 -18 220 ±10 18 ±1 320 ±20 27 ±1

8 3/4 -16 550 ±20 46 ±2 570 ±25 48 ±2

10 7/8 -14 900 ±50 75 ±5 1060 ±50 90 ±5

12 1 1/16 -12 1020 ±50 85 ±5 1300 ±50 110 ±5

14 1 3/16 -12 1550 ±75 130 ±6 1750 ±75 145 ±6

16 1 5/16 -12 1600 ±75 135 ±6 1920 ±75 160 ±6

20 1 5/8 -12 2700 ±150 225 ±12 2700 ±150 225 ±12

24 1 7/8 -12 3000 ±150 250 ±12 3000 ±150 250 ±12

32 2 1/2 -12 3900 ±200 325 ±15 3900 ±200 325 ±15

★ For steel Fittings.

★ Values in charts are for assemblies with O-ring lubricated.
★ Use upper limits of torque ranges for stainless steel fittings.
★ Lubricant is strongly recommended for threads and contact surfaces of stainless steel assemblies.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-31
FOREWORD GENERAL INSTRUCTIONS
12
4-Bolt Split Flange Assembly, Fitting To Port SAE 00

Code 61 (3000 psi) and Code 62 (6000 psi) 00

1. Make sure sealing surfaces are free of burrs, nicks, and scratches or
foreign particles.
2. Lubricate O-ring with oil.
3. Position flange and clamp halves.
4. Place lock washers on bolts and bolt through clamp halves.
5. Hand tighten bolts.
6. Torque bolts in diagonal sequence in small increments to the torque
level listed in the following chart for the flange size.

4-Bolt Split Flange Code 61 (3000 psi) Recommended Bolt Torque

ASSEMBLY TORQUE
FITTING FLANGE BOLT
SIZE SIZE SIZE
lbf ft lbf ft

12 3/4 3/8 -16 300 ±50 25 ±4.5

16 1 3/8 -16 375 ±50 31 ±4.5

20 1 1/4 7/16 -14 488 ±62 41 ±5

24 1 1/2 1/2 -13 625 ±50 52 ±6

32 2 1/2 -13 725 ±75 60 ±6

4-Bolt Split Flange Code 62 (6000 psi) Recommended Bolt Torque

ASSEMBLY TORQUE
FITTING FLANGE BOLT
SIZE SIZE SIZE
lbf ft lbf ft

12 3/4 3/8 -16 300 ±50 30 ±4.5

16 1 7/64 -14 375 ±50 46 ±4.5

20 1 1/4 1/2 -13 825 ±75 69 ±6

24 1 1/2 5/8 -11 1500 ±100 125 ±8

00-32 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD GENERAL INSTRUCTIONS
12
Pipe Thread Port Assembly, Fitting To Port 00

1. Make sure male and female threads are free of nicks, burrs, dirt, and etc.
2. Apply Loctite® 565 Thread Sealant on all pipe fittings without O-rings before installation.
3. Screw fitting into pipe port to finger tight position.
4. Turn fitting with wrench to the appropriate T.F.F.T (Turns From Finger Tight) shown on the following chart. Take into
consideration the final position of the fitting to accept incoming tube or hose.

PIPE THREAD SIZE

NPTF T.F.F.T.

1/8 -27 2-3

1/4 -18 2-3

3/8 -18 2-3

1/2 -14 2-3

3/4 -14 2-3

1 -11 1/2 1.5 -2.5

1 1/4 - 11 1/2 1.5 -2.5

1 1/2 - 11 1/2 1.5-2.5

2 -11 1/2 1.5-2.5

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-33
FOREWORD GENERAL INSTRUCTIONS
12
Standard Bolt Torque Chart (Inches) 00

SAE J429 Grade 8 FNL Grade 8

Nominal Threads Tinsile Clamp Tightening Torque Clamp Tightening Torque

Dia. per stress Load K=0.15 K=0.17 K=0.20 Load K=0.15 K=0.17 K=0.20
(inch) (inch) area (lbs.) (lb)
(in2)
Unified Coarse Thread Series
1/4 20 0.0318 2864 107 inf in 122 inf in 143 inf in 3357 126 inf in 143 inf in 168 inf in
5/16 18 0.0524 4719 221 inf in 251 inf in 295 inf in 5531 259 inf in 294 inf in 346 inf in
3/8 16 0.0775 6974 33 lbf ft 37 lbf ft 44 lbf ft 8174 38 lbf ft 43 lbf ft 51 lbf ft
7/16 14 0.1063 9568 52 59 70 11214 61 70 82
1/2 13 0.1419 12771 60 90 106 14969 94 106 125
9/16 12 0.1819 16375 115 130 154 19193 135 153 180
5/8 11 0.2260 20340 159 180 212 23840 186 211 248
3/4 10 0.3345 30101 282 320 376 35281 331 375 441
7/8 9 0.4617 41556 455 515 606 48707 533 604 710
1 8 0.6057 54517 681 772 909 63899 799 905 1065
1-1/4 7 0.9691 87220 1363 1545 1817 102229 1597 1810 2130
1-1/2 6 1.4053 126473 2371 2688 3162 148237 2779 3150 3706
Thread Series
1/4 28 0.0364 3274 107 inf in 139 inf in 164 inf in 3837 144 inf in 163 inf in 192 inf in
5/16 24 0.0581 5226 245 inf in 276 inf in 327 inf in 6125 287 inf in 325 inf in 383 inf in
3/8 24 0.0878 7905 33 lbf ft 42 lbf ft 49 lbf ft 9265 43 lbf ft 49 lbf ft 58 lbf ft
7/16 20 0.1187 10684 58 66 78 12523 68 78 91
1/2 20 0.1600 14396 90 102 120 16873 105 120 141
9/16 18 0.2030 18268 128 146 171 21412 151 171 201
5/8 18 0.2560 23036 180 204 240 27000 211 239 281
3/4 16 0.3730 33566 315 357 420 39343 369 418 492
7/8 14 0.5095 45853 502 568 669 53743 588 666 784
1 14 0.6799 61190 765 867 1020 71720 896 1016 1195
1-1/4 12 1.0729 96565 1509 1710 2012 113182 1768 2004 2358
1-1/2 12 1.5810 142292 2668 3024 3557 166778 3127 3544 4169

00-34 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD CONVERSION TABLES

12
CONVERSION TABLES 00

Method Of Using The Conversion Table 00

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.

B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.

C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-35
FOREWORD CONVERSION TABLES

12
Millimeters to Inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-36 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD CONVERSION TABLES

12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-37
FOREWORD CONVERSION TABLES

12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-38 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD CONVERSION TABLES

12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-39
FOREWORD CONVERSION TABLES

12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, 
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the 
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-40 XT430-3,XT430L-3,XT445L-3,XT460L-3
FOREWORD COATING MATERIALS

12
COATING MATERIALS 00

The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions and cork plugs from coming out
• Used in places requiring an immediately 
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 • Used for plastics (except polyethylene, 
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
• Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant 
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
500 g
Adhesives

Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
• Quick hardening type adhesive.
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container • Used mainly for adhesion of metals, rubbers,
plastics and woods.
• Quick hardening type adhesive.
• Quick cure type (max. strength after 30 min-
Aronalpha Polyethylene
790-129-9130 50 g utes).
201 container
• Used mainly for adhesion of rubbers, plastics
and metals.
• Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tempera-
648-50 container
ture.
• Used as adhesive or sealant for gaskets and 
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Gasket sealant

• Features: Resistance to heat

• Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent 
LG-3 790-129-9070 1 kg Can seizure.
• Used as sealant for heat resistant gasket for at
high temperature locations such as engine 
pre-combustion chamber, exhaust pipe.

XT430-3,XT430L-3,XT445L-3,XT460L-3 00-41
FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main applications, features

• Features: Resistance to water, oil
• Used as sealant for flange surface, thread.
• Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
• Used as sealant for mating surfaces of final
drive case, pump drive case.
• Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant

LG-5 790-129-9080 1 kg
tainer • Used as sealant for tapered plugs, elbows, 
nipples of hydraulic piping.
• Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case, etc.
• Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond • Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
• Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum

squeaking).
disulphide
lubricant

• Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
• Used for normal temperature, light load bearing
Grease

G2-CA SYG2-400CA-A Various Various

at places in contact with water or steam.
SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum

400 g
SYG2-400M Bellows type • Used for places with heavy load.
(10 per case)

00-42 XT430-3,XT430L-3,XT445L-3,XT460L-3
 01 GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
BOOM SWEEP DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
XT430-3, XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
XT445L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
Fuel Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
Engine Oil Performance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
Hydraulic and Engine Oil Selection, Lubricating Oils, and Grease . . . . . . . . . . . . . . . . 01-13
New Engine “Break-in” Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
Coolant Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
Coolant and Water for Dilution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
Hydraulic Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14
Hydraulic Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14
Hydraulic Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14
ISO Code Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15
General Hydraulic Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16
Minimum Technical Hydraulic Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16
Track Final Drive Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Pump Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Track Drive Pump (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Track Drive Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Return Oil Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Implement Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17
Typical Hydraulic Valve Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-18
Hydraulic Valve Configuration: Processor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-19
Hydraulic Valve Configuration: Processor 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20
Hydraulic Valve Configuration: Processor 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-21
Hydraulic Valve Configuration: Processor 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-22
Hydraulic Valve Configuration: Intermittent Disc Saw . . . . . . . . . . . . . . . . . . . . . . 01-23
Hydraulic Valve Configuration: Disc Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-24
Hydraulic Valve Configuration: Combination 233 Bar Saw w/Lateral Tilt or
Disc Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-25
Hydraulic Valve Configuration: 233 Bar Saw w/Lateral Tilt Option . . . . . . . . . . . 01-26

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-1
GENERAL

VOAC K220 Valve, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-27

VOAC L90LS Valve, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-29
Lubricant and Fill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-31
XT430-3, XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-31
XT445L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-31
XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-32
XT430-3, XT430L-3 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-32
XT445L-3, XT460L-3 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-32
Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-33
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-34
Operator’s Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-36
LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER . . . . . . . . . . . . . . . . . 01-37
Manually Lowering Work Equipment - Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-39

01-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
SPECIFICATIONS

Dimensions

Dimensions
XT430-3 XT430L-3 XT445L-3 XT460L-3

A 3.56 m 11 ft 8 in A 3.73 m 12 ft 3 in A 3.84 m 12 ft 7 in A 3.86m 12 ft 8 in

B 2.53 m 8 ft 4.5 in B 2.43 m 7 ft 11.7 in B 2.54 m 8 ft 4 in B 2.54 m 8 ft 4 in

C 4.92 m 16 ft 1.7 in C 4.59 m 15 ft 0.7 in C 4.77 m 15 ft 8.8 in C 4.77 m 15 ft 8.8 in

D 7.00 m 22 ft 11.6 in D 7.00 m 22 ft 11.6 in D 7.00 m 22 ft 11.6 in D 7.00 m 22 ft 11.6 in

E 0.73 m 28.7 in E 0.73 m 28.7 in E 0.81 m 31.9 in E 0.81 m 31.9 in

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-3
GENERAL BOOM SWEEP DIAGRAMS
12
BOOM SWEEP DIAGRAMS
Model XT430-3, XT430L-3, XT445L-3 and XT460L-3, Standard Boom and FB Arm

Lifting Capacity (w/o Attachment):

XT430-3, XT430L-3, XT445L-3 XT460L-3

10 ft (3.05 m) - 24,250 lb (11,000 kg) 10 ft (3.05 m) - 29,200 lb (13,245 kg)

15 ft (4.57 m) - 18,200 lb (8,255 kg) 15 ft (4.57 m) - 20,800 lb (9,435 kg)

20 ft (6.10 m) - 11,500 lb (5,215 kg) 20 ft (6.10 m) - 13,500 lb (6,123 kg)

01-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL BOOM SWEEP DIAGRAMS
12

Model XT430-3, XT430L-3, XT445L-3 and XT460L-3, Long Boom and FB Arm

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GENERAL BOOM SWEEP DIAGRAMS
12
Model XT430-3, XT430L-3, XT445L-3 and XT460L-3, Long Boom and Processor Arm

(For Harvesting Heads 2,495 kg (5,500 lbs.) Maximum)

01-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL BOOM SWEEP DIAGRAMS
12
Model XT430-3, XT430L-3, XT445L-3 and XT460L-3, Long Boom and Telescopic Arm

(For Harvesting Heads 2,495 kg (5,500 lbs.) Maximum)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-7
GENERAL SPECIFICATIONS
12
SPECIFICATIONS

XT430-3, XT430L-3

Item Description XT430-3 XT430L-3

STD 600 mm (24 in) Single Grouser 3,140 mm (10 ft 4 in) 3,140 mm (10 ft 4 in)

Machine Width OPT 700 mm (28 in) Double Grouser 3,240 mm (10 ft 8 in) 3,240 mm (10 ft 4 in)

OPT 900 mm (36 in) Triple Grouser 3,440 mm (11 ft 3 in) 3,440 mm (11 ft 3 in)

STD 600 mm (24 in) Single Grouser 55.8 kPa (8.1 psi) 58.0 kPa (8.4 psi)
Ground
OPT 700 mm (28 in) Double Grouser 47.0 kPa (6.8 psi) 48.3 kPa (7.0 psi)
Pressure
OPT 900 mm (36 in) Triple Grouser 37.2 kPa (5.4 psi) 38.0 kPa (5.5 psi)

Model Cummins QSC 8.3 Tier 3

Horse Power PEAK: 300 HP (224 kW) at 2000 rpm

Engine
RATED: 280 HP (209 kW) at 2200 rpm

Torque PEAK: 1355.82 N•m (1,000 lbf ft) at 1500 rpm

Machine weight 28,232 kg 29,239 kg

Base Machine*
(without attachments) (62,240 lb) (64,460 lb)

Front N/A 27° 51%

Cab Leveling Rear N/A 5° 9%

Side N/A 20° 36%

Cutting Area Maximum 6,530 mm (21 ft 5 in)

Standard length boom,
to attachment Minimum 2,290 mm (7 ft 6 in)

Swath 4,240 mm (13 ft 11 in)

Lifting Capacity At 3.05 m (10 ft) 11,000 kg (24,250 lb)

(without attachment)
At 4.57 m (15 ft) 8,255 kg (18,200 lb)

At 6.10 m (20 ft) 5,216 kg (11,500 lb)

Tractive effort 29,010 kg (61,775 lb)

Track System Effort to weight ratio 1.01:1 1.03:1

Speed 0-4.8 km/h (0-3.0 mph)

Swing Swing Torque 79,180 N•m (58,400 lbf ft)

*Approximate "woods ready" operating weight, fully serviced including one-half tank fuel and 80 kg (175 lb) operator.

01-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
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XT445L-3

Item Description Specification

STD 600 mm (24 in) Single Grouser 3,140 (10 ft 4 in)
Machine Width
OPT 700 mm (28 in) Single Grouser 3,240 (10 ft 8 in)

STD 600 mm (24 in) Single Grouser 61.36 kPa (8.9 psi)
Ground Pressure
OPT 700 mm (28 in) Double Grouser 53.43 kPa (7.75 psi)

Model Cummins QSC 8.3 Tier 3

Horse Power PEAK: 300 HP (224 kW) at 2000 rpm

RATED: 280 HP (209 kW) at 2200 rpm
Engine
Torque PEAK: 1,355.82 N•m (1,000 lbf ft) at
1500 rpm

Fuel Capacity 651 l (172 US gal)

Machine weight
Base Machine* 30,925 kg (68,180 lb)
(without attachments)

Front 27° 51%

Cab Leveling Rear 5° 9%

Side 20° 36%

Cutting Area Maximum 6,530 mm (21 ft 6 in)

Standard length boom, to 
attachment Minimum 2,290 mm (7 ft 6 in)

Swath 4,240 mm (13 ft 11 in)

Lifting Capacity At 3.05 m (10 ft) 11,000 kg (24,250 lb)

(without attachment)
At 4.57 m (15 ft) 8,255 kg (18,200 lb)

At 6.10 m (20 ft) 6,216 kg (11,500 lb)

Tractive effort 33,710 kg (74,315 lb)

Track System Effort to weight ratio 1.11:1

Speed 0-5.3 km/h (0-3.3 mph)

Swing Swing Torque 79,180 N•m (58,400 lbf ft)

*Approximate "woods ready" operating weight, fully serviced including one-half tank fuel and 80 kg (175 lb) operator.

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GENERAL SPECIFICATIONS
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XT460L-3

Item Description Specification

STD 600 mm (24 in) Single Grouser 3,175 mm (10 ft 5 in)
Machine Width
OPT 700 mm (28 in) Double Grouser 3,277 mm (10 ft 9 in)

Ground STD 600 mm (24 in) Single Grouser 0.68 kg/cm² (9.7 psi)
Pressure OPT 700 mm (28 in) Double Grouser 0.61 kg/cm² (8.7 psi)

Model Cummins QSC 8.3 Tier 3

Horse Power PEAK: 300 HP (224 kW) at 2000 rpm

RATED: 280 HP (209 kW) at 2200 rpm
Engine
Torque PEAK: 1,355.82 N•m (1,000 lbf ft) at
1500 rpm

Fuel Capacity 492 l (139 gal)

Machine weight 33,710 kg (74,320 lb)

(without attachments) Base Machine*

Front 22° 40%

Cab Leveling Rear 6° 11%

Side 18° 32%

Cutting Area Standard length Maximum 6,530 mm (21 ft 5 in)

boom, to attachment
Minimum 2,290 mm (7 ft 6 in)

Swath 4,240 mm (13 ft 11 in)

Lifting At 3.05 m (10 ft) 13,245 kg (29,200 lb)

Capacity (without attachment)
At 4.57 m (15 ft) 9,435 kg (20,800 lb)

At 6.10 m (20 ft) 6,123 kg (13,500 lb)

Tractive effort 33,710 kg (74,315 lb)

Track System Effort to weight ratio 1.07:1

Speed 0-5.3 km/h (0-3.3 mph)

Swing Swing Torque 79,180 N•m (58,400 lbf ft)

*Approximate "woods ready" operating weight, fully serviced including one-half tank fuel and 80 kg (175 lb) operator.

01-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
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Engine
Your machine comes equipped with a Cummins QSC 8.3 liter, 280 hp engine. You can identify your engine by looking at the
tag located on the engine (see photo). You will need the engine serial number when ordering spare or replacement parts for
your engine or for service work.

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-11
GENERAL SPECIFICATIONS
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Fuel Quality Requirements

Density, +15°C 0,82 . 8,84 kg/dm³ EN ISO 3675: 1998, EN ISO 12185
Viscosity, +40°C 2,0 . 4,5 mm²/s EN ISO 3104
Sulphur content Max. 0,0005 p-% EN ISO 14596:1998
Cetane number Min. 51 EN ISO 5165:1998
Water content Max. 200 mg/kg EN ISO 12937:1996
Lubricity/HFRR Max. 460 microns ISO 12156-1

Engine Oil Performance Information

The use of quality engine lubricating oils combined with appropriate oil drain and filter intervals are critical factors in main-
taining engine performance and durability.
The engine manufacturer recommends the use of high quality SAE 15W-40 heavy duty engine oils which meet the American
Petroleum Institute (API) performance classification CG-4 (preferred) or CF-4 (allowed).
A sulfate ash limit of 0.5 mass percent or less is suggested for optimum valve and piston deposit and oil consumption control.
All machines have the following decal on them as a reminder of which engine oil to use for ambient.
CG-4 E3-96
CH-4 E4-98
E5-99

01-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
Hydraulic and Engine Oil Selection, Lubricating Oils, and Grease
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed in the table
below.

Type Item Type

Engine Oil Engine oil pan Komatsu EO 15W40

Pump drive gearbox Shell Spirax ASX-R SAE 75W-90

Swing drive gearbox Shell Omala S4 GX 220

Lubricating Oils Track final drive Shell Spirax S4 CX 50

Hydraulic oil system Shell Tellus 32 or

Shell Tellus 46 or
Shell Tellus 68 depending on temperature

Pins and Bushings, Auto Lube Shell Retinax MDX-2

Grease
Bearings G2-L1

Coolant Radiator Supercoolant AF-NAC (density: 50%)

New Engine “Break-in” Oils

★ Do not use special break-in lubricating oils for new or rebuilt engines.
★ Use the same type of oil during the break-in that is used during normal operation.

Coolant Quality Requirements

The coolant used must meet the demands of standard ASTM D 3306 or BS 6580:1992.
★ Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. If machine is not equipped with a
corrosion resistor, Komatsu Supercoolant must be used.
★ Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent
anti corrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours. Komatsu
Supercoolant (AF-NAC) is strongly recommended wherever available. If machine is not equipped with a corrosion resis-
tor, Komatsu Supercoolant must be used.
Other than Komatsu Supercoolant (AF-NAC), the cooling mixture must consist 40 to 60% of ethylene/propylene-glycol based
antifreeze and water. The best proportion is 50% antifreeze and 50% of water.
★ For arctic conditions, use 60/40 ratio.
Coolant and Water for Dilution
When diluting the antifreeze coolant, use distilled water or tap water (soft water). Natural water, such as a river water or well
water (hard water), contains large amounts of minerals (calcium, magnesium, etc.), and this makes it easier for scale to form
inside the engine or radiator. Once scale is deposited inside the engine or radiator, it is extremely difficult to remove. It also
causes overheating due to poor heat exchange, so when you dilute the coolant, we recommend that you use water with an over-
all hardness of less than 100 PPM.
★ Change the coolant every two years.
★ Never use water alone as a coolant.

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-13
GENERAL SPECIFICATIONS
● The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where
freezing is not an issue, the use of antifreeze coolant is essential.
● When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
★ Antifreeze coolant is flammable, so be sure to keep it away from flame.
● The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
● Supercoolant (AF-NAC) may be supplied in premix. In this case, never add diluting water.
● If the engine overheats, wait for the engine to cool before adding coolant.
● If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering the
coolant.
Hydraulic Oil Information
Choosing the correct hydraulic oil to use in your hydraulic system is extremely important. Consider these two things when
selecting hydraulic oil:
1. Select a hydraulic oil with the properties that meet the equipment manufacturers performance specifications.
2. Use the correct ISO viscosity oil for your ambient temperature.
Using a hydraulic oil that meets the above requirements will help eliminate costly machine downtime and reduce the overall
operating cost of your machine. Failure to use the correct hydraulic oil will only create problems and cost you time and money.
Hydraulic Oil Type
Modern hydraulic systems use components that require hydraulic oil with specific properties and containing additives that
reduce wear, foaming, oxidation, etc. This is called the oils Performance Specifications.
All machines leaving the factory are filled with Shell Tellus S2 hydraulic oil that meets published performance specification
requirements. If you want to use a different brand, it must meet the recommended hydraulic oil performance specifications
found in this manual. You can provide your oil supplier a copy of these specifications so that he can keep you supplied with the
proper oil.
Hydraulic Oil Viscosity
The viscosity of an oil is identified by its ISO Viscosity Rating. The ISO viscosity rating can be found on the oil containers
label. The factory uses three ISO viscosity oils when filling machines during production.
1. ISO 32 – A light weight oil for cold weather conditions with ambient temperatures from -29 to 10ºC (-20 to 50ºF).
2. ISO 46 – A medium weight oil for mid-range conditions with ambient temperatures from -4º to 21ºC (+25º to 70ºF).
3. ISO 68 – A heavier oil for warm weather conditions with ambient temperatures from 4º to 32ºC (40º to 90ºF).
Although it is not supplied from the factory, the following ISO viscosity is commonly used in extreme cold weather.
ISO 22 – A light weight oil for arctic cold weather conditions with ambient temperatures from -40º to 4ºC
(-40º to 40ºF).
The viscosity of the hydraulic oil used at the factory is determined by the time of year the machine is manufactured and where
the machine will be shipped.
For example: A machine built in December for operation in Wisconsin would be factory filled with ISO 32 hydraulic oil.
That same machine if built in June, would be filled with ISO 46 hydraulic oil.
Using the correct hydraulic oil viscosity for your ambient conditions is extremely important. If the oil viscosity is too light for
ambient, the hydraulic oil system will overheat easily and damage to components can occur. If the oil viscosity is too heavy for
ambient, the oil will be too thick to flow easily and damage to components can occur from cavitation. Also, it may be harder to
start the machine.
Extreme weather conditions may require seasonal oil viscosity changes.
★ Check with your supplier before mixing hydraulic oils of different type, brand, or viscosity. Many oils are not compatible
and damage to your hydraulic system could result. 
When changing oil viscosity, flush and clean the hydraulic system before adding new oil.

01-14 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
ISO Code Rating
Cleanliness of hydraulic oil is rated on an ISO Code scale. An ISO
Code rating is made up of two numbers that reference the approximate
number of particles or contaminates, by size, that can be found in a
fixed volume (1 ml) of hydraulic oil.
For example: ISO Code 17/14 – This is the cleanliness required by the
manufacturer of the pumps and motors used in your track machine’s
hydraulic system.
The lower the ISO Code numbers, the cleaner the oil is. Generally, the
only time you will see an ISO Code rating is on an oil performance
specification sheet or an oil sample test results sheet. Because an ISO
Code rating is based on particles you cannot see with the naked eye, it
is difficult to use the ISO Code rating unless it references test results.

Here is an example to use for reference:

ISO Code 14/10 – Cleanliness required by most hydraulic servo-type
systems.
ISO Code 17/14 – Cleanliness required in the Komatsu Forest 
hydraulic systems.
ISO Code 21/19 – Generally, the cleanliness of new hydraulic oil
shipped in a drum.
On the ISO Code rating scale, a 14/10 rating is 10X cleaner than a 17/14 rating, and a 21/19 rating is 10X dirtier than a 17/14
rating. This is why it is so important to only add pre-filtered oil to your hydraulic system and to clean and flush hoses and fit-
tings before installing.

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GENERAL SPECIFICATIONS
12
General Hydraulic Oil Specification
For optimum efficiency and hydraulics component life, Komatsu Forest recommends that a high quality, wide temperature
range, shear stable hydraulic oil be utilized which incorporates the following additive agents and viscosity limits.

★ The hydraulic oil is the life blood of the hydraulic system and should never be compromised.

1. Operating hydraulic oil viscosity (at normal operating temperature) be selected in the range of 81 to 167 SUS (17 to
35 cSt).

2. Anti-wear Agents: Zinc dithiophosphate at a minimum level of 800 ppm to provide lubricity (or equivalent).

3. Defoamers or Release Agents: Prevents the formation of air bubbles within the hydraulic oil.

4. Anti-Oxidant Agents: Prevents the formation of corrosive acids and sludge.

5. Rust & Corrosion Inhibitors: Protects metallic components from water and acids.

6. Detergents & Dispersants: Keeps system components free of deposits.

Reference the oil manufacturers specification data sheet for the above hydraulic oil technical requirements.

Minimum Technical Hydraulic Oil Requirements

Any hydraulic oil utilized in Komatsu Forest produced equipment should meet the following minimum technical require-
ments:

Specification Minimum Requirement

FZG Rating, Din 5153410+
Vickers 35VQ Vane Pump Test <90 mg
Vickers M-2950-S
Foam Test, ASTM D89220/0I, II, III/ml
Emulsion Test, ASTM 1401 10 max
(minutes to 37 ml. Water @ 55°C {130°F})
Cincinnati Milacron Thermal Pass
Stability (135°C {275°F}, 168 hours)
Rust Test, ASTM D-665 Pass
Procedures A & B
Sonic Shear Stability, 5 max
ASTM D5621 (100C / 40 minutes) (% viscosity loss)
Water In Suspension <.1% (% by Volume)
Oil Cleanliness ISO Standard 17/14 min (16/12 prefer)
Viscosity Index, Min:
ISO 32 Rating 169
ISO 46 Rating 145
ISO 68 Rating 135
Pour Point, Max:
ISO 32 Rating -42.77°C (-45°F) 
ISO 46 Rating -37.22°C (-35°F)
ISO 68 Rating -34.44°C (-30°F)
Track Final Drive Oil Information
Shell Spirax S4 CX 50

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GENERAL SPECIFICATIONS

Hydraulic System
General
Type: Closed center, variable displacement, pressure compensated.
Pump Transmission:
Type: Triple pad type pump drive
Manufacturer: Funk Manufacturing
Model: YZ15961
Implement Pump
REXROTH 145cc:
Type: Variable displacement piston, load sense pressure compensated.
Manufacturer: REXROTH
Model: A11V0145DRS
Displacement: 325 Liters (86 gpm)
Pressure Capability: 422 kgf/cm² (6,000 psig)
Standby Pressure: 30 kgf/cm² (425 psig)
PCO Pressure: 267 kgf/cm² (3,800 psig)
Max Case Pressure: No greater than 0.70 kgf/cm² (10 psig) above the suction inlet pressure.
Track Drive Pump (2)
Type: Variable displacement piston, load sense pressure compensated hydrostatic.
Manufacturer: REXROTH
Model: AA4VG903.2
Displacement: 208 liters (55 gpm)
Pressure Capability: 386 kgf/cm² (6,000 psig)
POR Pressure: 386 kgf/cm² (5,500 psig)
High Pressure Relief: 408 - 422 kgf/cm² (5,800 - 6,000 psig)
Max Case Pressure: No greater than 0.70 kgf/cm² (10 psig) above the suction inlet pressure.
Track Drive Charge Pump
Type: Fixed displacement gear
Manufacturer: REXROTH
Model: MJ80871
Displacement: 114 liters (30 gpm)
Charge Pressure: 34 kgf/cm² (475 psig)
Return Oil Filtration
Type: ISO Rating 16/12) (Qty. 3) In tank 569 lpm (150 gpm) rating with diffused bypass
Manufacturer: SCHROEDER
Model: LRT18S7
Filtration: Varies by ambient conditions
Hydraulic Tank
Type: Steel construction, pressurized and baffled design equipped with individual suction ports for all pumps with
shut-off valves.
Capacity: 416 litres (110 US gal)
Pressurization: 0.49 kgf/cm² (7 psig) from engine turbo boost circuit
Level Indicator: Monitor displays red indicator lamp to warn when low oil level to protect against major oil loss.
Fill: Electric fill pump and 2 addition fill points provided, all oil is filtered before it enters the main tank.
Implement Control Valve
Type: 9 or 10-Section pressure compensated load sense control
Manufacturer: VOAC
Model: K220 / L90LS
System Pilot Pressure: 36 - 42 kgf/cm² (500 - 600 psig)
Valve Port Reliefs: 306 and 285 kgf/cm² (4,350 and 4060 psig)

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GENERAL SPECIFICATIONS
12
Typical Hydraulic Valve Set-up

01-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
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Hydraulic Valve Configuration: Processor 2
1. Attachment Section Plugged (not used): 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Attachment Section Plugged (not used): 7. Rotator Section: (Attachment)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Telescopic Section: 8. Level (Left) Section:

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 182 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm)
Minimum Flow B port: 35 l/m (9 gpm)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-19
GENERAL SPECIFICATIONS
12
Hydraulic Valve Configuration: Processor 3
1. Attachment Section Combined with Section 2: 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Attachment Section Combined with Section 1: 7. Rotator Section (Proc. 3) or Lateral Tilt (Proc. 4):
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Telescopic Section or (not used): 8. Level (Left) Section:

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm)
Minimum Flow B port: 35 l/m (9 gpm)

01-20 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: Processor 4

1. Attachment Section Combined with Section 2: 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Attachment Section Combined with Section 1: 7. Rotator Section (Proc. 3) or Lateral Tilt (Proc. 4):
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Telescopic Section or (not used): 8. Level (Left) Section:

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm)
Minimum Flow B port: 35 l/m (9 gpm)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-21
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: Processor 5

1. Attachment Section Combined with Section 2: 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Attachment Section Combined with Section 1: 7. Rotator Section (Attachment)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Telescopic Section or (not used): 8. Level (Left) Section:

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm)
Minimum Flow B port: 35 l/m (9 gpm)

01-22 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: Intermittent Disc Saw

1. Saw Section (Attachment): 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 142.7 kgf/cm² (2,030 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Clamp Section (Attachment): 7. Accumulator Section (Attachment)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Tool Tilt Section: 8. Lateral Tilt Section (not shown):

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 255 kgf/cm² (3,625 psi))
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Left) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section: 10. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 35 l/m (9 gpm)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-23
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: Disc Saw

1. Accumulator Section (Attachment): 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Clamp Section (Attachment): 7. Lateral Tilt Section (Attachment)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Tool Tilt Section: 8. Level (Left) Section:

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: None
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 54 l/m (14 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm)
Minimum Flow B port: 35 l/m (9 gpm)

01-24 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: Combination 233 Bar Saw w/Lateral Tilt or Disc Saw
1. Saw Section (Bar Saw) or  6. Swing Section:
Accumulator Section (Disc Saw) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Port Relief A & B: 306 kgf/cm² (4,350 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Minimum Flow A & B ports: 125 l/m (33 gpm)
Minimum Flow A & B ports: 165 l/m (44 gpm)

2. Clamp Section (Attachment): 7. Rotation Section (Proc. 3) or Lateral Tilt (Proc. 4)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Tool Tilt Section: 8. Lateral Tilt Section (not shown):

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 255 kgf/cm² (3,625 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 204 kgf/cm2 (2,900 psi)
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 125 l/m (33 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Left) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section: 10. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 35 l/m (9 gpm)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-25
GENERAL SPECIFICATIONS

Hydraulic Valve Configuration: 233 Bar Saw w/Lateral Tilt Option

1. Saw Section (Attachment): 6. Swing Section:
Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 245 kgf/cm² (3,481 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) Minimum Flow A & B ports: 125 l/m (33 gpm)

2. Clamp Section (Attachment): 7. Accumulator Section (Attachment)

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 306 kgf/cm² (4,350 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 255 kgf/cm² (3,625 psi)
Minimum Flow A & B ports: 165 l/m (44 gpm) A & B ports: 125 l/m (33 gpm)

3. Tool Tilt Section: 8. Lateral Tilt Section (not shown):

Port Relief A & B: 286 kgf/cm² (4,060 psi) Port Relief A & B: 255 kgf/cm² (3,625 psi)
Pressure Limiter A & B: 255 kgf/cm² (3,625 psi) Pressure Limiter A & B: 204 kgf/cm2 (2,900 psi)
Minimum Flow A port: 170 l/m (45 gpm)  Minimum Flow A & B ports: 125 l/m (33 gpm)
Minimum Flow B port: 190 l/m (50 gpm)

4. Arm Section: 9. Level (Left) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 180 l/m (48 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 25 l/m (7 gpm)

5. Boom Section: 10. Level (Right) Section:

Port Relief A & B: 306 kgf/cm² (4,350 psi) Port Relief A & B: 286 kgf/cm² (4,060 psi)
Pressure Limiter A & B: None Pressure Limiter A & B: None
Minimum Flow A port: 230 l/m (61 gpm) Minimum Flow A & B ports: 54 l/m (14 gp
Minimum Flow B port: 35 l/m (9 gpm)

01-26 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
VOAC K220 Valve, Typical

1. Pressure Limiters

2. Stroke Limiters

3. Port Limiters

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-27
GENERAL SPECIFICATIONS

1. Electro-Hydraulic Spool Actuators

2. Port Reliefs

01-28 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
VOAC L90LS Valve, Typical

1. Stroke Limiters

2. Pressure Limiters

3. Port Limiters

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-29
GENERAL SPECIFICATIONS

1. Electro-Hydraulic Spool Actuators

01-30 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
Lubricant and Fill Capacities
XT430-3, XT430L-3
Cooling System:
Komatsu Supercoolant (AF-NAC) (density 50%)
30.3 l (8.0 US gal)

Fuel Tank:
XT430L-3: 651 l (172 gal) A.S.T.M. Designation D-975
XT430-3: 825 l (225 US GAL)

Pump Drive:
Shell Spirax ASX-R SAE 75W-90
5.9 l (6.2 US qt)

Track Final Drive:

Shell Spirax S4 CX 50
11.0 l (11.6 US qt)

Hydraulic Oil Tank:

See Hydraulic Oil Charts in this section of the manual.
379.0 l (100.0 US gal)

Rexroth Swing Gearbox:

Shell Omala S4 GX 220
4.3 l (4.5 US qt)

See Hydraulic and Engine Oil Selection, Lubricating Oils, and

Lubricating Oils and Grease
Grease chart in this section of the manual.

Engine Oil: 18.93 l (20 qt) Komatsu EO 15W40

XT445L-3
Cooling System:
Komatsu Supercoolant (AF-NAC) (density 50%)
30.3 l (8.0 gal)

Fuel Tank:
A.S.T.M. Designation D-975
651 l (172 US gal)

Pump Drive:
Shell Spirax ASX-R SAE 75W-90
5.9 l (6.2 US qt)

Track Final Drive:

Shell Spirax S4 CX 50
11.0 l (11.6 US qt)

Hydraulic Oil Tank:

See Hydraulic Oil Charts in this section of the manual.
379 l (100.0 US gal)

Rexroth Swing Gearbox:

Shell Omala S4 GX 220
4.3 l (4.5 US qt)

See Hydraulic and Engine Oil Selection, Lubricating Oils, and

Lubricating Oils and Grease
Grease chart in this section of the manual.

Engine Oil: 18.93 l (20 qt) Komatsu EO 15W40

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-31
GENERAL SPECIFICATIONS
12
XT460L-3
Cooling System:
Komatsu Supercoolant (AF-NAC) (density 50%)
30.3 l (8.0 gal)

Fuel Tank:
A.S.T.M. Designation D-975
526 l (139 US gal)

Pump Drive:
Shell Spirax ASX-R SAE 75W-90
5.9 l (6.2 US qt)

Track Final Drive:

Shell Spirax S4 CX 50
11 l (11.6 US qt)

Hydraulic Oil Tank:

See Hydraulic Oil Charts in this section of the manual.
379 l (100.0 US gal)

Rexroth Swing Gearbox:

Shell Omala S4 GX 220
4.3 l (4.5 US qt)

See Hydraulic and Engine Oil Selection, Lubricating Oils, and

Lubricating Oils and Grease Grease chart in this section of the manual.

Engine Oil: 18.93 l (20 qt) Komatsu EO 15W40

XT430-3, XT430L-3 Undercarriage

TYPE Komatsu

FINAL DRIVES Komatsu

TRACK MOTORS Komatsu

TRACTIVE EFFORT 28,010 kg (61,775 lb)

EFFORT-TO-WEIGHT RATIO XT430-3 - 1.01:1

XT430L-3 - 1.03:1

TRAVEL SPEED 0 TO 3.0 mph

XT445L-3, XT460L-3 Undercarriage

TYPE Komatsu

FINAL DRIVES Komatsu

TRACK MOTORS Komatsu

TRACTIVE EFFORT 33,710 kg (74,315 lb)

EFFORT-TO-WEIGHT RATIO 1.11:1

TRAVEL SPEED 0 to 3.3 mph

01-32 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS
12
Upper Structure
REVOLVING FRAME CONSTRUCTION High quality, high strength alloy steel throughout

CONTINUOUS ROTATION Continuous

BEARING TYPE Large diameter ball bearing with induction hardened

races. Gear teeth located on inner race for protection
SWING SYSTEM from elements and debris.

BEARING DIAMETER 130 cm (51 in)

SWINGSPEED Adjustable to 8.5 rpm

SWING TORQUE 63,859 N•m (47,100 lbf ft)

TYPE Fixed displacement radial piston motor mounted on

reduction gearbox

GEARBOX MANUFACTURER REXROTH

REXROTH SWING MOTOR/
GEARBOX MODEL GFB-72

MOTOR MANUFACTURER REXROTH

DISPLACEMENT: 56 cc (3.42 in³)

SWING BRAKE Spring apply hydraulic release

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-33
GENERAL SPECIFICATIONS
12
Cylinders
TYPE Bolt-on bearing retainer design tested to 30 MPa (4,351 psi)

CYLINDER ROD Induction Hardened Chrome

ROD DIAMETER 102 mm (4.00 in)

XT445L-3: 197 mm (7.75 in)

BARREL O.D. DIAMETER
XT460L-3: 220.6 mm (9.0 in)

BOOM XT445L-3: 165 mm (6.5 in)

BORE
XT460L-3: 177.8 mm (7.0 in)

PISTON RETAINING NUT 2.75-12 UNF

RETRACTED LENGTH 152 cm (60.00 in)

STROKE 107 cm (42 in)

PIN SIZES 65 mm (3.00 in) rod and base

TYPE Bolt-on bearing retainer design tested to 30 MPa (4,351 psi)

CYLINDER ROD Induction Hardened Chrome

XT445L-3: 89 mm (3.50 in)

ROD DIAMETER
XT460L-3: 102 mm (4.0 in)

XT445L-3: 165 mm (6.5 in)

BARREL O.D. DIAMETER
XT460L-3: 213.9 mm (8.42 in)
ARM
XT445L-3: 140 mm (5.5 in)
BORE
XT460L-3: 165.1 mm (6.5 in)

PISTON RETAINING BOLT 2.00-12 UNF

RETRACTED LENGTH 142 cm (56.00 in)

STROKE 87 cm (34.25 in)

PIN SIZES 65 mm (2.56 in) rod and base

TYPE Bolt-on bearing retainer design tested to 28 MPa (4,061 psi)

CYLINDER ROD Induction Hardened Chrome

ROD DIAMETER 76 mm (3.00 in)

BARREL O.D. DIAMETER 159 mm (6.25 in)

Tool Tilt BORE 127 mm (5.00 in)

PISTON RETAINING BOLT 2.00-12 UNF

RETRACTED LENGTH 154 cm (60.50 in)

STROKE 107 cm (42.00 in)

PIN SIZES 64 mm (2.50 in) rod and base

01-34 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL SPECIFICATIONS

TYPE Bolt-on bearing retainer design tested to 34.5 MPa (5,000 psi)

CYLINDER ROD Induction Hardened Chrome

ROD DIAMETER 89 mm (3.50 in)

XT445L-3: 203 mm (8.00 in)

BARREL O.D. DIAMETER
XT460L-3: 288.6 mm (9.0 in)

XT445L-3: 165 mm (6.5 in)

BORE
Cab Level XT460L-3: 177.8 mm (7.0 in)

PISTON RETAINING BOLT 2.00-12 UNF

XT445L-3: 86 mm (34.00 in)

RETRACTED LENGTH
XT460L-3: 889 mm (35.0 in)

STROKE 36 cm (14 in)

XT445L-3: 65 mm (2.56 in) rod and base

PIN SIZES
XT460L-3: 88.9 mm (3.5 in)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-35
GENERAL SPECIFICATIONS

Operator’s Environment
TYPE High quality, high strength formed structure

ROPS/FOPS/OPS See certification placard located inside the Operators cab

CONSTRUCTION
MOUNTING Rubber isolators

WINDOWS Skylight, door, opera, boom side and rear windows, 12mm (1/2") polycarbonate

TYPE Heavy duty suspension

MANUFACTURER SEATS, INC.

SEAT
ADJUSTMENTS Seat height, Ride Seat fore & aft, Joystick fore & aft, Armrest up & down, and Lumbar
Backrest angle

NUMBER 3
EMERGENCY
ESCAPES
LOCATION Door, Roof Hatch and Front Window

HAND CONTROLS ELECTRONIC

JOYSTICK

FOOT CONTROLS ELECTRONIC

PEDAL

01-36 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
12
LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
This procedure is to be used to lower the work equipment ONLY when it can not be lowered hydraulically under system power
due to mechanical failure of the hydraulic system or engine failure. The work equipment should NEVER be lowered manually
with the system operational and running.

WARNING! You must read and understand the warnings and basic safety rules found in Section 00
of this manual before performing any operation or maintenance procedures. 
For additional engine maintenance guidelines, see the engine manufacturer’s manuals
provided with the machine.

WARNING! Lowering work equipment can be dangerous and may cause unexpected machine 
movement. Verify work area is stable and clear of all persons before lowering work
equipment.

WARNING! Hydraulic fluid under pressure can cause serious personal injury, blindness, or death. If
you come into contact with hydraulic oil or any other fluids, immediately seek treatment
by a doctor trained in the treatment of penetrating fluid injuries. Read all instructions
before attempting manual work equipment lowering procedure and comply with the rec-
ommended protective clothing and safety devices list.

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-37
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
12

WARNING! Wear the protective clothing and safety

devices, such as: 
- Hard Hat 
- Reflective Vest 
- Face Shield or Safety Glasses 
- Ear Protection 
- Work gloves 
- Steel toe work boots 
- Lockout Tag

01-38 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
12
Manually Lowering Work Equipment - Procedure
1. Turn master key to stop Position and remove.
2. Turn the Master Disconnect to the off position and place lockout tag
on disconnect switch.
3. Open rear valve door and secure with Stop Rod.
4. Locate Boom Control valve and manual lowering valve.
5. Verify that the work area around the work area around the machine is
clear from persons and hazards.

WARNING! When manually lowering work equipment,

the Main Boom (Lift Arm) must be 
lowered before the Arm (Stick Boom).
Releasing the Arm (Stick Boom) before
the Main Boom (Lift Arm), may cause the
Arm Attachment to swing back in to the
machine causing damage to the machine,
personal injury, or even death. 
Use extreme caution when lowering the
Arm (Stick Boom) manually.

6. Loosen the locknut on the Boom. See figure below.

7. Before loosening the valve control bolt, make sure that your position
is stable. Lowering work equipment may cause the machine to shift,
rock, or jerk.
8. Slowly loosen the valve control bolt on the Boom until it begins to
drop. Allow the Boom to drop slowly; one turn on the valve control
bolt is adequate.
9. Once the Boom has lowered, tighten the 3/16 inch valve control bolt
to 8 N•m (6 lbf ft).

3/16 Inch valve control bolt to 8 N•m (6 lbf ft)

10. Tighten the 5/8 inch locknut to 27 N•m (20 lbf ft) to secure control bolt closed.

5/8 Inch locknut to 27 N•m (20 lbf ft)

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-39
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
12
11. If the work equipment is not securely resting on the ground, and
additional drop is required, repeat steps 5 through 10 on the Arm
(Stick Boom) Valve.

01-40 XT430-3,XT430L-3,XT445L-3,XT460L-3
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER
12

MEMORANDUM

XT430-3,XT430L-3,XT445L-3,XT460L-3 01-41
GENERAL LOWERING WORK EQUIPMENT WITHOUT ENGINE POWER

01-42 XT430-3,XT430L-3,XT445L-3,XT460L-3
 10 STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD

12
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Track Frame And Recoil Spring, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . 10-2
Idler, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Track Roller, Carrier Roller, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Track Shoe, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Single Shoe, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Double Shoe, XT430-3 and XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Track Frame And Recoil Spring, XT445L-3 and XT460L-3 . . . . . . . . . . . . . . . . . . . . . 10-10
Idler, XT445L-3 and XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Track Roller, Carrier Roller, XT445L-3 and XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Track Shoe, XT445L-3 and XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Single Shoe, Heavy Duty Shoe, XT445L-3 and XT460L-3 . . . . . . . . . . . . . . . . . . . 10-18

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-1
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
UNDERCARRIAGE AND FRAME

Track Frame And Recoil Spring, XT430-3 and XT430L-3

1. Idler 5. Track roller

2. Track frame 6. Track shoe
3. Carrier roller 7. Center guard
4. Final drive 8. Front guard

10-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

● The dimensions and the number of track rollers depend on the model. The basic structure is not different.
● Number of track rollers
Model Quantity (one side) Flange type and arrangement
S: Single Flange; D: Double Flange
XT430L-3 9 DDDDDDDDD
XT430-3 8 SSSDDDDD

Standard Shoe

Model
Item XT430L-3 XT430-3
Shoe width (triple shoe) (mm)[in] 600 [23.6] 600 [23.6]
Link pitch (mm)[in] 216 [8.5] 216 [8.5]
No. of shoes (one side) 44 47

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-3
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
Idler, XT430-3 and XT430L-3

10-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

12

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Rapair limit
Outside diameter of
1 protrusion 635 (25) -
2 Outside diameter of tread 590 (23.23) 578 (22.76) Build-up
welding
3 Difference of tread 22.5 (0.89) 28.5 (1.12) for
rebuilding
4 Thickness of tread - - or replace
5 Total width 190 (3.54) -
6 Width of tread 44 (1.73) 50 (1.97)

Standard Tolerance Standard Clearance

Clearance between shaft size Shaft Hole clearance limit
7 and bushing
80 -0.225 (-0.009) +0.130 (+0.005) 0.201 - 0.455 -
(3.15) -0.325 (-0.013) -0.024 (-0.001) (0.0079 - 0.0179)

Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit Replace
8 bushing
idler and bushing
87.6 +0.087 (+0.003) -0.027 (-0.0011) 0.064 - 0.166 -
(3.45) +0.037 (+0.001) -0.079 (-0.0031) (0.0025 - 0.0065)
Clearance between Standard size Clearance limit
bushing and
9 support
(Sum of clearance at 0.68 - 1.22 (0.027 - 0.048) -
both sides)

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-5
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
Track Roller, Carrier Roller, XT430-3 and XT430L-3

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of outer flange
216 (8.5) —
Outside diameter of inner flange
2 210 (8.27) —
(Double flange)
3 Outside diameter of tread 180 (7.09) 168 (6.61) Build-up
4 Thickness of tread 54 (2.13) 48 (1.89) welding for
rebuilding or
5 Overall width 250 (9.8) — replace
Single flange 49 (1.93)
6 Width of tread —
Double flange 47.7 (1.88)
Single flange
7 Width of flange 27 (1.06) —
Double flange
Clearance between bushing and
8 collar 0.44 – 0.97 (0.017 - 0.038) —
(Sum of clearance at both sides)
Standard Tolerance Clearance
Standard clearance
Clearance between shaft and size Shaft Hole limit
9 Replace
bushing –0.250 (-0.0098) +0.186 (+0.0073) 0.186 – 0.536
65 (2.56) — bushing
–0.350 (-0.0138) –0.064 (-0.0025) (0.0073 - 0.0211)
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
10
bushing +0.108 (+0.00425) –0.006 (-0.0002) 0.014 – 0.144
72 (2.83) —
+0.008 (+0.0003) –0.036 (-0.0014) (0.0005 - 0.0056)
TORQUE
N•m lbf ft
11 Bolt 10 - 20 7.3 - 14.0
1st: 200 ±20 1st: 147 ±14.7
12 Bolt
2nd: 105 ±5° 2nd: 105 ±5°

10-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Track Shoe, XT430-3 and XT430L-3

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch
216.3 (8.516) 219.3 (8.634) Reverse or
Standard size Repair limit replace
2 Outside diameter of bushing
66.9 (2.634) 61.9 (2.437)
3 Thickness of bushing metal 10.8 (0.425) 5.8 (0.228) Adjust or replace
Standard size Repair limit
4 Link height
116 (4.57) 107 (4.21)
Repair or replace
Thickness of link metal (bushing
5 30.7 (1.21) 21.7 (0.85)
press-fitting portion)
6 178.4 (7.02)
7 Shoe bolt pitch 140.4 (5.5) Replace
8 76.2 (3.0)

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-7
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

Unit: mm (in)
No. Check Item Criteria Remedy
Inside
9 102 (4.0)
width
Overall
10 Link 47.8 (1.89) Repair or replace
width
Tread
11 42.6 (1.68)
width
12 Protrusion of pin 4.2 (0.165)
13 Protrusion of regular bushing 5.25 (0.207)
14 Overall length of pin 242 (9.53)
Adjust or replace
15 Overall length of bushing 148.4 (5.84)
Standard size Reverse
16 Thickness of spacer
10.8 (0.425) 5.8 (0.228)
17 Bushing 98 – 264.6 kN {10 – 27 ton}
Regular
18 147 – 362.6 kN {15 – 37 ton}
Press-fitting force pin —
19 Master
98 – 215.6 kN {10 – 22 ton}
(*) pin
Tightening torque
Retightening angle (deg.)
a. Regu- (N•m {lbf ft})
lar link Triple grouser 393 ±39
120 ±10°
shoe {290 ±29}
20 Shoe bolt Retighten
Tightening
Lower limit torque
b. Master torque Retightening angle (deg.)
(N•m {lbf ft})
link (N•m {lbf ft})
— — —
Tolerance Standard
Standard size
Interference between bushing and Shaft Hole interference
21
link +0.464 (+0.018) +0.074 (+0.0029) 0.350 – 0.464
66.5 (2.62)
+0.424 (+0.017) +0 (0) (0.0138 - 0.0183)
Interference between regular pin +0.235 (+0.0093) –0.188 (-0.0054) 0.273 – 0.485
22 44.6 (1.76)
and link +0.085 (+0.0034) –0.250 (-0.0098) (0.0107 - 0.0190)
Tolerance
Standard size Standard clearance
Clearance between regular pin and Shaft Hole
23
bushing +0.235 (+0.0093) +0.915 (+0.0360) 0.180 – 0.830
44.6 (1.76) Adjust or replace
+0.085 (+0.0033) +0.415 (+0.0163) (0.0063 - 0.0327)
Tolerance Standard
Standard size
24 Interference between master pin Shaft Hole interference
(*) and link +0.03 (+0.0012) –0.188 (-0.0054) 0.188 – 0.280
44.6 (1.76)
+0 (0) –0.250 (-0.0098) (0.0074 - 0.0110)
Tolerance
Standard size Standard clearance
25 Clearance between master pin and Shaft Hole
(*) bushing +0.050 (+0.0020) +0.915 (+0.0059) 0.365 – 0.965
44.3 (1.74)
–0.050 (-0.0020) +0.415 (+0.0163) (0.0143 - 0.0380)

* Dry type track link

10-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

12
Single Shoe, XT430-3 and XT430L-3

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
Single
1 Height of grouser 71.4 (2.81) 25 (0.98) Build-up welding
shoe
or replace
Single
2 Thickness of grouser 86.4 (3.40) 40 (1.57)
shoe

Double Shoe, XT430-3 and XT430L-3

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
Build-up welding
1 Height 49.5 (1.95) 25 (0.98)
or replace
2 Thickness 64.5 (2.54) 40 (1.57)

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-9
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

Track Frame And Recoil Spring, XT445L-3 and XT460L-3

1. Idler 5. Track roller

2. Track frame 6. Track shoe
3. Carrier roller 7. Center guard
4. Final drive 8. Front guard

10-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

12
● The dimensions and the number of track rollers depend on the model. The basic structure is not different.
● Number of track rollers
Model Quantity (one side) Flange type and arrangement
S: Single Flange; D: Double Flange
XT445L-3, XT460L-3 8 SSSDDDDD

Standard Shoe

Model
Item XT445L-3 and XT460-3
Shoe width (triple shoe) (mm)[in] 600 [23.6]
Link pitch (mm)[in] 228 [8.97]
No. of shoes (one side) 43

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-11
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

Idler, XT445L-3 and XT460L-3

10-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

12

Unit: mm (in)
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of protruding
704 (27.72) ---
2 Outside diameter of tread 660 (25.98) 648 (25.51)
3 Depth of tread 22 (0.867) 28 (1.10
4 Thickness of tread 21 (0.827) 15 (0.590)
Rebuild or
5 Total width 202 (7.953) --- replace
6 Width of tread 48.5 (1.91) 54.5 (2.15)
Clearance between bushing
and 
7 support 0.46 - 0.86 (0.018 - 0.034) ---
(Sum of clearance at both
sides)

Standard Tolerance Standard

Clearance between shaft and size Shaft Hole clearance
8 bushing
-0.120 (-0.0047) +0.360 (+0.0142) 0.340 - 0.507
95 (3.74) -0.207 (-0.0081) +0.220 (+0.0087) 0.0134 - 0.0200) Replace
Tolerance bushing
Standard Standard
Interference between idler and size Shaft Hole interference
9 bushing
102.6 +0.087 (+0.0034) -0.027 (-0.0011) 0.010 - 0.149
(4.039) +0.027 (+0.0011) -0.062 (-0.0024) (0.0004 - 0.0059)
N•m 130 - 180
10 Bolt (lbf ft) 96 - 132

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-13
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
Track Roller, Carrier Roller, XT445L-3 and XT460L-3

10-14 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

12

Unit: mm (in)
No Check Item Criteria Remedy
Standard size Rapair limit
Outside diameter of outer
1 flange 240 (9.45) -
Outside diameter of inner
2 237 (9.33) -
flange (Double flange)
3 Outside diameter of tread 200 (7.87) 188 (7.40)
4 Thickness of tread 56.2 (2.21) 50.2 (2.21)
5 Overal width 278 (10.94) -
Single Build-up
54.6 (2.15) welding for
flange
rebuilding
6 Width of tread Doubl - or replace
e 51.6 (2.03)
flange
Single
flange 34.4 (1.35) -
7 Width of flange Doubl
e 34.4 (1.35) -
flange
Width of inner frange
8 23.0 (0.91) -
(Double frame)
9 Axial play 0.4 - 1.0 (0. 16 - 0.039) -

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between -0.250 (-0.0098) +0.174 (+0.0068) 0.279 - 0.524
80 (3.15) - Replace
10 shaft and bushing -0.350 (-0.0138) +0.029 (+0.0011) (0.0110 - 0.0017)
bushing
Tolerance Interferenc
Standard Standard e
size Shaft Hole interference limit
Interference between 87.6 +0.087 (+0.0034) +0.022 (+0.0008) 0.015 - 0.100 -
11 roller and bushing (3.45) +0.037 (+0.0015) -0.013 (+0.0005) (0.0006 - 0.0039)
N•m 10 - 20
12 Bolt (lbf ft) 7.3 - 14.0

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-15
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
Track Shoe, XT445L-3 and XT460L-3

★ P portion shows the link of bushing press fitting end.

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch 228.9 (9.01) 231.9 (9.13) Reverse or replace
2 Outside diameter of bushing 71.5 (2.81) 66.5 (2.62)
3 Thickness of bushing metal 11.9 (0.49) 6.9 (0.27) Adjust or replace
4 Link height 129 (5.1) 119 (4.68)
Thickness of link metal Repair or replace
5 34.5 (1.36) 24.5 (0.96)
(bushing press-fitting portion)

10-16 XT430-3,XT430L-3,XT445L-3,XT460L-3
STRUCTURE, FUNCTION AND 
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Unit: mm (in)
No Check Item Criteria Remedy
6 184 (7.24)
7 Shoe bolt pitch 144 (5.67) Replace
8 76.2 (3.0)
Inside
9 106 (4.17)
width
Overall Repair or
10 Link 51.6 (2.03)
width replace
Tread
11 44.8 (1.76)
width
12 Protrusion of pin 4.4 (0.173)
13 Protrusion of regular bushing 5.25 (0.206)
Adjust or
14 Overall length of pin 252 (9.92) replace
15 Overall length of bushing 164.5 (6.48)
16 Thickness of spacer -
17 Bushing 118 - 304 kN (12 - 31 ton)
Regular
18 Press-fitting force 176 - 451 kN (18 - 46 ton)
pin -
19 Master 137 - 284 kN (14 - 29 ton)
(*) pin
Torque (N•m {lbf ft}) Retightening angle (deg.)
a. Regu-
lar link Triple grouser 393 ±39 120 ±10
shoe {15.47 ±1.54}
20 Shoe bolt Retighten
Torque Lower limit torque
b. Master Retightening angle (deg.)
(N•m {lbf ft}) (N•m {lbf ft})
link
- - -
Tolerance Standard
Standard size
Shaft Hole interference

21 Interference between 71 (2.79) +0.494 (+0.0194) +0.074 (+0.0029) 0.380 - 0.494

bushing and link +0.454 (+0.0178) 0 (0) (0.0149 - 0.0194)

22
Interference between 47 (1.85) +0.235 (+0.0092) -0.218 (-0.0085) 0.303 - 0.515
regular pin and link +0.085 (+0.0033) -0.280 (-0.0110) (0.0119 - 0.0202)
Standard
Clearance between regular +0.235 (+0.0092) +0.915 (+0.0360) clearance
23 47 (1.85) Adjust or
pin and bushing +0.085 (+0.0033) +0.415 (+0.0163 0.180 - 0.830
(0.0070 - 0.0326) replace

Standard
24 Interference between master +0.03 (+0.0011) -0.218 (-0.0085) interference
47 (1.85)
(*) pin and link 0 (0) 0.280 (-0.0110) 0.218 - 0.310
(0.0085 - 0.0122)
Standard
+0.915 (+0.0360) clearance
25 Clearance between master pin -0.2 (-0.0078)
47 (1.85) +0.415 (+0.0163
(*) and bushing -0.4 (-0.0157) 0.615 - 1.315
(0.0242 - 0.0517)

* Dry type track link

XT430-3,XT430L-3,XT445L-3,XT460L-3 10-17
 STRUCTURE, FUNCTION AND
UNDERCARRIAGE AND FRAME MAINTENANCE STANDARD

12
Single Shoe, Heavy Duty Shoe, XT445L-3 and XT460L-3

Unit: mm (in)
No. Check Item Criteria Remedy
Standard size Repair limit
Single
1 Height of grouser 80 (3.15) 30 (1.18) Build-up welding
shoe
or replace
Single
2 Thickness of grouser 99 (3.89) 49 (1.93)
shoe

10-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
 30 TESTING AND ADJUSTING

FIRE SUPPRESSION SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

Ansul™ Fire Suppression Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Ansul Fire Suppression Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Ansul Fire Suppression Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
HYDRAULIC PRESSURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Hydraulic Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Charge Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Main Track Pump Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Track Drive Pump Null Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Implement Pump Stand-by Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Implement Pump PCO Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Auxiliary Pump Stand-by Adjustment (Common & Separate) . . . . . . . . . . . . . . . . . 30-10
Auxiliary Pump PCO Adjustment (Common & Separate) . . . . . . . . . . . . . . . . . . . . 30-11
Main Control Valve Differential Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . 30-12
Main Control Valve LS Max Pressure Setting (PLM) . . . . . . . . . . . . . . . . . . . . . . . 30-13
Main Control Valve Port Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Main Control Valve Feed Reducer Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
System Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Main Control Valve Section Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Case Drain Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Adjusting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Checking Swing Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Maintenance for Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Measurement of Tilting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-1
TESTING AND ADJUSTING
12

MEMORANDUM

30-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING FIRE SUPPRESSION SYSTEM (OPTIONAL)

FIRE SUPPRESSION SYSTEM (OPTIONAL)

WARNING! Make sure to inspect the charge

gauge on a routine basis to make sure
the fire suppression supply tank (1) is
fully functional. 
If the gauge indicator is not in the
Green zone, have the system
inspected and recharged by an
ANSUL™ authorized dealer.

Ansul™ Fire Suppression Controls (Optional)

Refer to the Ansul Vehicle Fire Protection Owner’s Manual

for information on the fire suppression/detection systems.

When equipped with the optional ANSUL™ fire suppression system

(1), there are two manual system activation locations. On the exterior
of the machine, the activation button is located at the right hand base
side of the boom (2). Inside the cab the activation button is located on
the left hand side of the cab, behind the operator's seat.
To activate the fire suppression system, pull the safety pin from the 
system control button and press the button. The fire suppression system
will automatically discharge through nozzles located at key positions
throughout the machine.

WARNING! Only an ANSUL™ authorized dealer can

service the fire suppression system. The
machine owner will be responsible for any
malfunctions of the fire suppression 
system if anyone other than an ANSUL™
authorized dealer services the system. 
To locate an ANSUL authorized
dealer near you, call (800) 862-6785
or go to the ANSUL web site at
www.ansul.com

Ansul Fire Suppression Daily Inspections

The vehicle operator must check the system daily by visually
verifying that the GREEN power LED is flashing and no other
LED is illuminated. Also, no audio alarm should be sounding. If
any other conditions exist, contact the local authorized Ansul
distributor or whoever has been trained and authorized by Ansul
to perform inspection and maintenance on the fire suppression
system.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-3
TESTING AND ADJUSTING FIRE SUPPRESSION SYSTEM (OPTIONAL)
12
Ansul Fire Suppression Monthly Inspections
Inspection is a quick check that the system is operable. It is intended to give reasonable assurance that the system is fully
charged and will operate. This is done by seeing that the system has not been tampered with and there is no obvious physical
damage or condition to prevent operation. The value of an inspection lies in the frequency and thoroughness with which it is
conducted.
The system shall be inspected monthly by competent personnel following an approval schedule necessitated by conditions as
determined by the operator.
To Provide Reasonable Assurance That Your ANSUL™ A-101/LT-A-101 System Is Charged and Operable:

1. Note general appearance of system components for mechanical damage or corrosion.

2. Check all hoses to ensure they are securely fastened and not cut or show signs of abrasion.

3. Ensure all hose fittings are tight.

4. Ensure the nozzle openings are clean and not obstructed and the blow off caps are properly installed.

5. Check nameplate(s) for readability and ensure they are properly attached.

6. The automatic detection system should be inspected as follows: If the system is equipped with a CHECKFIRE SC-N auto-
matic detection system, make certain the GREEN POWER LED is blinking. If the system is equipped with CHECKFIRE
Series 1, push the button on top of the module and note illumination of the indicator light.

7. Check to ensure the hazard size or components being protected have not changed since original installation.

8. If there are any broken or missing lead and wire seals or any other deficiency is noted, immediately contact the authorized
Ansul Distributor.

9. Keep permanent records of each inspection.

Maintenance
Semi-Annual Maintenance must be performed by a trained qualified service technician who has received training and certifi-
cation from the manufacturer (Ansul).
This requirement is per NFPA-17 and/or manufacturers guidelines.
For the qualified distributor closest to your location, please refer to an Ansul Contact.

30-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
HYDRAULIC PRESSURE SETTINGS

WARNING! Make sure to read and understand all operational warnings in this manual. Additional
safety precautions will be included in this section as required by the procedure.

WARNING! Relieve hydraulic pressure before servicing any hydraulic component. 

Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.

WARNING! Wait for the hydraulic fluid to cool before servicing any hydraulic component. 
Hot hydraulic fluid can cause severe burns.

Hydraulic Pressure Gauges

★ You will require 703 kg/cm² (10,000 psi) and 70 kg/cm² (1,000 psi) hydraulic pressure gauges to perform the pressure set-
tings.
★ All the hydraulic pressure settings should be done when the hydraulic oil is at operating temperature.

Charge Relief Adjustment

1. Set the engine speed just above idle.

Install a 703 kg/cm² (1000 psi) gauge
into the charge pressure test port.

Remark
Make sure hydraulic oil is at
operating temperature, for all
pressure settings.

2. Increase engine speed to full throttle.

Check current charge relief pressure
reading (should read 30 kg/cm² or
425 psi.
• If pressure is too high, back off
charge relief (CCW) to a lower
setting. Adjust pressure to
30 kgf cm² or 425 psi (CW).
• If pressure is too low, adjust pressure up to 30 kg/cm² (425 psi).
• If pressure rises above 30 kg/cm² (425 psi), lower pressure below 30 kg/cm² (425 psi) and bring it up again.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-5
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
3. Remove gauge from test port.
Remark
Make sure hydraulic oil is at operating temperature, for all
pressure settings.

30-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Main Track Pump Relief Adjustment

1. Install track pins for safety. Set engine speed just above idle.

2. Install 703 kg/cm² (10,000 psi) gauge at

high-pressure test port.
• Stroke pump at about 20% stroke.
• Record pressure (should be
386 kgf cm² or 5500 psi).
• De-stroke pump.

3. Begin adjustment.
Turn POR valve out (CCW) to lower
pressure to 245 kg/cm² (3500 psi).

4. Adjust relief valves A and B inward

(CW) to a higher setting or until they
stop.
• To adjust relief settings, loosen 
second jam nut (gold) then turn on black nut.
• Do not adjust set screw.
Remark
Make sure that tow option set screw is bottomed out.

5. Stroke pump to about 20%.

• Read gauge.
• Turn POR inward (CW) to adjust pressure to 422 kg/cm² (6000 psi).

6. Back off main relief valve adjustment screw (CCW) until gauge just starts to move below 422 kg/cm² (6000 psi) (relief
valve opens).
• Turn in relief until it is above 422 kg/cm² (6000 psi) (relief valve closes).
• Back off relief until it is just at 422 kg/cm² (6000 psi) (relief valve is cracking only).
• Gauge should not drop below 422 kg/cm² (6000 psi).
• Stroke pump in opposite direction to set other main relief valve.

7. Stroke pump to about 20%.

• Lower POR adjustment (CCW) to 245 kg/cm² (3500 psi).
• Adjust POR (CW) back up to 378 kg/cm² (5500 psi).

8. Set opposite side pump with same procedure.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-7
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Track Drive Pump Null Adjustments
★ Make sure hydraulics are at correct operating temperature.
★ Apply track locking pins to both tracks to prevent accidental machine movement.

1. Remove plugs from ports X1 and X2.

• Install adapters into the ports.
• Connect jumper hose between ports X1 and X2.

2. Install 422 kg/cm² (6000 psi) pressure gauge to track

motor test port.
Loosen mechanical null adjustment jam nut and turn setscrew 
in/out until gauge indicates lowest possible pressure.

3. Remove 422 kg/cm² (6000 psi) pressure gauge and replace with 70
kg/cm² (1000 psi) gauge.
Loosen mechanical null adjustment jam nut and turn setscrew 
in/out until gauge indicates lowest possible pressure.

4. Remove jumper hose and adapters. Reinstall plugs into ports X1

and X2.

5. Remove 70 kg/cm² (1000 psi) pressure gauge and replace with 422
kg/cm² (6000 psi) gauge.

6. Loosen hydraulic null adjustment jam nut and turn setscrew in/out
until gauge indicates lowest possible pressure.

7. Remove 422 kg/cm² (6000 psi) pressure gauge and replace with 70 kg/cm² (1000 psi) gauge.

8. Loosen hydraulic null adjustment jam nut and turn setscrew in/out until gauge indicates lowest possible pressure.

9. Shut down engine and remove jumper hose, fitting and gauge.

10. Repeat procedure for other pump.

30-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Implement Pump Stand-by Adjustment

1. Load Sense (LS) line.

Disconnect load sense hydraulic hose from
hydraulic pump.
★ Plug hose end.
★ Leave pump vented.

2. Start engine and run at low idle.

Remark
Do not connect pressure gauge until
engine is running.

3. Connect 70 kg/cm² (1000 psi) pressure gauge to 

centralized pressure testing block.

4. Increase engine speed to 1500 rpm.

5. Read and record stand-by pressure (should be set at 30 kg/cm² or 425 psi).

WARNING! Do not set stand-by pressure with Load Sense (LS) hose connected. 
All functions will slow down

6. If adjustment is required, adjust stand-by adjustment

screw on implement pump inwards to increase pres-
sure and outwards to decrease pressure.

7. Stop engine and connect load sense hydraulic hose.

Implement Pump PCO Adjustment

1. Connect 422 kg/cm² (6000 psi) gauge to implement test port.

2. Start engine and increase engine speed to 1500 rpm.

3. Have another person bottom out main boom up function (on your signal), while you read the pressure gauge.

4. Read and record the pressure settings (should be 267 kg/cm² or 3800 psi).

5. If adjustment is required, adjust at PCO adjustment screw on implement pump inwards to increase pressure and outwards
to decrease.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-9
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Auxiliary Pump Stand-by Adjustment (Common & Separate)

1. (Common): Disconnect LS hoses on implement and auxiliary pump.

(Separate): Disconnect LS hose on auxiliary pump.
• Plug hose end.
• Leave pump vented.

2. Start engine and run at idle.

Remark
Do not connect pressure gauge until engine is running.

3. Install 70 kg/cm² (1000 psi) gauge at test port on auxiliary pump.

4. Increase engine rpm to 1500.

5. Read and record stand-by pressure (should be 30 kg/cm² or

425 psi)).

6. If adjustment is required, adjust stand-by adjustment screw on aux-

iliary pump inwards to increase pressure and outwards to decrease.

7. Stop engine.

8. Connect LS hose.

30-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Auxiliary Pump PCO Adjustment (Common & Separate)

1. Install a 422 kg/cm² (6000 psi) gauge to test port on auxiliary pump.

2. Start engine and increase rpm to 1500.

3. Common: Have another person bottom out main boom up function, as you read pressure (should indicate 253 kg/cm² or
3600 psi)).
Separate: 
Leveling: Have another person bottom out a leveling function, as you read pressure (should indicate 267 kg/cm² or
3800 psi).
Non-leveling: Switch swing section wires to capped leveling section. Have another person bottom out the "swing" func-
tion as you read pressure (should indicate 267 kg/cm² or 3800 psi)). Switch wires back to swing section.

4. If adjustment is required, adjust PCO adjustment setscrew on 

auxiliary pump inwards to increase pressure and outwards to
decrease.
Remark
Identify pumps by geometry. Orientation may vary.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-11
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Main Control Valve Differential Pressure Adjustment

1. Turn PLS adjustment screw in until it bottoms out (this

gives a 36 - 38 kg/cm² or 500-550 psi differential pres-
sure).

30-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Main Control Valve LS Max Pressure Setting (PLM)
★ Do not use excessive force when bottoming out adjustment.

1. Bottom out LS max pressure adjustment (PLM). Back out adjust-

ment 1/4 turn.

2. Have another person bottom out a boom function, as you read PCO
pressure (should be set at 265 kg/cm² or 3800 psi)). If pressure is
incorrect, refer to PCO pressure setting procedure.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-13
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Main Control Valve Port Reliefs
★ The main control valve port reliefs are not adjustable.

1. Run engine at idle. Bottom out each implement function in both directions.

2. If engine labors or pulls down, the port relief for that function may be incorrect or worn.

3. Replace.

Main Control Valve Feed Reducer Pressure

1. Install a 422 kg/cm² (6000 psi) gauge to implement test port on

centralized manifold.

2. Start engine and increase rpm to 1500.

3. Have another person bottom out an attachment function and set

pressure to the attachment manufacturer's setting. Turn feed
reducer adjustment inwards to increase pressure and outwards to
decrease.

System Pilot Pressure

★ The system pilot pressure is not adjustable.

1. Start engine and increase rpm to 1500.

2. Install 70 kg/cm² or 1000 psi gauge to pilot pressure test port on centralized manifold.

3. Have another person actuate the boom function as you read and record pressure (should be set at 35 kg/cm² or 500 psi).

30-14 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Main Control Valve Section Components

Valve Section Compensator Pilot A (spots) Pilot B (spots)

All Saw Sections K1 6 6

Clamp K1 6 6

Tool Tilt K3 6 6

Stick Arm K2 6 6

Main Boom K3 6 –

Swing KX 4 4

Disc Saw Accum. K1 6 6

Bar Saw Accum. KX 2 2

Level Left/Right KH 2 2

Lateral Tilt KX 2 2

Telescopic Arm K3 6 6

*Auxiliary K1 6 6

*Auxiliary sections are those labeled "not used" for processors.

Compensator Springs:

• K1: Inner and outer spring +1.5 mm shim

• K2: Inner and outer spring +1.5 mm and 3 mm shim
• K3: One spring + no shims
• KH: green
• KX: no color

WARNING! If pilot orifices are missing, Functions can

activate on their own.

Spots PN
9 28887

6 27260

4 27261

2 28888

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-15
TESTING AND ADJUSTING HYDRAULIC PRESSURE SETTINGS
12
Case Drain Flows
Pump wear or failure can be determined by checking the case drain flow, and comparing the result to the recommended maxi-
mum case drain flow as noted in the table below.

Maximum Case Drain Flows

Component Displacement Operating pressure Max Case Flow

— cc in³ MPa psi GPM l/m

Aux. Pump
45 2.75 26.2 3,800 1.85 7.03
A10V045

Aux. Pump
71 4.33 26.2 3,800 2.57 9.76
A10V071

Swing Motor
45 2.75 26.2 3,800 1.25 4.73
A2FE45

Swing Motor
56 3.42 26.2 3,800 1.55 5.87
A2FE56

Impl. Pump
145 8.85 26.2 3,800 9.22 34.9
AA11VL0145

Drive Pump
90 5.49 37.8 5,500 9.5 36.0
AA4VG90

Rexroth
Drive Motor 107 6.53 37.8 5,500 5.59 21.1
A6VM107

Komatsu
Drive Motor 196 11.96 37.8 5,500 6.93 26.2
KMV200

★ All case drain flows should be tested:

1. With the engine at full throttle.
2. At operating pressure listed above.
3. At operating temperature listed below.
Temperature
ISO Grade
°C °F
32 44 111

46 54 129

68 62 144

30-16 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING SWING MACHINERY

SWING MACHINERY
WARNING! Read and follow the safety instructions in this manual before performing these procedures. Failure to comply
could cause injury or death.
WARNING! Relieve hydraulic pressure before servicing any hydraulic component. 
Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.
WARNING! Wait for the hydraulic fluid to cool before servicing any hydraulic component.
Hot hydraulic fluid can cause severe burns.

Adjusting Gear Backlash

1. Position the machine on level ground. Raise the Boom with the
attachment and position close to the front of the machine. Then
lower the Boom so the attachment is firmly on the ground and the
revolving frame is not able to rotate. This position will allow room
under the Boom for accessing the Swing Machinery.
NOTE: Tag and mark hoses before removal to ensure correct
assembly. Plug all hydraulic hoses and fittings after removal to
prevent contamination.

2. Open the hydraulic tank vent to release the pressure in the hydrau-
lic tank.

3. Remove three hoses (1), (2) and (3) from the anti-cavitation valve
(4).

4. Remove hose (6) from the Swing Motor (5).

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-17
TESTING AND ADJUSTING SWING MACHINERY
5. Remove the two Swing Motor retaining bolts (1) and pull the
motor from the Gearbox.

6. Remove the Drive Coupler (2).

7. Remove twenty-four bolts (3), washers (4), and spacer (5) from the
Gearbox.

8. Mark the position (7) of the eccentric notch (6) in relation to the
mounting flange before removing the Gearbox.

30-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING SWING MACHINERY
9. Bolt a suitable lifting device to the two tapped holes in Swing
Motor housing.

10. Remove the Gearbox.

11. Clean the Gearbox flange and mounting surface using a Loctite solvent to remove the factory applied Loctite.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-19
TESTING AND ADJUSTING SWING MACHINERY
12. Locate the swing bearing gear high spot by carefully following these instructions.
IMPORTANT: The high spot on the Swing Bearing must be
located before reinstalling the eccentric swing drive. Three of the
swing bearing gear teeth are painted green to indicate the high
spot (1). If the green paint on the gear teeth cannot be located due
to wear, then a dial indicator must be used to locate the high spot.
Machines manufactured from February 2015 also have three "X"
stamped on the top bearing surface as shown (2).

WARNING: One technician must be on the revolving frame while

an operator lifts the attachment off the ground and rotates the
upper slowly. The operator must not activate any other machine
joystick function while activating the swing function. Failure to
comply could cause the boom to lower causing serious injury to
the technician on the revolving frame.
With one technician standing on top of the revolving frame to
observe the swing bearing teeth in the swing drive mounting hole, have an operator slowly rotate the machine until the
high spot is located in the center of the Swing Gearbox mounting hole.

13. Apply Loctite 5699 to the mounting surface of the Swing Machin-
ery as shown (1).

14. Locate the Gearbox back to the original bolt hole

position, aligning the notch to the mark.

30-20 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING SWING MACHINERY
15. Rotate the drive CCW until it stops at zero back-
lash, then rotate back CW to the nearest mount-
ing hole to set the Gear backlash.

16. Reinstall the Swing Motor to the position shown.

17. Apply Loctite 262 to all Gearbox retaining bolts and torque to 211 lb ft (286 N•m).

18. Install Swing Motor retaining bolts and torque to 190 lb ft (257 N•m).

19. Reinstall hoses to the Swing Motor and Manifold to complete the installation.

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-21
TESTING AND ADJUSTING SWING MACHINERY

Checking Swing Bearings

The Rotek swing bearings allow the rotation of the upper portion of the machine to the lower portion. The swing system bear-
ings for the XT430-3, XT430L-3 and XT445L-3 machines use the single row ball system, and the XT460L-3 machines use the
double row ball system.

Wear of the bearing is shown by changes in the axial motion of the slewing ring. Measurement of the tilting clearance deter-
mines the wear of the slewing ring. Keep yearly records of the measurements to determine wear of the slewing ring and when
service is required. Contact your Komatsu distributor for replacement of parts.

Maintenance for Swing Circle

The diagrams show specifics for the bearing location and measurements. If measurement of internal clearance is greater than
the allowable clearance noted in the table, replace the bearings.

XT430/XT430L/XT445L

KPXT0138

30-22 XT430-3,XT430L-3,XT445L-3,XT460L-3
TESTING AND ADJUSTING SWING MACHINERY

XT460L

KPXT0139

Use the following table for clearance values based upon the bearing ball size (41.3mm for single row, 28.6mm for double row).
The initial baseline numbers used for comparison are measured when the equipment is first installed on site.

Criteria
No. Item Machine Maximum
Standard clearance
Allowable clearance

XT430-3, XT430L-3, 0.127 to 0.254 mm

1 Wear measurement based upon 3.2 mm (0.126 in)
XT445L-3 (single row) (0.005 to 0.010 in)
tilting clearance of bearing
(when mounted on machine) 0.127 to 0.254 mm
2 XT460L-3 (double row) 2.5 mm (0.098 in)
(0.005 to 0.010 in)

XT430-3,XT430L-3,XT445L-3,XT460L-3 30-23
TESTING AND ADJUSTING SWING MACHINERY

Measurement of Tilting Clearance

The tilting clearance measurements are used to determine wear on
bearings. The diagram shows the loading principle for this measure-
ment with axial motion.

Take the measurements noting the following:

• Measure location between lower companion structure and bearing
ring.
• Measure as close to the raceway system as possible.

Remark
Initial measurement should be taken when equipment is first
installed, to be used as the baseline.

To perform measurement:

1. Define a starting point and mark measuring points around the cir-
cumference.

2. Apply maximum backward moment and set the dial gauge to zero.

3. Apply forward tilting moment, with load uptake if necessary.

4. Swivel the superstructure to the next position, and repeat measure-

ment steps using marked points.

5. Record all values and maintain record for future measurement

comparison.

Repeat measurements every 12 months, using identical conditions as the base measurement. If there is a great increase in wear,
shorten the time intervals between measurements. Contact your Komatsu distributor if these wear values are exceeded.

30-24 XT430-3,XT430L-3,XT445L-3,XT460L-3
 40 TROUBLESHOOTING

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3

Points to Remember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-5
Handling Electric Equipment and Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . 40-6
Checks Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
GENERAL HYDRAULIC PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
MACHINE OVERHEAT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
IMPLEMENT FUNCTION PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
TRACK DRIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
ENGINE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
ELECTRICAL PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
IQAN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Main Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Display Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
Main Menu Screen Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-49
Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Measure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51
Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Adjustment Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Hydrostat Sub Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Preferences Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Options Display Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
HP Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
Restrict Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
Select Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
Track Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Disc Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Information Display Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Engine Display Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
Faults Display Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
Operating the IQAN MD4 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61
First Time Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
Engine Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
Handling a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
DISC SAW CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-1
TROUBLESHOOTING
12

MEMORANDUM

40-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION

GENERAL INFORMATION

Points to Remember

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.

WARNING! When performing the operation with two or more workers, keep strictly to the agreed 
signals, and do not allow any unauthorized person to come near.

WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.

WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to prevent re-occurrence 
of the failure.
When performing troubleshooting, an important point is to understand the structure and function of the machine. However, 
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the 
failure that would produce the reported symptoms.

1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled 
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of 
the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior 
investigation and to perform troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the failure occurred?

C. Did the failure occur suddenly, or were there problems with the machine condition before this?

D. Under what conditions did the failure occur?

E. Had any repairs been performed before the failure? When were these repairs performed?

F. Has the same kind of failure occurred before?

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-3
TROUBLESHOOTING GENERAL INFORMATION
3. Check before troubleshooting.

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4. Confirming the failure.

Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the 
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not perform any investigation or 
measurement that may make the problem worse.

5. Troubleshooting

A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the 
troubleshooting flowchart to locate the position of the failure exactly.

B. The basic procedure for troubleshooting is as follows.

i. Start from the simple points.

ii. Start from the most likely points.

iii. Investigate other related parts or information.

6. Measures to remove root cause of failure.

Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.

40-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION
12
Sequence of Events

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-5
TROUBLESHOOTING GENERAL INFORMATION

Handling Electric Equipment and Hydraulic Components

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be performed. This section deals
particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose,
it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic
oil).
Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and 
disconnecting one wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be affected by the direct
effects of rain, water, heat, or vibration. Furthermore, during
inspection and repair operations, they are frequently removed and
installed again, so they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely careful when han-
dling wiring harnesses.

2. Main failures occurring in wiring harness

A. Defective contact of connectors (defective contact between

male and female)
Problems with defective contact are likely to occur because
the male connector is not properly inserted into the female 
connector, or because one or both of the connectors is
deformed or the position is not correctly aligned, or because
there is corrosion or oxidation of the contact surfaces. The
corroded or oxidized contact surfaces may become shiny
again (and contact may become normal) by connecting and
disconnecting the connector about ten times.

B. Defective crimping or soldering of connectors 

The pins of the male and female connectors are in contact at
the crimped terminal or soldered portion, but if there is exces-
sive force brought to bear on the wiring, the plating at the joint
will peel and cause improper connection or breakage.

40-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION
12
C. Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or
components are lifted with a crane with the wiring still con-
nected, or a heavy object hits the wiring, the crimping of the
connector may separate, or the soldering may be damaged, or
the wiring may be broken.

D. High-pressure water entering connector

The connector is designed to make it difficult for water to
enter (drip-proof structure), but if high-pressure water is
sprayed directly on the connector, water may enter the con-
nector, depending on the direction of the water jet. Accord-
ingly, take care not to splash water over the connector. The
connector is designed to prevent water from entering, but at
the same time, if water does enter, it is difficult for it to be
drained. Therefore, if water should get into the connector, the
pins will be short-circuited by the water, so if any water gets
in, immediately dry the connector or take other appropriate
action before passing electricity through it.

E. Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, so there will be
defective contact. If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry with compressed
air and spray it with a contact restorer.
★ When wiping the mating portion of the connector, be 
careful not to use excessive force or deform the pins.
★ If there is oil or water in the compressed air, the contacts
will become even dirtier, so remove the oil and water
from the compressed air completely before cleaning with 
compressed air.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-7
TROUBLESHOOTING GENERAL INFORMATION
12
3. Removing, installing, and drying connectors and wiring harnesses

A. Disconnecting connectors

i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors.
For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors in each hand
and pull apart. For connectors which have a lock stopper,
press down the stopper with your thumb and pull the con-
nectors apart.
★ Never pull with one hand.

ii. When removing from clips

• Both the connector and clip have stoppers, which are
engaged with each other when the connector is
installed.

• When removing a connector from a clip, pull the con-

nector in a parallel direction to the clip for removing
stoppers.
★ If the connector is twisted up and down or to the
left or right, the housing may break.

iii. Action to take after removing connectors

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the 
connector portion.
★ If the machine is left disassembled for a long time, it is
particularly easy for improper contact to occur, so
always cover the connector.

40-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION
12
B. Connecting connectors

i. Check the connector visually.

Check that there is no oil, dirt, or water stuck to the con-
nector pins (mating portion).
Check that there is no deformation, defective contact, cor-
rosion, or damage to the connector pins.
Check that there is no damage or breakage to the outside
of the connector.

★ If there is any oil, water, or dirt stuck to the connec-

tor, wipe it off with a dry cloth. If any water has got
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage, replace the con-
nector.

ii. Fix the connector securely.

Align the position of the connector correctly, and then
insert it securely. For connectors with the lock stopper,
push in the connector until the stopper clicks into posi-
tion.

iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion of
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected easily, remove
the clamp and adjust the position.
• If the connector clamp has been removed, be sure to
return it to its original position. Check also that there
are no loose clamps.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-9
TROUBLESHOOTING GENERAL INFORMATION
12
C. Heavy duty wire connector (DT 8-pole, 12-pole)
Disconnection (Left of figure)
While pressing both sides of locks (a) and (b), pull out
female connector (2).
Connection (Right of figure)

i. Push in female connector (2) horizontally until the lock

clicks.
Arrow: 1)

ii. Since locks (a) and (b) may not be set completely, push in
female connector (2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
★ Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.

(1): Male connector

(2): Female connector
(a), (b): Locks

D. Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the 
connector must be washed in water, do not use high-pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows.

i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with compressed air,
there is the risk that oil in the air may cause defec-
tive contact, so remove all oil and water from the 
compressed air before blowing with air.

ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but regulate the
time that the hot air is used in order not to make the
connector or related parts too hot, as this will cause
deformation or damage to the connector.

40-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION
12
iii. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, blow it with
contact restorer and reassemble.

4. Handling controller.

A. The controller contains a microcomputer and electronic control

circuits. These control all of the electronic circuits on the
machine, so be extremely careful when handling the controller.

B. Do not place objects on top of the controller.

C. Cover the control connectors with tape or a vinyl bag. Never

touch the connector contacts with your hand.

D. During rainy weather, do not leave the controller in a place

where it is exposed to rain.

E. Do not place the controller on oil, water, or soil, or in any hot

place, even for a short time. (Place it on a suitable dry stand).

F. Precautions when carrying out arc welding.

When carrying out arc welding on the body, disconnect all 
wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding point.

5. Points to remember when troubleshooting electric circuits.

A. Always turn the power OFF before disconnecting or connect-

ing connectors.

B. Before carrying out troubleshooting, check that all the related

connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.

C. Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be 
generated.

D. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the
related wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-11
TROUBLESHOOTING GENERAL INFORMATION
12
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.

1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing the
machine in rain or high winds, or places where there is a lot of
dust.

2. Disassembly and maintenance work in the field.

If disassembly or maintenance work is performed on hydraulic
equipment in the field, there is danger of dust entering the equip-
ment. It is also difficult to check the performance after repairs, so it
is desirable to use unit exchange. Disassembly and maintenance of
hydraulic equipment should be performed in a specially prepared
dustproof workshop, and the performance should be checked with
special test equipment.

3. Sealing openings.
After any piping or equipment is removed, the openings should be
sealed with caps, tapes, or vinyl bags to prevent any dirt or dust
from entering. If the opening is left open or is blocked with a rag,
there is danger of dirt entering or of the surrounding area being
made dirty by leaking oil so never do this. Do not simply drain oil
out onto the ground, but collect it and ask the customer to dispose
of it, or take it back with you for disposal.

4. Do not let any dirt or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it
clean, and also use clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the dirt that has col-
lected during storage, so this is an even more effective method.

5. Change hydraulic oil when the temperature is high.

When hydraulic oil or other oil is warm, it flows easily. In addi-
tion, the sludge can also be drained out easily from the circuit
together with the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as possible of the old
hydraulic oil must be drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of the hydraulic oil.

40-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL INFORMATION
12
6. Flushing operations.
After disassembling and assembling the equipment, or changing
the oil, use flushing oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit. Normally, flushing is performed
twice: primary flushing is performed with flushing oil, and second-
ary flushing is performed with the specified hydraulic oil.

7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine (about 3 microns) parti-
cles that the filter built in the hydraulic equipment cannot remove,
so it is an extremely effective device.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-13
TROUBLESHOOTING GENERAL INFORMATION

Checks Before Troubleshooting

Item Criterion Remedy

1. Check of level and type of fuel - Add fuel
2. Check of fuel for foreign matter - Clean and drain
3. Check of hydraulic oil level Between H - L Add oil
4. Check of hydraulic oil strainer - Clean and drain
Lubricating
5. Check of swing machinery oil level Between H - L Add oil
oil/Coolant
6. Check of level and type of engine oil (in oil pan) Between H - L Add oil
7. Check of coolant level (in sub tank) Between H - L Add coolant
8. Check of dust indicator for clogging No red part Clean or replace
9. Check of hydraulic oil filter - Replace
1. Check for abnormal noise/smell - Repair
Hydraulic/
Mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air
1. Check of battery terminals and wiring for 
- Retighten or replace
looseness and corrosion
2. Check of alternator terminals and wiring for
- Retighten or replace
looseness and corrosion
3. Check of starting motor terminals and wiring for
- Retighten or replace
looseness and corrosion
4. Check of battery voltage (with engine stopped) 20 - 30 V Charge or replace
5. Check of electrolyte level Between H - L Add or replace

Electric, 6. Check of wires for discoloration, burn, and

- Repair or replace
electrical removal of cover
equipment
7. Check for released wire clamp and drooping
- Repair
wire
8. Check of wires for wetness (Check connectors
- Dry
and terminals for wetness, in particular)
9. Check of fuse for disconnection and corrosion Replace
10. Check of alternator voltage (while engine speed After operating for several Replace
is at middle or higher) minutes: 27.5 - 29.5 V
11. Check of battery relay for operating sound
- Replace
(when starting switch is turned ON or OFF)

40-14 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION
1. Engine runs,  a. No Door Interlock Signal: 
• Close cab door.
No functions work. Cab door open.
b. No Door Interlock Signal: • Check the door safety interlock fuse. Replace if
Blown door safety interlock fuse. required.
c. Low Implement Stand-By Pressure: • Adjust implement stand-by pressure if required.
Stand-by pressure setting out of • If implement stand-by pressure cannot be adjusted,
adjustment. skip ahead to Step h.
d. No Door Interlock Signal:
Malfunction in door safety interlock
switch.

• Remove and check door safety interlock switch (1)

for proper operation.
• Replace if required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-15
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

e. Malfunction Of Door Solenoid Coil
(1).

Pilot Pressure Valve Door Solenoid

• Check continuity of coil (1) with ohm meter.
• Replace if required.
f. Malfunction Of Door Solenoid Valve • Remove door solenoid (1) (figure above).
Cartridge. • Check for contamination or damaged seals.
• Replace seals or cartridge if required.
g. No Implement Stand-By Pressure:
Implement Pump compensator
control Malfunction.

Implement Pump Compensator

• Remove stand-by pressure spool (1) and check for
damage or contamination.
• Clean spool or replace compensator (2) if necessary.

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TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

h. No implement Pump Output: 
• Check the case drain filter for metal flakes.
Worn pump or internal failure.
• If metal flakes are found in the case drain filter or
Remark case drain flow is excessive, the implement pump is
If an internal pump/motor fail- worn or failed.
ure is suspected, always
• Replace the implement pump.
check the component’s case
• If no metal flakes are found in the case drain return
drain line and the case drain
filter and there is very little or no case drain flow, the
return filter for metal particle
pump input shaft or coupling may have failed.
contamination first.
i.No Implement Pump Pressure Output: • If you have track drive charge pressure, and there is
Implement pump input shaft failure or no evidence of an internal implement pump failure,
possible pump drive flex plate failure. the input shaft of the pump may be damaged.
Remark • Remove the implement pump and inspect the input
Broken pump input shafts shaft.
and pump drive flexplate fail- • Replace the implement pump if the shaft is damaged.
ures are rare. Be sure all
other possible causes have
been explored before remov-
ing these components.

Flexplate
• If there is no track drive charge pressure and no
evidence of an implement pump failure, the pump
drive flexplate may be damaged, which would
prevent any pump operation.
• Remove and inspect the engine flexplate.
• Replace the flexplate if damage is found.
2. All Functions Slow a. Hydraulic Oil Viscosity Too Low For • Follow recommended machine warm-up procedures
Or Sluggish. Ambient Conditions. in the Operation and Maintenance Manual.
• Change oil to an ISO grade that matches your
ambient conditions if required.
b. Poor Engine Performance. • See Engine Troubleshooting Guide.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-17
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

3. Excessive noise from a. Air In Pump Suction Line(s). 
pump area. Pump suction line shut-off valve
partially closed causing pump
cavitation.

Pump Suction Lines

• Make sure all pump suction line shut-off valves (1)
are fully open and secured by tightening the lock
knob (2).
b. Air In Pump Suction Line(s). 
Loose connections in pump suction • Tighten all suction line connections.
lines.
c. Air In Pump Suction Line(s). • Check all pump suction lines.
Collapsed pump suction line. • Replace any collapsed lines.
d. Air In Pump Suction Line(s). 
Low hydraulic oil level in tank.

Hydraulic Oil Level Sight Gauge

• Low oil level can allow the suction strainers to be
exposed to air when traveling up a slope.
• Check oil level at the sight gauge (1). Oil should be
in the “green” zone at operating temperature.
• Add oil if required.

40-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

e. Air In A Pump Suction Line. 
Air entering hydraulic tank from
cylinders and motors.

Hydraulic Tank Access Cover

• Trapped Air can enter the hydraulic tank during
initial start up or after replacing a major hydraulic
component.
• Check for trapped air bubbles in the oil with a flash-
light.
• If there are air bubbles, or the oil has a foamy
appearance, de-aerate the machine.
f. Failing hydraulic pump. • Check all pump case drains for shavings or flakes.
• Check the case drain return filter for metal shavings
and flakes. If found, replace pump.
• If no metal shavings or flakes are found, perform
“Case Drain Flows” tests.
• If case drain flow is excessive, the component may
be near failure.
• Replace component if required.
g. Plugged pump suction line strainer. • Check all pump suction line strainers for debris.
• Remove and clean plugged strainer.
Remark
The hydraulic tank will need to be
drained to remove and clean a strainer.
h. Rear engine mounts worn. • Check and inspect for worn or damaged rubber
isolators on the rear engine mounts.
• Replace isolators if required.
4. Hydraulic tank turbo a. Turbo boost release valve stuck open.
boost not building
pressure.

Turbo Boost Release Valve

• Check the turbo boost release valve (1) located in the
engine compartment behind the battery.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-19
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

5. Hydraulic oil coming a. Machine not level during operation. • If the machine is operated on a steep slope and facing
from tank overflow downhill, the oil level can reach the bottom of the
hose. relief stem inside the tank.
• If the pressure in the tank exceeds the relief cap
setting while the stem is submerged in oil, the oil will
be purged instead of air.
• Avoid operation on a steep slope facing downhill.
b. Hydraulic oil tank overfilled.

Hydraulic Oil Level Sight Gauge

• Check oil level at sight gauge (1).
• Oil should be in the “green” zone at operating
temperature.
• If the tank has been overfilled, use an appropriate
container and drain hydraulic oil until the level
shown in the sight gauge is in the green zone.
6. Low hydraulic oil a. Hydraulic oil level sensor
warning sounds, but malfunction.
oil level O.K.

Hydraulic Oil Level Sensor

• Remove and replace the hydraulic oil level sensor
(1).
Remark
Sensor is located on the front side of the oil
tank, behind the air cleaner. (Some items
removed for photo clarity.)
b. Electrical ground or short between • Inspect for a worn or damaged wire harness.
sensor and indicator in dash. • Repair or replace wires or harness if required.

40-20 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING GENERAL HYDRAULIC PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

7. Low hydraulic oil a. No power to low hydraulic oil level • Check for power at the warning alarm.
warning alarm does warning alarm. • Repair wiring if required.
not work. • Refer to the Electrical Schematics.
b. Open circuit between sensor and • Inspect for a loose connection or broken wire.
indicator in dash. • Tighten connections or replace wires if required.
Remark
See the Electrical Schematics.
c. Hydraulic oil level sensor
malfunction.

Hydraulic Oil Level Sensor

• Remove and replace the hydraulic oil level sensor
(1).
Remark
Sensor is located on the front side of the oil
tank, behind the air cleaner. (Some items
removed for photo clarity.)

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-21
TROUBLESHOOTING MACHINE OVERHEAT PROBLEMS

MACHINE OVERHEAT PROBLEMS

Remark
Overheating of both the engine and hydraulics will most likely be the result of not enough cooling air flow-
ing past the radiator and oil cooler.
PROBLEM PROBABLE CAUSE ACTION
1. Engine & hydraulics a. Blocked airflow across radiator/oil
overheating. cooler fins: 
Forest debris plugging debris screen
and radiator/oil cooler fins.

Radiator/Oil Cooler Fins & Debris Screen (Typical)

• Make sure to keep the radiator/oil cooler fins (1) and
the debris screen (2) clean of forest debris.
b. Blocked airflow across radiator/oil
cooler fins: 
Damaged radiator/oil cooler fins,
• Check and repair or replace damaged components.
debris screen or louvered radiator
guard preventing proper cooling air
flow.

40-22 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING MACHINE OVERHEAT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

c. Re-circulation of hot engine air across
radiator/oil cooler.

Radiator/Oil Cooler Baffle

• Be sure rubber baffle (1) is in place around the entire
radiator/oil cooler assembly to prevent hot air
bypass.
d. Not enough cooling air flow across
the radiator/oil cooler fins. 
Damaged engine fan or missing/
damaged fan shroud.

Engine Fan & Shroud

• Check engine fan (2) and fan shroud (1).
• Replace damaged or missing components.
e. Not enough cooling air flow across
• Ensure fan belt is correct for engine installed.
the radiator/oil cooler fins. 
• Inspect fan belt and pulleys for wear and correct
Incorrect fan belt or fan belt worn or
tension.
slipping.
2. Only engine over- a. Thermostat Stuck Closed. • Check and correct or replace.
heating. • See engine manuals supplied with the machine for
procedure.
b. Incorrect thermostat installed for • Replace thermostat with one that has a lower opening
ambient conditions. temperature.
• See engine manuals supplied with the machine for
procedure.
c. Excessive coolant anti-freeze ratio • Check coolant for correct anti-freeze ratio and adjust
causing gelling. as required.
d. Failed water pump. • Check water pump and replace if required.
Remark
See the engine manuals supplied with
the machine for this procedure.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-23
TROUBLESHOOTING MACHINE OVERHEAT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

e. Failed head gasket. allowing • Open the radiator cap and inspect engine coolant for
combustion gases into the engine gas bubbles while the machine is running.
coolant. • If combustion gas bubbles are present, contact your
Komatsu dealer for further instructions.
f. Engine is over fueled. • Contact your Komatsu dealer for further instructions.

3. Only track drive a. Track drive pump POR (Pump Over

hydraulics overheat- Ride) pressure setting too low.
ing.

Track Drive Pump POR Relief

• Adjust or replace the POR relief valve (1).
b. Track drive pump directional relief
setting incorrect.

Track Drive Pump Directional Relief Valves

• Adjust or replace the relief valves (1 and 2) as
required.
c. Running track drives hard and • Running the track drives hard or rough forces oil
excessively lugging engine down. through relief valves causing heat.
• Use correct operating technique.
d. Excessive leakage in track drive • Perform “Case Drain Flows”" tests.
pump or motor.
e. Leakage in rotary manifold between • Contact your Komatsu dealer.
track drive galleries (only on
machines equipped for continuous
rotation swing).

40-24 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING MACHINE OVERHEAT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

4. All hydraulics over- a. Oil cooler thermal bypass valve
heating. malfunction.

Oil Cooler Thermal Bypass Valve

• Replace oil cooler thermal bypass valve (1) if
required.
b. Wrong hydraulic oil viscosity. • Change hydraulic oil viscosity to match ambient con-
ditions.
• See the hydraulic oil viscosity decal inside the
swing-out pump access guard.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-25
TROUBLESHOOTING IMPLEMENT FUNCTION PROBLEMS
12
IMPLEMENT FUNCTION PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

1. No implement func- a. Low implement PCO (Pressure Cut- • Adjust the implement pump PCO pressure if
tions work, track Off) pressure. required.
drives o.k. • If the implement pump PCO pressure cannot be
adjusted, remove the compensator PCO spool and
check for damage or contamination.
• Replace the spool or compensator if required.
b. No implement pump PCO pressure,
implement pump compensator control
malfunction.

Implement Pump Compensator

• Remove the compensator PCO spool (1) and check
for damage or contamination.
• Replace the spool or compensator (2) if required.
c. No implement pump output: worn
pump or internal failure.
Remark
If an internal pump/motor fail-
ure is suspected, always
check the component’s case
drain line and the case drain
return filter for metal particle
contamination first.

Implement Pump
(Rexroth 145cc Shown)
• It is possible for the implement pump (1) to fail inter-
nally, but still produce enough pressure to allow the
control valve to produce the system pilot pressure
required to operate the track drives.
• Check the case drain filter for metal flakes and per-
form “Case Drain Flows” tests.
• If metal flakes are found in the case drain filter or
case drain flow is excessive, the implement pump is
worn or failed.
• Replace the implement pump.

40-26 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING IMPLEMENT FUNCTION PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

2. Implement functions a. Sticking spools in implement pump
slowly and no power, compensator control.
track drives are O.K.

Implement Pump Compensator

• Remove the stand-by and PCO spools from the com-
pensator control (2).
• Inspect for damage, clean, and re-install.
• Replace compensator control if necessary.
b. Erratic load sense control signal:  • Bleed air from load sense line where it enters the
Air trapped in load sense line between implement pump compensator control.
control valve and implement pump.
3. Electric operated a. No power at function solenoid valve
function will not coil: 
work. Hand Control switch malfunction.

Hand Control Switches

• Check operation of problem switch.
• Replace the switch if required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-27
TROUBLESHOOTING IMPLEMENT FUNCTION PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

4. Cab level cylinder a. Cab level cylinder counter-balance
retracts without con- valve cartridge malfunction.
trol input.

Cab Level Cylinder

• Remove cab level cylinder counterbalance valve car-
tridges (1).
• Check for contamination or damaged seals.
• Replace seals or cartridge if required.
b. Worn cylinder seals. • Replace cylinder seals if required.
5. Cab level cylinder Cab level cylinder counter- balance • Replace cab level cylinder counter balance valve car-
squeals when acti- valve cartridge malfunction. tridge.
vated.
6. Swing is too fast or Swing function speed too fast. • Reduce swing speed.
jerky. Remark
Typically, the larger the timber, the slower
the swing speed should be set.
7. Swing is too slow or a. Swing function speed too slow. • Increase swing speed.
sluggish. b. Also reference Steps 4 and 5 in this
section.
8. Swing stops too hard. Swing stop slope in IQAN to low. • Adjust swing stop slope from IQAN Main Menu, by
choosing Adjust  Valves  Swing and change
settings.
9. Swing floats or drifts a. Swing stop slope in IQAN to high. • Adjust swing stop slope from IQAN Main Menu, by
when stopping. choosing Adjust  Valves  Swing and change
settings.
b. Swing anti-cavitation valve cartridge
malfunction.

Swing Anti-Cavitation Valve

Remove the swing anti-cavitation cartridge (1) and check
for contamination or damaged seals.
Replace seals or cartridge if required.

40-28 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING IMPLEMENT FUNCTION PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

c.Worn swing motor or internal failure. • Check the case drain filter for metal flakes.
Remark • If metal flakes are found in the case drain filter or
If an internal pump/motor fail- case drain flow is excessive, the swing motor is worn
ure is suspected, first check or failed. Replace the swing motor.
the component’s case drain
line and the case drain return
filter for metal particle con-
tamination.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-29
TROUBLESHOOTING TRACK DRIVE PROBLEMS
12
TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

1. Track drives do not a. Track brakes engaged. • Check track brake solenoid and cartridge.
work, implements b. Dirty hydrostatic charge filter.
O.K.

Hydrostatic Charge Filter

• Change hydrostatic charge filter element (1).
c. Oil too cold to flow properly through • Warm machine up properly before starting to work.
the hydrostatic charge oil filter.
d. Wrong hydraulic oil viscosity. • Change hydraulic oil viscosity to match ambient con-
ditions. See hydraulic oil viscosity decal inside the
swing-out pump access guard.

40-30 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

2. Track drives do not a. Dirty hydrostatic charge oil filter. • See Step1 in this section.
work and no charge b. Charge pressure relief out of
pressure. adjustment.

Hydrostatic Charge Pressure Relief

• If correct pressure setting cannot be made, remove
the relief cartridge (1) and inspect the seals.
• Replace the seals or the relief cartridge if required.
c. Charge pump thru-drive coupling
failure.

Hydrostatic Charge Pump

• Pull the charge pump (1) back from the thru drive
adapter and check for a damaged thru drive coupling.
• Replace the thru drive coupling and key if required.
d. Charge pump failure.

Hydrostatic Charge Pump

• Replace charge pump mounted at the rear of the RH
track drive pump (1).
e. RH track drive pump input shaft • Pull the RH track drive pump back from the pump
failure. drive and check for a broken input shaft.
• Replace RH track drive pump if required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-31
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

3. Both track drives a. Dirty hydrostatic charge oil filter. • See Step1 in this section.
slow or sluggish in b. Charge pressure set too low.
both directions.

Hydrostatic Charge Pressure Relief

• If correct pressure setting cannot be made, remove
the relief cartridge (1) and inspect the seals.
• Replace the seals or the relief cartridge if required.
c. All track drive pump towing reliefs • Disengage all towing reliefs on the track drive
engaged. pumps.
d. Leakage in rotary manifold between • Replace seals as required. Contact your Komatsu
track drive galleries. (when equipped dealer.
with continuous rotation swing only)
4. One track drive slow a. POR relief out of adjustment.
or sluggish in both Remark
directions. When adjusting POR pres-
sure be careful not to turn the
adjustment setscrew in too
tight. Doing so may damage
the cartridge or cause it to
stick.

Track Drive Pump POR Relief

• If correct pressure setting cannot be made, remove
the relief cartridge (1) and inspect the seals.
• Replace the seals or the relief cartridge if required.
b. POR relief sticking. • Remove the POR relief cartridge and check for a
sticking spool. Replace cartridge if necessary.
c. Track drive pump towing reliefs • Disengage towing reliefs on the track drive pump.
engaged.
d. Track drive pump or motor failed or • Check case drain lines and filter for metal flakes then
worn: indicated by debris or excessive perform “Case Drain Flows”" tests, beginning with
flow from the case drain. the motor.
• If debris or a high case flow is found, replace the
component.

40-32 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

e. Track drive pump or motor failed: • If case flows are O.K., cap the high pressure drive
non-typical failure of the lens plate or lines at the track drive motor and re-test POR pres-
stroke controller. sure.
• If POR pressure now is O.K., replace the track drive
motor.
• If POR pressure remains low, continue with Step 4. f.
below to check the track drive pump internally.
Remark
If the machine is equipped with continuous
rotation swing and POR pressure remains
low, re-test with the lines capped above the
swivel to determine any leakage in the
swivel galleries.
f. Pump stroke controller malfunction.

Pump Stroke Controller

• If Xl and X2 pressures are O.K. the problem is likely
the stroke piston, replace the pump.
• If the Xl and X2 pressures are low, replace the stroke
controller.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-33
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

5. One track drive slow a. Debris blocking movement of foot • Clear debris from under and around foot pedals.
or sluggish in one pedal.
direction. b. Directional relief out of adjustment.

Track Drive Pump Directional Relief Valves

• If correct pressure setting cannot be made, remove
the relief cartridge (1) and inspect the seals.
• Replace the seals or the relief cartridge if required.
c. Directional relief sticking. • Swap the directional reliefs on the pump.
• If the problems moves with the switch, remove the
problem directional relief and check for a sticking
spool.
• Replace the directional relief if required.
d. One track drive pump towing relief • Disengage towing relief on the track drive pump.
engaged.
e. Pump stroke controller malfunction.

Pump stroke Controller

• If X1 and X2 pressures are O.K. the problem is likely
the stroke piston or a scratched lens plate, replace the
pump.
• If Xl or X2 pressure is low, replace the stroke con-
troller.

40-34 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

6. Track drives lose a. Incorrect track drive pump pressure • If a correct pressure settings cannot be made, remove
pressure when run- settings. the relief cartridge and inspect the seals.
ning hot. • Replace the seals or the relief cartridge if required.
b. Missing or incorrect track drive pump
case flushing orifice.

Drive Pump Case Flushing Orifice

• Remove the plug (1).
• Remove and clean the orifice.
• Replace the 1.2 mm orifice if it is damaged or the
wrong size.
c. Wrong hydraulic oil viscosity. • Change hydraulic oil viscosity to match ambient con-
ditions.
• Refer to the hydraulic oil viscosity decal inside the
swing-out pump access guard.
d. Leakage in rotary manifold between • Replace seals as required.
track drive galleries (when equipped • Contact your Komatsu dealer.
with continuous rotation swing only).
7. Failure of high pres- a. Hose fitting blown off. • Hose fitting crimped incorrectly. Replace hose.
sure driveline hose. • Be sure hose fittings are crimped to the hose accord-
ing to manufacturer’s specifications.
b. Burst hose. • Replace hose. Be sure hose is the proper 6-wire spi-
ral with a minimum working pressure of 457 kg/ cm2
(6,500 psi).

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-35
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

8. Machine creeps in a. Sticking foot pedal.
neutral.

Foot Pedal Cleaning

• Open cab door to prevent machine operation.
• Manually check to make sure that the foot pedal for
the problem track is not sticking or that debris is pre-
venting the pedals return to the neutral position.
• See (1) for areas to inspect.
b. Leakage in rotary manifold - between • Replace seals as required. Contact your Komatsu
track drive galleries (when equipped dealer.
with continuous rotation swing only).
9. Not tracking straight a. Incorrect track tension. • Track tension may be tighter on one side than the
in both directions. other. Check and adjust track tension on both tracks.
b. One track binds or is jammed with • Visually inspect undercarriage components and track
debris. as it travels around the frame. Look for binding roll-
ers, idler, etc. or debris. Clean and repair, or replace
components as required.
c. One track drive operating slower than • Check displacement adjustments on both track drive
the other: track drive motor motors.
displacement out of adjustment. • Adjust as required.
Remark
A good indicator of a track drive motor dis-
placement out of adjustment is that the
machine will track straight in only one
speed. After shifting, the machine will not
track straight even with the pedal in full
deflection forward or reverse.
Remark
It is also very common, especially after a
pump or motor has been changed, to sim-
ply have a component with a higher effi-
ciency than the rest of the system. Usually
a 10% difference in individual track speed
is acceptable. If not, an adjustment to the
faster track’s motor displacements will have
to be made to slow that track down.
d. One track drive operating slower than • See Step 4 in this section.
the other: hydraulic system
malfunction.
10. Not tracking straight a. Debris blocking movement of foot • Clear debris from under and around foot pedals.
in one direction. pedal.
b. One track drive operating slower in • See Step 5 in this section.
one direction: hydraulic system
malfunction.

40-36 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING TRACK DRIVE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

c. Debris blocking control orifice.

Control Orifice Locations

• Remove the ports “X1 and X2” plugs (1).
• Using a 5 mm allen wrench, remove the control ori-
fice from the plug cavity.
• Clean any debris logged in the orifice and re-install.
Replace the orifice if required.
Remark
A good indicator of a blocked control orifice
is that one track will take slightly longer to
reach full speed. The machine will mis-track
during this time and then straighten out.
11. Track brakes will not a. No power at track brake release • Check output from IQAN module #1 when track
release. solenoid coil. pedals are actuated.
b. Track brake release solenoid valve • Check continuity of coil with ohm meter. Replace
malfunction. coil if required.
• Remove cartridge.
• Check for contamination or damaged seals.
• Replace seals or cartridge if required.
c. Failed brake piston seals. • Remove the track drive motor and brake module
from the track final drive and check for damaged
seals.
• Replace seals if required.
d. Warped or seized brake discs and • Repair or replace brake module.
plates.
12. Track brakes slip- a. Worn or damaged brake discs and • Repair or replace brake module.
ping or will not hold. plates.
13. Low speed lock will a. No power at low speed lock solenoid • Check for power at solenoid coil.
not work. coil. • If no power, replace low speed lock rocker switch in
dash panel.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-37
TROUBLESHOOTING ENGINE PROBLEMS
12
ENGINE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

1. Engine stalls at start- a. Improper oils used in gearbox, • Use proper oils for your ambient conditions and fol-
up, turns over hard. hydraulics, or engine for ambient low the cold weather starting instructions in the
temperatures. Operation and Maintenance Manual.
b. Incorrect throttle position for engine • Set throttle control to 1/3 range for engine start.
start.
c. Optional disc saw pump on stroke at
engine start-up: 
solenoid coil at the disc saw shut-off
valve stuck causing the pump to be on
stroke as the engine is starting.

Disc Saw Shut-Off Valve Solenoid Coil

• Check for a stuck solenoid coil (1).
• Unstick or replace coil.
d. Fuel system: air trapped in fuel • Check for air leaks in fuel suction line around hose
system. connections.
• Repair if found.
• Bleed fuel system.
• See engine manufacturer’s manuals shipped with
machine.
e. Fuel System: contamination in fuel • Flush fuel suction line.
suction line.

40-38 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING ENGINE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

2. Engine stalls easily a. Dirty air cleaner elements. • Clean or change air filter elements.
during normal opera- b. Collapsed or plugged muffler. • Inspect muffler.
tion.
• Replace muffler if required.
c. Fuel System: dirty fuel filters. • Change fuel filters.
d. Fuel system: air trapped in fuel • Check for air leaks in fuel suction line around hose
system. connections.
• Repair if found.
• Bleed fuel system.
• See engine manufacturer’s manuals shipped with
machine.
e. Fuel system: fuel line restriction. • Check for kinked fuel lines or debris plugging the
fuel tank vent line where it exits the upper revolving
frame base plate.
f. Fuel system: contamination in fuel • Flush fuel suction line.
suction line.
g. Fuel system: contamination in fuel • Clean and flush fuel tank.
tank. • Refill tank with fresh, clean fuel.
h. Fuel system: fuel pump timing out of • Time fuel pump to engine.
adjustment. • See engine manufacturer’s manuals shipped with
machine.
i. Track drive pump poor pressure • Check track drive pump pressure settings.
setting or directional relief out of
adjustment.
j. Implement Pump pco pressure setting • Check implement pump pressure settings.
out of adjustment.
k. Intake and/or exhaust valves out of • Adjust intake and exhaust valves.
adjustment. • See engine manufacturer’s manuals shipped with
machine.
l. Intake or exhaust manifold gasket • Replace gasket.
leaking. • See engine manufacturer’s manuals shipped with
machine.
m. Engine malfunction. • Contact your Komatsu dealer.
3. Engine loses power a. Dirty fuel filters. • Change fuel filters.
after running for a b. Fuel tank vent line restriction. • Check for a kinked fuel tank vent line or debris plug-
short time. ging the line where it exits the upper revolving frame
base plate.
Remark
Other indications of a plugged fuel tank
vent line are suction on the fuel tank when
the fill cap is removed or the fuel filters par-
tially full when removed.
c. Wet air filter elements. • Remove air filter elements and inspect.
• Allow elements to dry or replace if required.
4. Engine labors exces- a. Track brakes not fully released. • Check brakes.
sively, while using b. Dirty air cleaner elements. • Clean or replace air cleaner elements.
track drives.
c. Dirty fuel filter(s). • Change fuel filters.
d. Fuel injector pump malfunction. • Contact your dealer.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-39
TROUBLESHOOTING ENGINE PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

5. Engine surges or a. Air trapped in fuel system. • Check for air leaks in fuel suction line around hose
“hunts” even when connections. Repair if found.
not operating a func- • Bleed fuel system.
tion. • See engine manufacturer’s manuals shipped with
machine.
b. Contamination in fuel suction line. • Flush fuel suction line.
c. Engine malfunction. • Contact your Komatsu dealer.

40-40 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING ELECTRICAL PROBLEMS
12
ELECTRICAL PROBLEMS
PROBLEM PROBABLE CAUSE ACTION
1. Engine will not start a. Master electrical disconnect switch
and no electrical will turned off.
work.

Master Electrical Disconnect Switch

• Turn the master electrical disconnect switch (1) to
the ON position.
b. Main electrical system fuse blown.

Main Electrical System Fuse

WARNING! To avoid an electrical shock, make
sure the master electrical disconnect
switch is in the OFF position before
removing the main electrical system
fuse.
• Remove and check the main electrical system fuse
(1) located in the engine compartment.
• Replace if required.
c. Battery cables loose or corroded. • Clean battery cables and posts.
• Tighten all connections.
d. Battery has low electrolyte level. • Check and restore battery electrolyte levels.
e. Battery is dead or frozen. • Replace battery.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-41
TROUBLESHOOTING ELECTRICAL PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

2. Engine will not start, a. Battery cables loose or corroded. • Clean battery cables and posts.
other electrical O.K. • Tighten all connections.
b. Battery has low electrolyte level. • Check and restore battery electrolyte levels.
c. Starter relay fuse blown. • Check the starter relay fuse. Replace as required.
d. Starter relay malfunction: starter relay • Check to be sure the starter relay is seated firmly in
loose or malfunctioning. its mount. Replace as required.
e. Starter switch malfunction.

Starter Switch (Typical)

• Check for power at the “S” terminal of the Starter
Switch.
• Replace starter switch if required.
f. Starter malfunction. • Repair or replace starter.

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TROUBLESHOOTING ELECTRICAL PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

3. Starter turns, but a. Failed starter bendix drive.
engine does not.

Starter Bendix Drive (Typical)

• Remove starter.
• Repair bendix drive (1) or replace starter if required.
b. Damaged starter pinion gear.

Starter Pinion Gear (Typical)

• Remove starter.
• Repair pinion gear (1) or replace starter if required.
c. Engine flywheel gear teeth broken.

Flywheel Teeth (Typical)

• Remove starter and check engine flywheel gear teeth
(1).
• If damaged, replace engine flywheel.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-43
TROUBLESHOOTING ELECTRICAL PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

4. Starter motor contin- a. Starter relay sticks closed. • Tap on the starter relay. If the starter releases, replace
ues to run after the starter relay.
engine starts. b. Starter pinion gear not disengaging
flywheel gear.

Starter Pinion Gear (Typical)

• Tap on the starter.
• If the pinion gear (1) releases, repair or replace the
starter.
c. Starter switch sticking. • Replace starter switch if required.
5. Noisy alternator. a. Worn alternator belt. • Replace alternator belt and clean pulleys.
b. Pulley not aligned properly. • Align Pulleys.
c. Worn alternator bearings. • Remove alternator belt and spin alternator pulley by
hand.
• If the pulley spins hard, has excessive play, or does
not spin freely, repair or replace alternator.
d. Alternator malfunction. • Repair or replace alternator.
6. Voltmeter reading in a. Worn alternator belt. • Replace alternator belt and clean pulleys.
dash showing under- b. Poor ground connection on alternator, • Inspect all ground wires for loose connections.
voltage condition. starter, or battery. Tighten as required.
c. Alternator malfunction. • Repair or replace alternator.
7. Voltmeter reading in a. Shorted battery. • Battery plates may be loose or have debris on them
dash showing over- causing a short.
voltage condition. b. Shorted wiring. • Disconnect wiring circuits one at a time until the
shorted circuit is found. Inspect for loose connec-
tions, etc. Repair or replace components as required.
c. Dust, dirt, or debris shorting out • Remove and clean alternator. Replace alternator if
alternator. required.
d. Alternator malfunction. • Repair or replace alternator.
8. Lights do not work, a. Headlight circuit fuse blown. • Check the headlight circuit fuses. Replace if
all other electrical Remark required.
okay. There are three main head- Remark
light circuits, two with branch If the headlight circuit fuses keep blowing,
circuits. These include Head- remove any non-factory installed lights that
light #1, Headlight #2 and may be causing an overload condition.
Hella Light (cab visor lights).
b. Headlight circuit relay(s) • Check to be sure the headlight relays are seated
malfunction. headlight relay(s) loose firmly in their base. Replace relay as required.
or malfunctioning.

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TROUBLESHOOTING ELECTRICAL PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

c. Exterior light switch malfunction.

Relay Pin Sockets

• Test the exterior light rocker switch in the dash by
checking for power at the headlight circuit relay’s pin
86 socket when the light switch is in the ON position.
• Replace the exterior light switch as required.
9. Electric hydraulic oil a. Fill pump circuit fuses blown • Check the hydraulic fill pump circuit.
fill pump will not Remark
work. There is a relay fuse and a circuit fuse.
Replace as required.
b. Hydraulic fill pump circuit relay • Check to be sure the hydraulic fill pump relay is
malfunction. hydraulic fill pump relay seated firmly in its mount base. Replace relay as
loose or malfunctioning. required.
c. Fill Pump activation switch
malfunction.

Fill Pump Activation Switch

• Check for power across the hydraulic fill pump acti-
vation switch (3) (located near the left rear engine
mount) while it is held in the ON position.
• Replace the hydraulic fill pump activation switch if
required.
d. Loose wire connection. • Check for loose wire connection in the fill pump cir-
cuit, especially ground wire connections.
• Repair if found.
e. Fill pump motor malfunction. • Repair or replace fill pump motor.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

IQAN CONTROL SYSTEM

The IQAN MD4 Touch-Screen Master Display Module is the primary operator interface for the equipment. The MD4 Display
monitors the machine functions and stores system settings for the equipment, along with optional modes for operator prefer-
ences. Any computer interface to the system is accomplished through the MD4.
If program changes are required, your equipment dealer can access the program through the back of the module with a laptop
connection and program authorization.

Main Screen Display

The main display screen is the home screen of the IQAN MD4, and appears directly after the Komatsu logo when the machine
is turned on.

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Display Indicators
Each of the lamps and gauges on the Main Display screen provides the status of the system. Some lamps are buttons that allow
navigation to menu selections for additional information or to make changes to the system. A white or gray lamp means no
faults.

ID Lamp Name Description Color Indication

1 System Armed The Arm System button has been pressed on the dash Green indicates
panel to activate hydraulic functions on the machine. the system is
armed.

2 Engine Start Inhibit Indicates when the vacuum pump is on, or after the Red when on.
vacuum pump has been used. There is a delay built
into the system that does not allow the engine to be
started until the hydraulic tank is vented to atmo-
sphere.

3 Vacuum Pump ON While the vacuum pump is on, engine starting is dis- Red when on.
abled.

4 Fault The fault lamp appears on the screen when any fault or Red indicates a
error is reported to the IQAN system. fault has occurred.
Touch the fault lamp to access the Faults Display
Page.

5 Check Engine Indicates a problem with the engine. Red when on.
Touch the engine lamp to access the Engine Display
Page for details.

6 Low Hydraulic Oil Monitors the level of the hydraulic oil for the hydrau- Red when low.
Level lic oil reservoir. The hydraulic oil level lamp shows
red when the oil level reaches below the settings con-
figured for the oil type that is selected on the MD4
Options Display Page. See “Select Oil Type” on page
40-58 for information on this setting.

7 Engine Grid Heater The Engine Grid Heater lamp is displayed when the Yellow when acti-
engine cold start is activated by the engine ECM. vated.
Wait until the lamp disappears to crank the engine.

8 High Hydraulic Oil Alarms are raised when the temperature for the Red lamp when
Temperature hydraulic oil in the main hydraulic tank rises above active and alarm
normal operating range for the oil type selected in the sounds.
IQAN MD4. See “Select Oil Type” on page 40-58 for
information on this setting.

9 Information Display Button to display service information for the machine. --

Page

10 Hydraulic Tank Filter Indicates the status of the hydraulic tank filter pres- Red lamp when
sure. A fault occurs for this component when the active and alarm
hydraulic filter pressure reaches 25 psi. sounds.
The cause of this alarm could be cold oil or dirty fil-
ters.
Do not operate the machine until the problem has been
resolved.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

ID Lamp Name Description Color Indication

11 Silence Alarm Button to stop the Alarm Buzzer when it is sounding. --

Only visible when the Alarm Buzzer is sounding.

12 Low Oil Pressure Indicates the oil pressure for the engine. Alert is raised Red lamp when
when oil pressure is low, below 20 psi. active and alarm
sounds.

13 Disc Saw The lamp gives the operator a visual display for the Red lamp when
speed of the cutting blade. When the lamp is red, the speed is increas-
blade speed is still increasing. Peak cutting perfor- ing.
mance is reached when the lamp turns green. Green lamp when
blade is ready.

14 High Coolant Tem- Indicates the Coolant Temperature of the engine. Alert Red lamp when
perature is raised when the coolant temperature is above 210°F. active and alarm
sounds.

15 Charge Filter Indicates the charge filter pressure for the machine. Red lamp when
Alert is raised if pressure is above normal. active and alarm
The cause of this alarm could be cold oil or dirty sounds.
charge filter.

16 Options Display Button to display Options Display Page. Options that --

can be set from this selection include Operator Mode,
Horsepower Control, Select Oil Type, Track Speed,
Disc Saw Use, and Restrict Mode.

17 Menu Screen Selector Button to display Main Menu Screens. Menus avail- --
able from this selection include Info, Measure, Adjust
and Preferences.

18 Low Voltage Indicates the condition of the machine’s electrical Red lamp when
charging system. Alert is raised if the voltage drops active and alarm
below 18 volts. Areas that can affect this value include sounds.
batteries and engine alternator belt.

19 Oil Heater On If the optional charge oil heater is equipped on the Text flashes red
machine, the “Oil Heater On” text will appear when it when on.
is functioning.
While the Oil Heater On message is displayed, all
machine functions are disabled.

Gauges
The system gauges on the Main Display screen reflect a visual status
of the engine condition. When a fault occurs, the lamp below the
gauge shows red.
Values from the gauges are also reflected on the Fault Display Page.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

ID Gauge Name Description

1 Battery Volts The Battery Volts gauge reflects the condition of the machine’s electrical
charging system. The gauge shows green for optimal operation.
If the voltage drops below 18 volts, the Low Voltage lamp is red and an alarm
sounds. Areas that can affect this value include batteries and engine alternator
belt.

2 Coolant Temperature The Coolant Temp gauge reflects the status of the engine coolant temperature.
When the coolant temperature is above 210°F, the High Coolant Temperature
lamp is red and the alarm sounds.

3 RPM The RPM gauge shows the revolutions per minute of the engine.

4 Disc Saw Pressure The Disc Saw gauge displays the status of the hydraulic pressure for the
optional disc saw system. This information is only shown if the disc saw has
been attached to the machine.
The gauge and Disc Saw lamp reflect red when the RPM is too low. As the
speed of the blade increases, the gauge moves into the green zone. Peak cut-
ting performance is reached when the Disc Saw lamp turns green.

5 Engine Oil Pressure The Engine Oil Pressure gauge reflects the status of the engine oil pressure.
When oil pressure is below 20 psi, the Low Oil Pressure lamp is red and the
alarm sounds.

6 Hydraulic Oil Temperature The Hydraulic Oil Temperature gauge reflects the hydraulic oil temperature in
the main hydraulic tank. When the temperature rises above normal operating
range of the oil type selected in the IQAN MD4, the Hydraulic Oil Tempera-
ture lamp is red and the alarm sounds. Verify the oil type selected within the
IQAN MD4.

Main Menu Screen Selector

The Menu Screen Selector button on the Main Display screen displays the Main menu used to configure set-
tings for the MD4.
These menus include:
• Info Menu - Provides system information for each module, which
reflect whether each component is on line and enabled. In addition,
log information is provided for the system actions and faults.
• Measure Menu - Shows the list of monitored components detailing
all inputs and outputs from the system. A malfunction or performance
variance can be easily viewed from the screen.
• Adjust Menu - Allows the operator to set the adjustable parameters
for inputs or outputs as determined by the manufacturer of the
machine. This enables operator 1 through 3 to set the minimum and
maximum current to a valve to control the minimum and maximum
flow of a function, as well as the start and stop ramps of the joystick
and foot pedal functions. It also provides the ability to set a two-slope control on a function for a creep then high speed
control.
• Preference Menu - Includes settings to allow the operator to adjust the MD4 display preferences. Settings include the dis-
play back light adjustment, date and time settings, and language selection.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-49
TROUBLESHOOTING IQAN CONTROL SYSTEM

Info Menu

The Info menu provides information on module communication and sta-

tus. This allows review of each module of the system to determine if com-
ponents are on line and enabled. In addition, Log output from the
application is available which shows a list of errors and actions performed
on the IQAN MD4 system.

Modules
Modules for each of the components monitored by the MD4 system are
listed. Selecting a component shows detailed information for that module.
This information can include serial number, software version and statistics
about the module.

Details regarding the given module include:

• Production date of module.
• SW Version - The module software version.
• Bios - The module hardware bios version.
• Serial Number - The module serial number.
• Temp - Internal Temperature of the module in degrees Celsius.
• VRef - Reference voltage as supplied by XS, XP, XP2 should be 5.0
Volts
• VBB - Main Power Supply Voltage for module.

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TROUBLESHOOTING IQAN CONTROL SYSTEM
Logs
Log information for the IQAN MD4 shows a list of events and actions
taken on the system, including fault errors and configuration changes.
• Log events are listed in reverse order of occurrence (1).
• Date and time are provided for each event or action (2).
• Description is provided for each event or action taken on the MD4
(3).

Measure Menu
The Measure menu allows the operator to monitor all inputs or outputs of the components managed
by the IQAN MD4. The operator is able to see any performance changes or malfunctions for each component at a glance.
The modules monitored by the system can be accessed from the Measure
Menu, and include:
• Left Joystick Raw Values
• Left Joystick
• Right Joystick Raw Values
• Right Joystick
• Left Handle Buttons
• Right Handle Buttons
• Foot Pedals
• Sensors
• Digital Inputs
• Current Outputs
• Digital Outputs
• Engine J1939
• IQAN Diagnostic
• HP Control

Each of the items that are measured are reflected on separate sub menus.
All functions listed can be monitored and are assigned the name as speci-
fied by the machine manufacturer.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

Adjust Menu
The Adjust Page allows the operator to set the adjustable parameters for inputs or outputs as deter-
mined by the manufacturer of the machine. Each operator mode (Modes 1, 2 and 3) can be configured to specific settings such
as the minimum and maximum current to a valve, which can control minimum and maximum flow of a function. Other set-
tings include the start and stop ramps of the joystick and foot pedal functions.
Adjustments can be made to the valves and hydrostat settings.
Remark
Updates from the Adjust sub menus can only be made for
Operator Modes 1, 2 and 3. When the Mode is set to Default
from the Options Display Page, no changes can be made in the
Adjust menu.

Adjustment Settings
Minimum Current (mA): The setting that determines how fast your function moves when you move a joystick or activate a
function in milliampere. All hydraulic proportional control valves have a minimum current that determines when movement of
a function occurs.
If you set the minimum current too low, a joystick could move an excessive amount before the function moves.
If a minimum current is set too high:
• An abrupt start can occur when the joystick is moved; or
• As the function is being ramped off; a shock or sudden stop could occur, as opposed to a nice ramping.
Maximum Current (mA): The setting that determines the maximum speed for a function in milliampere. This is the current
used to determine the maximum flow out of the hydraulic proportional valve. The lower the number, the slower the speed of a
function. This can be used in conjunction with a MODE setting to allow MODE 1 to be fast, but MODE 2 can be a creep set-
ting.
Start Slope (ms): The Ramp up of a function from the stopped condition to the full on condition. The function is specified in
milliseconds. If an operator moves a joystick rapidly to full on, this Start Slope will ramp the signal to the value to ensure elim-
ination of shocks.
Stop Slope (ms): The Ramp down of a function from full speed to stop. If a Function is suddenly stopped, this will ramp down
the signal from the original command condition to zero output. Function is expressed in milliseconds. This allows for smooth
operation of a function and reduces abrupt and jerky stops from rapid deceleration.
WARNING! An output will continue to move after a signal is ended; this could be hazardous based on the
machine function. The machine manufacturer is responsible for verifying safe function of the
machine.

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TROUBLESHOOTING IQAN CONTROL SYSTEM
Valves Sub Menu
The Valves selection opens a screen to allow valve measurements to be set for the selected function. Scroll through the list for
the valve selection.
• Stick
• Tool Tilt
• Main Boom
• Swing
• Cab Level Left
• Cab Level Right
• Sp7 Clamp
• Sp8 Accumulator
• Sp1 Lateral Tilt

Valves Edit
After selecting a valve item to adjust, the editing screen appears to modify the settings. Any changes are saved to the selected
Operator Mode as shown on screen (7).
Valve settings include:
• Minimum Current
Determines when the movement of a function occurs.
• Maximum Current
Determines the maximum speed for a function.
• Start Slope
The ramp up of a function from the stopped condition to the full on
condition.
• Stop Slope
The ramp down of a function from full speed to stop.

• Touch the + or - buttons (1) to raise or lower the current value for
each component setting based upon movement.
• To save the new value, touch the check mark (2).
• To cancel the change, touch the “X” next to the selection (3).
• To return to the previous menu, touch back button (6).
• To cancel or reset all changes on the page, touch the reset button (4).
• To return to the Main Display Screen of the MD4, touch close button (5).

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-53
TROUBLESHOOTING IQAN CONTROL SYSTEM

Hydrostat Sub Menu

The Hydrostat selection opens a screen to allow hydrostat measurements
to be set. Adjustments can be made to:
• Left hydro pump
• Right hydro pump

Hydrostat Edit
After making a selection, the editing screen appears to modify function
measurements for the selected Operator Mode (7).
• Minimum Current
Determines when the movement of a function occurs.
• Maximum Current
Determines the maximum speed for a function.
• Start Slope
The ramp up of a function from the stopped condition to the full on
condition.
• Stop Slope
The ramp down of a function from full speed to stop.

• Touch the + or - buttons (1) to raise or lower the current value for each component setting based upon movement.
• To save the new value, touch the check mark (2).
• To cancel the change, touch the “X” next to the selection (3).
• To return to the previous menu, touch back button (4).
• To cancel or reset all changes on the page, touch the reset button (5).
• To return to the Main Display Screen of the MD4, touch close button (6).

Preferences Menu
The Preference Menu allows the operator to set the MD4 display preferences. Changes include the
display back light adjustment, language selection, and date and time settings.
• Display
Button to access monitor display preferences.
• Date/Time
Button to set the Date and Time.
• Language
Button to set the Language preference. English and French are sup-
ported languages.

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TROUBLESHOOTING IQAN CONTROL SYSTEM
Display Sub Menu
Display menu options that can be set include:
• Backlight
The back light display for the MD4 monitor.
• Screensaver
Turn screensaver ON or OFF.

• Touch the + or - buttons to raise or lower the value for each setting
(1).
• To save the new value, touch the check mark (2).
• To cancel the change, touch the “X” next to the selection (3).
• To return to the previous menu, touch back button (4).
• To return to the Main Display Screen of the MD4, touch close button (5).

Date/Time Sub Menu

The system date and time values can be set.
• Date
The current date for the MD4 system.
• Time
The current time for the MD4 system.

• Touch the + or - buttons to raise or lower the current value for each
setting (year, month, day, hours and minutes) (1).
• To save the new value, touch the check mark (2).
• To cancel the change, touch the “X” next to the selection (3).
• To return to the previous menu, touch back button (4).
• To return to the Main Display Screen of the MD4, touch close button (5).

Language Sub Menu

The default language used by the MD4 display can be set. Language
change can be made from the primary to secondary language settings that
the manufacturer has configured for their machine.
IQAN Supports the following Languages:
• English (default value)
• French

• Touch the desired language to set the value (1).

• To return to the previous menu, touch back button (2).
• To return to the Main Display Screen of the MD4, touch close button
(3).

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-55
TROUBLESHOOTING IQAN CONTROL SYSTEM

Options Display Page

The Options Display Page shows the current optional settings in use, including operator mode being used,
restrict mode status, horsepower, oil type, track speed, and disc saw status. Touch the Options Display button
from the Main Display to access this page.
To change any of the optional settings, touch the menu button.
• Operator Mode
The operator button changes the operator mode of the machine (1).
• HP Control
The HP control button changes the horsepower control for the
machine (2).
• Restrict Mode
The restrict mode button sets the machine to a restricted mode (3).
• Select Oil Type
The select oil type button changes the selected oil type based upon
exterior temperature (4).
• Track Speed
The track speed control button controls output percentage for Rabbit
and Turtle mode, using a range of 60 to 100% (5).
• Disc Saw
The Disc Saw button enables or disables pressure for the optional disc saw (6).
• Close
To return to the Main Display Screen of the MD4, touch close button (7).

Operator Mode
This machine can be set up with three customizable operator modes, where each mode can hold custom settings for speed,
ramps, joystick, and foot pedal functions. A fourth operator mode is the factory Default.
As an example, a day shift operator can tune a machine with different
maximum speeds and ramps on the outputs for the system for Mode 1. A
2nd shift operator can use Mode 2 which may be set a little slower or have
smoother ramping than the day shift operator.
1. From the Options Display Page touch the Operator Mode button.
2. On the Machine Set-Up page, choose the mode to set for the machine
by touching the selection (1).
3. Touch the “...” button to Cancel or Reset the changes to the factory
setting.

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TROUBLESHOOTING IQAN CONTROL SYSTEM
Modes available include:

Mode 1 Operator Setting Changes allowed in Adjust sub menu

Mode 2 Operator Setting Changes allowed in Adjust sub menu

Mode 3 Operator Setting Changes allowed in Adjust sub menu

Mode 4 Default Settings Factory Setting. No changes allowed

Remark
The Mode 4 setting is the manufacturer’s default setting and can be used to verify machine performance with
factory settings. If an operator tunes the machine to a poor performance, Default (Mode 4) setting can be
selected and the machine performance is returned to factory settings.

Resetting Mode Adjustments

When an operator has made multiple changes to settings that cannot be recovered, these custom settings can be reset to factory
defaults as set by the manufacturer. Please note that when this feature is used, all settings adjusted by the operator for that
MODE will be wiped clean.
Each of the Operator Modes can be reset individually from the Adjust sub menu pages. A mode can only be reset by accessing
each individual component for a specific mode and resetting the values. It is not possible to reset all values for all components
for a mode at the same time.
All Adjust sub menus show the current Operator Mode that has been selected.
For each Adjust sub menu page, you can reset the values by touching the
Reset button (1), which shows a list to either Cancel or Reset the page val-
ues.
Touch Reset (2) to reset the values.

When you choose to Reset the values, a second prompt then appears ask-
ing you to confirm that you really want to reset all component values on
this screen for the selected mode.
• To Cancel and not reset the values, touch the Cancel button (1).
• To reset all values on the current screen for the selected mode, touch
the check mark to save the Reset (2).

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TROUBLESHOOTING IQAN CONTROL SYSTEM

HP Control
The horse power control option changes the horse power control for the
machine.
• Standard Mode applies the horse power load evenly for the engine,
crane and tracks and is used for standard operation.
• Track Mode takes a percentage of the load from the engine and
applies to the tracks, as is used for sloping terrain.
• Crane Mode takes a percentage of the load from the engine and
tracks to provide more power for the crane, as used on a flat surface
with active boom functions and little or no movement.

Restrict Mode
The restrict mode button sets the machine to a preset RPM for movement
with restricted boom access. Standard running mode does not use restrict
mode.

Select Oil Type

The Select Oil Type button changes the MD4 settings to match the type of oil currently in the machine. This setting should be
verified or updated whenever the oil is changed in the engine.
The lower the temperature, the lower the oil type.
• 32 for low outdoor temperatures
• 46 for normal outdoor temperatures
• 68 for hot outdoor temperatures
The warning alarm setting varies depending on the ISO rating of the
hydraulic oil.
Remark
If high hydraulic oil temperature is a continuous or recurring
problem, make sure the oil cooler fins are not plugged with
debris or have the hydraulic systems checked for a faulty relief
valve.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

Track Speed
The Track Speed Control button controls the output percentage for Rabbit
and Turtle modes. This controls the speed of the machine based upon
pedal pressure, using a range of 60% to 100%.

Disc Saw
The Disc Saw button enables or disables hydraulic pressure for the disc
saw. This setting should only be enabled when the optional disc saw is
attached and being used.
The gauge for the Disc Saw is not shown on the Main Display screen of
the MD4 when this setting is disabled.

Information Display Page

The Information Display Page includes machine service and statistics, including service hours, engine hours,
hours until next service, and tree counter. Touch the Information Display Page button to access this page.
• Service Machine Hours
Shows the service life of the machine (1).
• Engine Hours
Engine hours of machine (2).
• Hours until Service
Hours until next service due (3).
• Tree Counter
• Number of trees serviced during this period (4).
• To close the page and return to the Main Display Screen, touch the
close button (5).

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-59
TROUBLESHOOTING IQAN CONTROL SYSTEM

Engine Display Page

The Engine Display Page includes a list of the current settings for the engine. Most of these settings are also
reflected on the Main Display page of the MDM. Touch the Engine Display Page button to access this infor-
mation.
• Active measurements for the engine are listed (1).
• To close the page and return to the Main Display Screen, touch the
close button (2).

Faults Display Page

The Faults Display page shows a status list of the various fault areas monitored by the system. The Fault lamp
appears in red when a fault occurs. Touch the Fault Display Page button to access detailed information.
• A list (1) shows possible faults for the system as monitored by the
MD4.
Active faults are shown in red.
Inactive faults are shown in gray or white.
• To close the page and return to the Main Display Screen, touch the
close button (2).

See “Handling a Fault” on page 40-64 for information.

NOTICE
If the active fault warning is ignored, severe engine damage or
hydraulic component damage could occur.

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TROUBLESHOOTING IQAN CONTROL SYSTEM

Operating the IQAN MD4 Monitor

First Time Start-up
1. The MD4 monitor automatically turns on when the key is turned to
ON for the machine.
When the MD4 initially starts, the Komatsu logo appears, followed
by the Main Display screen.

2. The Main Display shows the current dormant status of the system.
Menus and Information Pages can be accessed at this point, even
when the engine is not running.

3. Once the engine is Started and running, press the Arm System button
on the machine dashboard to activate the hydraulics on the machine.
The IQAN MD4 system reflects the System Armed button as green.

NOTICE
The IQAN system cannot be armed with the operator door open or if
any controls or pedals are in use.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-61
TROUBLESHOOTING IQAN CONTROL SYSTEM

Menu Navigation
1. The Main Display screen shows the status of the system.
Touching sub menu buttons allows you to navigate to other informa-
tion pages, such as the Options Display Page, Service Information
Page, Engine Display Page and Faults Display Page, and Main Menu
Screen.

2. Touch the Menu Screen button (1) to access the Main Menu settings.

3. The Main menu provides a selection of sub menus to configure the

system.
See “Main Menu Screen Selector” on page 40-49 for details.

4. Basic navigation buttons through sub menu pages include:

• To return to the previous menu, touch Back button (4).
• To return to the Main Display Screen of the MD4, touch Close
button (6).
Additional menu buttons are available depending upon the screen you
are on.
• When modifying settings, touch the + or - buttons (1) to raise or
lower the current value.
• To save the new value for a setting, touch the check mark (2).
• To cancel the change for a setting, touch the “X” next to the
selection (3).
• To cancel or reset all changes on an Adjust sub menu page, touch
the Reset button (5). This menu is only available on screens with multiple settings.
• For Adjust sub menus, the Mode (7) indicates the selected mode to which any configuration changes are saved. The
Mode is selected from the Options Display Page.

40-62 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING IQAN CONTROL SYSTEM
5. From the Options Display menus, resetting a value is a little different.
To cancel or reset changes to a specific option on the Options Display
sub menu page, touch the Reset “...” button (8).
A list appears (9) to allow you to Reset the values or Cancel the but-
ton.

If you touch Reset, a second prompt appears asking you to confirm

that you want to reset the value for the selected item.
• To cancel the reset and keep existing value, touch the “X” to
Cancel the reset (1).
• To Reset the value to the default settings for that component,
touch the check mark (2).

Engine Configuration
The Engine Display Page provides the current status on the engine.

1. From the Main Display screen, touch the engine lamp.

2. The Engine Display Page is displayed.

• The engine settings for the system are listed with the current val-
ues (1).
• To return to the Main Display Screen of the MD4, touch close
button (2).

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-63
TROUBLESHOOTING IQAN CONTROL SYSTEM

Handling a Fault
1. When a fault occurs for a component, the lamp for the affected com-
ponent (1) and the Fault lamp (2) turn red to indicate an error.
2. From the Main Display screen, touch the Fault lamp (2) in the center
of the screen.

3. The Fault Page is displayed, showing the possible faults for the sys-
tem and their status (1).
Messages in red, indicate an active fault.
Messages in gray, indicate an inactive fault.
4. Review and note the faults so that they can be properly handled.
5. Touch the close button (2) to return to the Main Display screen.

NOTICE
If the active fault warning is ignored, severe engine damage or
hydraulic component damage could occur.
Check the system based upon the error message to avoid damage to
the engine.

Fault Messages
When a fault occurs for a component module, an error message is shown
on the display.
1. The Error message provides details of the error.
Review the error and make note of what needs to be checked.
2. There may be multiple Error messages as noted.
3. Touch the close button to clear the first error message, and review the
next message.

4. Review the next error message and make note of what needs to be
checked.
Continue for each error message.

NOTICE
If the active fault warning is ignored, severe engine damage or
hydraulic component damage could occur.

40-64 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING IQAN CONTROL SYSTEM
Fault List
Use the following information to handle each fault as listed on the Faults Display Page. When a fault occurs, the ECM pro-
vides the error code for the fault. If you are still experiencing a problem after the action step has been completed, contact your
local Komatsu Forestry dealer.

Fault Description Action

Low Hydraulic Oil Level The level of the hydraulic oil in the Stop work and check the hydraulic oil
hydraulic tank is too low when this lamp level. Check also for leaks.
shows Red.

Charge Filter Pressure When the charge filter pressure is above Shut down the engine based upon warn-
normal, the charge filter lamp shows red ing alarms from ECM. The cause for this
and the warning alarm sounds. alarm can be a dirty charge filter or cold
oil.

Hydraulic Tank Filter Pressure The return filter pressure lamp shows red Shut down the engine based upon warn-
and the alarm sounds when the hydraulic ing alarms from ECM.
filter pressure reaches 25 psi. The cause of this alarm could be cold oil
or dirty filters. Do not operate the
machine until the problem has been
resolved.

Low Engine Oil Pressure The Engine Oil Pressure gauge reflects Shut down the engine based upon warn-
the engine oil pressure. The Low Engine ing alarms from ECM, and check for low
Oil Pressure lamp shows red and the engine oil level.
warning alarm sounds when the oil pres- Refer to the engine manufacturer’s man-
sure drops below 20 psi. ual to determine the normal operating
range for the engine type and oil type.

High Coolant Temperature The Coolant Temp gauge reflects the Shut down the engine based upon warn-
engine coolant temperature. The High ing alarms from ECM.
Coolant Temperature lamp shows red and
the warning alarm sounds when the cool-
ant temperature is above 210°F.

Low Voltage The Battery Volts gauge reflects the con- If a low battery charge is indicated (red),
dition of the machine’s electrical charging check the following:
system. • The machine batteries
Normal operation should be in the green • The engine’s alternator belts
zone.
The machine can operate with low battery
The Low Voltage lamp shows red when
charge, but any use of auxiliary electrical
the voltage drops below 18 volts.
equipment, such as exterior lights, will
rapidly drain the batteries.

High Hydraulic Temperature The Hydraulic Oil Temperature gauge Shut down the engine, based upon warn-
monitors the temperature of the hydraulic ing from ECM.
oil in the main hydraulic tank.
Check the hydraulic oil coolers to see if
If the temperature exceeds the normal
they are plugged. Clean the coolers if
operating range of the oil type selected in
needed.
the IQAN MD4, the High Hydraulic Tem-
perature lamp shows red and the warning Check the oil type selected in the IQAN
horn sounds. MD4, under Options Display to be sure it
is correct for current environment.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-65
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

DISC SAW CIRCUIT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

1. Disc saw will not a. Disc saw pump load sense orifice
start. plugged.

Disc Saw Pump Load Sense Line

• Locate the disc saw pump load sense orifice (1) at the
pump pressure output flange block.
• Remove the straight fitting containing the orifice and
check for contamination.
• Clean or replace the orifice if required.
b. No power at disc saw stop valve
solenoid.

Disc Saw Stop Valve Solenoid

• Check for power at the disc saw stop valve solenoid
coil (1).
• If no power, replace disc saw rocker switch in the
dash panel.
c. Disc Saw stop valve solenoid • Check continuity of coil with an ohm meter. Replace
malfunction. coil if required.
• Remove cartridge. Check for contamination or dam-
aged seals.
• Replace seals or cartridge if required.
d. Pressure and return lines between disc • Switch lines and re-start.
saw pump and motor switched.
e. Over running check valve at saw • Remove and inspect check valve. See manufacturer’s
motor failed or stuck open. manuals shipped with the attachment.

40-66 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

2. No stand-by pressure, a. Implement pump thru drive coupling
no flow. failure.

Thru Drive Coupling (Typical)

• Remove disc saw pump (1) and check for damage to
the thru drive coupling (2) or disc saw pump input
shaft splines.
• Replace thru drive coupling or pump if required.
b. Worn disc saw pump. • Check the case drain filter for metal flakes.
Remark • If metal flakes are found in the case drain filter or
If an internal pump/motor fail- case drain flow is excessive, the disc saw pump is
ure is suspected, always worn or failed.
check the component’s case • Replace the disc saw pump.
drain line and the case drain
return filter for metal particle
contamination first.
c. Disc saw pump with incorrect rotation • Check the serial number tag on the disc saw pump.
installed. Rotation should be counterclockwise.
• If rotation is clockwise, install pump with correct
rotation.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-67
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

3. Disc saw circuit will a. Disc saw pump compensator control
not produce full pres- spool sticking.
sure.

Disc Saw Pump Compensator Spool

• Remove disc saw pump compensator spool (1).
• Check for free movement in it’s bore.
• Free spool, replace spool or replace complete com-
pensator.
b. Air trapped in disc saw pump load
sense line.

Disc Saw Pump Load Sense Line

• Bleed disc saw pump load sense line (1).
c. Worn disc saw pump. • Check the case drain filter for metal flakes.
Remark • If metal flakes are found in the case drain filter or
If an internal pump/motor fail- case drain flow is excessive, the disc saw pump is
ure is suspected, always worn or failed.
check the component’s case • Replace the disc saw pump.
drain line and the case drain
return filter for metal particle
contamination first.

40-68 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

4. Disc saw circuit loses a. Saw stop valve cartridge leakage.
pressure when run-
ning hot.

Disc Saw Stop Valve Cartridge

• Remove saw stop cartridge (1) and check O-ring for
damage or being rolled over in its groove.
• Replace O-ring if required.
b. Disc saw pump load sense orifice
plugged.

Disc Saw Pump Load Sense Line

• Locate the disc saw pump load sense orifice (1) at the
pump pressure output flange block.
• Remove the straight fitting containing the orifice and
check for contamination.
• Clean or replace the orifice if required.
c. Disc saw attachment motor or • See manufacturer’s manuals shipped with the attach-
evolving malfunction. ment.

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-69
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

5. Poor or erratic perfor- a. Saw disc plugged with debris. • Clear debris from saw disc.
mance of disc saw.
b. Saw stop valve cartridge leakage.

Disc Saw Stop Valve Cartridge

• Remove saw stop cartridge (1) and check O-ring for
damage or being rolled over in its groove.
• Replace O-ring if required.
c. Disc saw pump stand-by or pco • Adjust disc saw pump pressures.
pressure out of adjustment.
d. Disc saw attachment motor or valving • See manufacturer’s manuals shipped with the attach-
malfunction. ment.
6. Disc saw blade a. Disc saw pump stand-by pressure set • Adjust stand-by pressure as required.
rotates when shut off. too high.
b. Saw stop valve cartridge leakage.

Disc Saw Stop Valve Cartridge

• Remove saw stop cartridge (1) and check O-ring for
damage or being rolled over in its groove.
• Replace O-ring as required.
c. Disc saw attachment motor leakage. • See manufacturer’s manuals shipped with the attach-
ment.

40-70 XT430-3,XT430L-3,XT445L-3,XT460L-3
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS
12

MEMORANDUM

XT430-3,XT430L-3,XT445L-3,XT460L-3 40-71
TROUBLESHOOTING DISC SAW CIRCUIT PROBLEMS

40-72 XT430-3,XT430L-3,XT445L-3,XT460L-3
 50 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2

Removal And Installation Of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Disassembly And Assembly Of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Stripping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Insertion Of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Crimping Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Insertion Of Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Precautions when Performing Removal Work . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Precautions when Performing Installation Work . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Precautions when Completing The Operations . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
Stick Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Tool Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-22
Stick Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-1
DISASSEMBLY AND ASSEMBLY

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27

Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-27
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
Filling the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
Auxiliary Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Removal (Hydraulic Driven Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-36
Hydraulic Tank Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
Machine Start-Up After Hydraulic Component Replacement . . . . . . . . . . . . . . . 50-38
Vent Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
Hydraulic System Start-Up for Machines With A Vacuum Pump . . . . . . . . . 50-38
Rotary Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Swing Motor Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Swing Motor Gearbox Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Swing Motor/Gearbox Assembly, XT430-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52
Fill and Check Swing Pinion Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
Revolving Frame Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Removall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Intermediate Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
45 cc Auxiliary Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
45 cc Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-65
71 cc Auxiliary Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
71 cc Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-67
Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-69

50-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
Auxiliary Oil Cooler Fan Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
Charge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-78
Right Side Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-79
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-79
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-81
Left Side Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-93
Disassembly of Number 1 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
Assembly of Number 1 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
Disassembly of Number 2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
Assembly of Number 2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113
FILL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
CHARGE MANIFOLD HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-116
CHARGE FILTER MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-118
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-118
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-119
PILOT PRESSURE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
RETURN OIL MANIFOLD (LOGIC BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-121
SAW STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122
ENGINE FLEXPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123
Remove Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123
Separate Transmission From Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-123
Flexplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-125
Flexplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-125
Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-126
Install Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-127
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-128
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-128
Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-142

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-3
DISASSEMBLY AND ASSEMBLY

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-149
TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-162
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-162
Check Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-162
Increasing Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-163
Decreasing Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-163
Track Shoe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-164
Track Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-164
Idler Wheel, Recoil Spring and Track Adjuster Assembly . . . . . . . . . . . . . . . . . 50-169
Idler Wheel and Recoil Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-169
Idler Wheel and Recoil Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . .50-170
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-171
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-171
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-174
Recoil Spring: XT430-3, XT430L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-178
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-178
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-179
Recoil Spring: XT445L-3, XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-181
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-181
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-182
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-184
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-184
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-185
Final Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-186
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-186
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-186
Track Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-187
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-187
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-187
Carrier Roller (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Track Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-189
LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-191
Cylinder Removal for XT430L-3, XT445L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-191
Cylinder Installation for XT430L-3, XT445L-3 . . . . . . . . . . . . . . . . . . . . . . . . . .50-194
Cylinder Removal for XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-196
Cylinder Installation for XT460L-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-205
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-205
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-213
OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-221
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-221
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-223

50-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

12
HOW TO READ THIS MANUAL

Removal And Installation Of Assemblies

Special Tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.

A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.

B. Distinction of new and existing special tools

N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank: Tools already available for other models. They can be used without any modification.

C. Circle mark ❍ in sketch column:

The sketch of the special tool is presented in the section of "Sketches of special tools".
This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).

Removal
• The [Removal] section contains procedures and precautions for implementing the work, expertise, and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and 
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.

WARNING! This mark indicates safety-related precautions that must be followed when implementing the work.

★ : Instructions or precautions for work.

[*1] :This mark shows that there are instructions or precautions for installing parts.:

This mark shows the amount of oil or coolant to be drained.

Weight of part or component.

Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• Marks shown in the Installation Section stand for the following.

WARNING! Precautions related to safety in execution of work.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-5
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
★ :This mark gives guidance or precautions when doing the procedure.

Type of coating material.

Tightening torque.

Quantity of oil or coolant to be added.

Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.

Disassembly And Assembly Of Assemblies

Special Tools
• Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.

A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.

B. Distinction of new and existing special tools

N : Tools newly developed for this model. They respectively have a new part number.
R : Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank : Tools already available for other models. They can be used without any modification.

C. Circle mark ❍ in sketch column:

• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).
Disassembly
• In Disassembly section, the work procedures, precautions and expertise for carrying out those procedures, and quantity of
the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• The meanings of the symbols used in Disassembly section are as follows.

WARNING! This mark indicates safety-related precautions that must be followed when implementing the work.

★ Instructions or precautions for work

Quantity of oil or coolant drained.

Assembly
• In Assembly section, the work procedures, precautions and expertise for carrying out those procedures, and quantity of the
oil and coolant added are described.

50-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
• General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and 
quantities are not described.
• The meanings of the symbols used in Assembly section are as follows.

WARNING! Precautions related to safety in execution of work.

★ : This mark gives guidance or precautions when doing the procedure.

Type of coating material.

Tightening torque.

Quantity of oil or coolant to be added.

Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

12
SPECIAL TOOLS LIST
★ Tools with part number 79❍T-❍❍❍-❍❍❍❍ cannot be supplied (they are items to be locally manufactured).
★ Necessity:
■ ...........Cannot be substituted, must always be installed (used).
● ...........Extremely useful if available or can be substituted with commercially available part.
★ New/Remodel:
N...........Tools with new part numbers, newly developed for this model.
R:...........Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: ...Tools already available for other models, can be used without any modification.
Tools marked ❍ in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools).

New/remodel
Necessity
Symbol

Sketch
Qty
Component Part number Part name Nature of work, remarks

791-430-3230 Installer ■ 1
Carrier roller assembly
791-601-1000 Oil pump ■ 1
796-670-1010 Installer ■ 1
Track roller assembly L Installation of floating seal
791-601-1000 Oil pump ■ 1
796-570-1020 Installer ■ 1
Idler assembly
791-601-1000 Oil pump ■ 1
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
1 Cylinder
790-101-1600 ■ 1
(686 kN {154,219 lbf})
Recoil spring  790-101-1102 Pump ■ 1 Disassembly and assembly of
M
assembly recoil spring assembly
790-201-1500 Push tool kit ● 1
790-201-1620 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 2

50-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures 
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.

Stripping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or 
corroded sections of the wire being repaired referring to the table below.

Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)

0460 - 202 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)

0460 - 215 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0460 - 204 - 0490 6 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (0.430 - 0.492)

Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the "Strip Length" above.

Wire Inspection
After stripping insulation from wire, inspect wire strands for:
• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-9
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Contact Terminal Removal (HD30 Type)

1. Obtain the correct removal tool according to the wire size used in
the connector.

2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.

Remark
Using a removal tool that is too large or too small will hinder
wire removal and may damage the connector or removal
tool. Always use the correct removal tool size for the wire
gauge you are servicing.

3. In a straight line, carefully slide the removal tool along the wire and
into the grommet until a contact resistance is felt.

Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or con-
nector may result.

4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.

5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.

50-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Crimping Contact Terminal (HD30 Type)
1. After insulation has been stripped from the wire and contact termi-
nal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw coun-
terclockwise until contact terminal surface is flush with indenter
cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is cen-

tered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-11
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Insertion Of Contact Terminal (HD30 Type)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.

2. Hold connector with rear grommet facing you.

3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.

4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.

5. For unused wire cavities, insert sealing plugs for full environmental
sealing.

50-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Contact Terminal Removal (DT Type)
1. Remove the wedge lock using needle nose pliers or a hooked-
shaped wire.

2. Pull the wedge lock straight out and save for reinstallation.

3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.

4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-13
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Crimping Contact Terminal (DT Type)
1. After insulation has been stripped from the wire and contact termi-
nal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw coun-
terclockwise until contact terminal surface is flush with indenter
cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is cen-

tered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.

50-14 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES

12
Insertion Of Contact Terminal (DT Type)
1. Grasp the crimped contact terminal approximately 25.2mm (1in)
behind the crimped barrel.

2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.

3. Push the contact terminal straight into the connector until a "click"
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.

4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The wedge
lock will snap into place. Rectangular wedges are not oriented and
may fit either way.

Remark
As the connector receptacle is shown - use the same procedures for a
plug.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-15
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION

12
PRECAUTIONS DURING OPERATION
★ Be sure to follow the general precautions given below when performing removal or installation (disassembly or 
assembly) of units.

Precautions when Performing Removal Work

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before removal 
to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the 
connectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after 
removal.
★ Precautions when handling piping during disassembling
• Fit the blind plugs into the piping after disconnecting it during disassembly operations.

Precautions when Performing Installation Work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three 
drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, 
then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of 
the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

50-16 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION

12
Precautions when Completing The Operations
• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate 
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add oil to the specified level. Run the engine to circulate
the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed 
air from the system after reassembling the parts.
★ See “Vent Air From Hydraulic System” on page 50-41.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.

Other Precautions
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the 
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, 
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when 
disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be 
disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Perform thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that 
have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to 
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also 
perform a thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the 
air before starting the engine to prevent seizure of the pump. See “Vent Air From Hydraulic System” on page 50-41.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing 
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always 
vent the air after completion of installation.
★ See “Vent Air From Hydraulic System” on page 50-41.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-17
DISASSEMBLY AND ASSEMBLY ARM

12
ARM

Stick Arm

WARNING! Make sure to read and understand all operational warnings shown in this manual. 
Additional safety precautions will be included in this section as required by the procedure.

WARNING! Relieve hydraulic pressure before servicing any hydraulic component. 

Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.

WARNING! Wait for the hydraulic fluid to cool before servicing any hydraulic component. 
Hot hydraulic fluid can cause severe burns.

Removal
Remark
The boom, stick arm, and telescopic arm have different configurations for the hydraulic tubes and hoses
depending on which attachment the machine was designed to accommodate. Refer to the Parts Book for
components of the boom, arm, hydraulic hoses, and tubes.

1. Remove the attachment from the arm.

2. Remove the tool tilt cylinder, links, and pins if required. See “Tool
Tilt Cylinder, Removal”.
Remark
Tag and mark the hydraulic hoses before removal to
ensure correct installation.

3. Remove the hydraulic hoses (1) from the stick arm.

4. Use a suitable adjustable lifting strap to secure the stick arm 

cylinder (2) to the arm (3).

5. Remove locknut (1) and bolt (2) from pin (3).

Remark
Adjust the lifting strap so the cylinder can be lowered
from the stick arm in the following step. Use a “come-a-
long” ratchet strap.

6. Remove the pin (3) and lower the rod end of the stick arm cylinder
(4) from the stick arm (5).

50-18 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY ARM

12

WARNING! Use a suitable lifting device to support the stick arm before removing the pin that attaches the stick
arm to the boom. Failure to comply could cause personal injury or death.

7. Use a suitable lifting device to support the stick arm (1).

8. Remove locknut (2) and washer (3) from pin (4).

9. Remove bolt (5), washer (6), retainer washer (7), and pin (4) from
stick arm (1) and boom (8).

10. Set the stick arm (1) down on the ground with the lifting device.

11. If required, remove the hydraulic tubes from the stick arm.

Installation

1. Inspect the pin bushings (1) for wear and replace if required.

2. Inspect the hydraulic tubes (2) for wear and replace if required.

3. Inspect the stick arm for any broken welds or damage and repair as
required.
.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-19
DISASSEMBLY AND ASSEMBLY ARM

12

WARNING! Use a suitable lifting device to support the stick arm before removing the pin that attaches the stick
arm to the boom. Failure to comply could cause personal injury or death.

4. Using a suitable lifting device, raise the stick arm (1) and align the
pin hole to the boom (8).
Remark
The inner bushing is greased, do not apply anti-seize
compound to the inner bushing and pin.

5. Apply anti-seize compound to the outer bushing (9) on each side

only before installing the pin.

6. Install the pin (4) and align the pin, then install the retainer washer
(7), washer (6), and bolt (5).

7. Install washer (3) and locknut (2). Do not over tighten the
locknut. Tighten the locknut so it is tight against the boom
only.

8. Using a suitable lifting device, align the rod end of the stick
arm cylinder (4) to the pin hole in the stick arm (5,).

9. Install the pin (3), bolt (2), and locknut (1).

10. Install the hydraulic hoses as noted before removal.

11. Grease the arm components. The grease fittings are located
on the underside of the stick arm.

Shell Retinax MDX-2

12. See “Vent Air From Hydraulic System” on page 50-41.

13. Check for any leaks and repair as required.

50-20 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY BOOM

12
BOOM

Removal
Remark
The boom, stick arm, and telescopic arm have different configurations for the hydraulic tubes and hoses
depending on which attachment the machine was designed to accommodate. Refer to the Parts Book for
the components of the boom, arm, hydraulic hoses, and tubes.

1. Remove the attachment from the boom.

2. See “Stick Cylinder, Removal” and remove the stick cylinder.

3. See “Stick Arm, Removal” and remove the stick arm from the boom.

4. See “Boom Cylinder, Removal” and remove the boom cylinder from the boom.
Remark
Tag and mark the hydraulic hoses before removal to ensure correct installation.

5. Remove the hydraulic hoses (1) from the boom tubes (2).

WARNING! Use a suitable lifting device and chain to

secure the boom before removing the boom
pin. Failure to comply could cause personal
injury or death.

6. Remove six bolts and washer (3), (4) and center bolt lock (5) from
the tapered hub cap (6) on each side of the boom.

7. Remove center bolt (7), tapered hub cap (6), and tapered hub (8)
from each side of the boom.

Remark
Make sure the boom is secured with the lifting device and
the chain is tight before removing the boom base pin.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-21
DISASSEMBLY AND ASSEMBLY BOOM
8. Remove pin (4) and shim (5) from the boom and boom base.

9. Remove the boom from the machine.

Installation
1. Inspect the tapered hubs (1) and replace if required.

2. Inspect the boom pin bushings (11) for wear and replace if
required.

3. Inspect the hydraulic tubes (12) for wear and replace if required.

4. Inspect the grease lines for damage and replace if required.

5. Inspect the boom for any broken welds or damage and repair as
required.

6. Apply anti-seize to the bushings only.

7. Apply grease to the center area of the boom pins. Do not apply
grease on the ends where the pins are in the bushings.

Shell Retinax MDX-2

50-22 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY BOOM
8. Place the boom (2) in the boom base (3) using the lifting device and align the holes.

Remark
In the following steps: Place the shims between the boom and the boom base on the right side and left side
as required to remove the gap (if only one or two shims are required, install the shims on the right side
only).
Hand tighten both tapered hubs using five of the bolts and washers, leaving one bolt out for installing the
center bolt lock after adjusting the boom pin in the assembly.
Then install the center bolt on one side and tighten using an impact wrench and then back the center bolt
out approximately 1/8 to 1/4 inch.
Then tighten the other center bolt using the impact wrench (this will insure that there is a gap of 1/8 to 1/4
inch on each side of the pin).
Place the center bolt locks on and install the washer and bolt with the center bolt lock.

Torque all the bolts to 100 lbf ft (136 N•m).

9. Install the boom pin (4), shims (5), tapered hub (1), tapered hub cap (6), center bolt (7), center bolt lock (8), six bolts (9),
and washers (10).
Remark
Use a chisel to install the tapered hub.

10. See “Boom Cylinder, Installation” in this section of the manual

and install the boom cylinder onto the boom.

11. See “Stick Arm Installation” and install the stick arm onto the
boom.

12. See “Stick Cylinder Installation” and install the stick cylinder.

13. See “Vent Air From Hydraulic System” on page 50-41.

14. Check for any leaks and repair as required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-23
DISASSEMBLY AND ASSEMBLY BOOM

12
Tool Tilt Cylinder
Removal

1. Attach a suitable lifting strap to the tool tilt cylinder (1) and to a
lifting device before removing the tool tilt cylinder from the 
arm (2).

2. Remove the hydraulic hoses from the tool tilt cylinder (1).

3. Remove the grease lines from the tool tilt cylinder (1).

4. Disassemble the tool tilt cylinder (1) and

links (2) as shown.

50-24 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY BOOM

12
Installation

1. Attach a suitable lifting strap to the tool tilt cylinder (1) and to a
lifting device before installing the tool tilt cylinder onto the 
arm (2).

2. The cylinder bushing is greased, do not

apply anti-seize compound to the cylinder
bushing and pin (2).

3. Apply anti-seize on each side of the arm

before installing pin (2) into the arm.

4. Assemble the cylinder (3) and links (4) as

shown.

5. Install the hydraulic hoses on the tool cyl-

inder.

6. Install the grease lines on the tool cylinder.

7. Grease the cylinder and links.

Shell Retinax MDX-2

8. See “Vent Air From Hydraulic System”

on page 50-41.

9. Check for any leaks and repair as required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-25
DISASSEMBLY AND ASSEMBLY BOOM

12
Stick Cylinder
Removal

WARNING! Lower the stick arm to the ground so the arm will not move when the stick 
cylinder is removed from the boom sections. Failure to comply could cause 
personal injury or death.
Use suitable straps and a lifting device to support the stick cylinder before 
removing the pins that attach the stick cylinder to the boom sections. Failure to comply could cause
personal injury or death.

1. Lower the stick arm (1) to the ground before removing the stick
cylinder (2) pins.
Remark
The stick cylinder must be secured with a strap and 
suitable lifting device before removing the pins in the 
following steps.

2. Remove the hydraulic hoses from the stick cylinder (2).

3. Remove locknut (3), bolt (4), and pin (5) from stick cylinder (2)
and stick arm (1).

4. Remove bolt (6), washer (7), retainer washer (8), and pin (9) from
stick cylinder (2) and boom (10).

5. Remove the stick cylinder (2) from the boom sections using the
lifting device.

Installation

WARNING! The stick arm must be resting on the ground before performing the installation of the stick cylinder.
Use suitable straps and a lifting device to install the stick cylinder. Failure to comply could cause
personal injury or death.

1. Inspect the pin bushings for wear and replace if required.

2. Apply anti-seize to the stick arm and boom (1 and 11) on each side only.
Remark
Do not apply anti-seize to the cylinder pins. 
The cylinder pins are greased with Shell Retinax MDX-2 grease.

3. Place the stick cylinder in place using a suitable lifting device and align the pin holes with the boom sections.

4. Install pin (9) and secure using retainer washer (8), washer (7), and bolt (6).

5. Install pin (5) and secure using bolt (4) and locknut (3).

6. Grease the stick cylinder pins. The grease fittings are located on the underside of the stick arm.

7. See “Vent Air From Hydraulic System” on page 50-41.

8. Check for any leaks and repair as required.

50-26 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY BOOM

12
Boom Cylinder
Removal

1. Remove the attachment from the boom.

2. See “Stick Cylinder Removal” in this section of the manual and

remove the stick cylinder.

3. See “Stick Arm Removal” in this section of the manual and

remove the stick arm from the boom.

4. Support the boom (6) using a suitable lifting device. 

Attach a chain to the hook (11) on top of the boom.

5. Support the boom cylinder (A) using a suitable support (B) before
performing the following steps.
• Remove the grease fitting from the rod end of the cylinder and
screw in a bolt.
• Place a 3/8 x 2 x 10 inch bar (C) between the bolt and the cyl-
inder (A) to hold the rod from moving.
• Then attach a 45 inch rod (B) to a hydraulic jack (D) to sup-
port the boom cylinder as shown.

6. Remove bolt (1), washer (2), retainer washer (3), and pin (4) from
the rod end of boom cylinder (5) and boom (6).

7. See the “Boom, Removal” in this section of the manual and

remove the boom from the machine.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-27
DISASSEMBLY AND ASSEMBLY BOOM
8. Place a block (E) under the bottom rear of boom cylinder (F).

9. Move the boom cylinder (F) back using a suitable lifting device so
the cylinder base is resting on block (E) and the cylinder is slightly
back from straight up.

10. Remove the hydraulic hoses from the boom cylinder.

11. Remove the grease lines (G) from the bottom of the boom cylinder.

12. Attach a lifting strap to the boom cylinder and to a suitable lifting
device to support the cylinder.

13. Remove four bolts and washers, (7) and (8), and two pin retainer
blocks (9) from cylinder pin (10).

14. Remove the boom cylinder (5) from the machine using the lifting
device.
Installation

1. Inspect the pin bushings for wear and replace if required.

2. Apply anti-seize to the boom (12) on each side only.

3. Apply anti-seize to the ends of the base end cylinder pin (10).
Grease the center area of the pin.

Shell Retinax MDX-2

4. Grease the cylinder pins with Shell Retinax MDX-2.

5. Install the base end boom cylinder pin (10) into cylinder (5).

6. Install the base end of boom cylinder (5) into boom cylinder 
support (13) using a suitable lifting device.

7. Install two pin retainer blocks (9) with four washers (8) and 
bolts (7).

50-28 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY BOOM
8. Support boom cylinder (A) using a suitable support (B).
• Remove the grease fitting from the rod end of the cylinder and
screw in a bolt.
• Place a 3/8 x 2 x 10 inch (9.5 x 50.8 x 254 mm) bar (C) between
the bolt and cylinder (A) to hold the rod from moving.
• Then attach a 45 inch (114.3 cm) rod (B) to a hydraulic jack (D)
to support the boom cylinder as shown.

9. Install the hydraulic hoses onto the boom cylinder.

10. Install grease lines (G) on the bottom of boom cylinder (F).

11. See the “Boom, Installation” in this section of the manual and
install the boom onto the machine.
Remark
Use a pry bar to move the base end of the boom cylinder
so the rod end will line up with boom in the following step,
if required.

12. Use the hydraulic jack (D) to position the rod end of boom 
cylinder (5) and install pin (4) with retainer washer (3), washer (2),
and bolt (1).

13. Remove hydraulic jack (D), support rod (B), and bar (C).

14. Remove the bolt in the rod end of the cylinder and install the
grease fitting.

15. See “Vent Air From Hydraulic System” on page 50-41.

16. Check for any leaks and repair as required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-29
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
HYDRAULIC SYSTEM

Hydraulic Oil Tank

WARNING! Position the machine where the hydraulic tank can be accessed by a crane or other lifting device.

WARNING! Lower the work equipment to the ground and shut off the engine

WARNING! Pressure on the hydraulic tank must be released before beginning any work on the hydraulic sys-
tem.

★ Release pressure in the hydraulic oil tank by opening the

tank vent.
Draining

100 gal (379 l)

Remark
Have a suitable container or other appropriate means of
disposing of the waste oil.

Remark
There are shut-off valves on the bottom of the tank that
can be used (with a hose attached) to drain the tank.

1. Close one of the suction shut-off valves on the bottom of the

hydraulic tank.

2. Remove the hose from the fitting on the shut-off valve and attach a
drain hose.

3. Open the shut-off valve and drain the tank.

50-30 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Removal and Disassembly
Remark
Tag and mark all of the hydraulic hoses, wire connectors,
and fittings before removal to ensure correct installation.
Remark
Cap and plug all the fittings and hoses after removal to
prevent contaminants from entering the hydraulic system.

1. If equipped with a vacuum pump, remove the pump cover from the
top of the tank.

2. Remove the hydraulic filter cover from the top of the tank.

3. Remove all the hoses and fittings from the hydraulic filters on top
of the tank.

4. Unplug the oil level sensor connector (1) from the back of the tank.
Remark
Follow the wires down to the connector.

5. Remove all the hydraulic hoses from the bottom of the tank. 
The fittings are easier to remove after the tank is removed from the
machine.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-31
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
6. Remove the oil temperature sensors (1 and 2) from the bottom of
the tank.
Remark
Sensor (1) is hardwired. Push the metal clip in and dis-
connect the sensor connector, then remove the 
sensor from the tank.

7. Attach a suitable lifting device to the hydraulic tank.

Remark
Make sure the straps or chains are tight so the tank does
not fall when the hardware is removed. Remove the top
two bolts (9) last.

8. Remove the two locknuts (1), washers (2), and bolts (3) from the
front bottom corners of the tank (4).

9. Remove locknut (5), washers (6), and bolt (7) from the rear sup-
port (8).

10. Remove the top two bolts (9), washer (10), and remove the hydrau-
lic tank (4) from the machine using the lifting device.

11. Set the tank on blocks to prevent damaging the hydraulic fittings
on the bottom of the tank. Or, set the tank on it’s side so you can
access both the bottom and top of the tank.

12. Remove the vacuum pump assembly from the tank.

50-32 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
13. Remove hydraulic filter assemblies (2) from the tank.

Remark
The three suction fittings have strainers attached that
need to be removed.

14. Remove four screws (1) from each suction strainer fitting (2).
Remove the strainer fitting with the flange fitting/shut-off valves
attached.

15. Remove the O-rings from the grooves on the bottom of the tank
where suction strainers (2) were attached.
Remark
Heat strainer fitting (3) before trying to remove the
fitting. The strainer fitting is the larger fitting that is srce-
wed into the tank.

16. Remove strainer fitting (3) from the tank with the shut-off valve attached.
Remark
Heat optional heater fitting (4) before trying to remove the fitting.

17. Remove heater fitting (4) from the tank.

18. Remove the oil level sensor from the front of the tank.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Cleaning

WARNING! Pressurized steam can cause personal injury. Wear protective clothing, face shield, and shoes
when steam cleaning.
Pressurized air can cause personal injury. Wear protective clothing, face shield, and shoes when
using pressurized air.

Remark
Pressurized steam is the best way to clean the hydraulic tank. Use only steam, do not use a detergent.
Detergents can leave a residue inside the tank which can react adversely with the hydraulic oil.
Avoid towel drying the inside of the tank. Towels can snag on corners and leave threads and lint behind
which can damage pumps.

1. Open all the suction line shut-off valves.

2. Thoroughly steam clean the tank, suction line shut-off valves, and suction strainers.

3. Thoroughly rinse the tank, suction line shut-off valves, and suction strainers.

4. Allow the tank, suction line shut-off valves, and suction strainers to air dry or use compressed air. 
Avoid towel drying the inside of the tank.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Assembly
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification charts.

1. Inspect suction strainers. Replace any damaged suction strainers.

2. Install the suction strainer O-rings and strainer fittings (1), (2) and
(3) in the tank.

3. Install the optional heater (4) in the bottom of the tank.

4. Inspect the O-ring seal on the vacuum pump. 

Replace if damaged.

5. Install the vacuum pump.

6. Install the return filter assemblies (2) into the tank. Be sure the rub-
ber gasket at the base of the return filter head is in place.

7. Remove and replace all the filter elements.

8. Install the filter assemblies in the tank.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Installation
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

1. Use a suitable lifting device to position the tank (4) on the

machine.

LT-2 Threadlocker

2. Apply LT-2 Threadlocker to bolts (9). Install the tank using top
bolts (9) and washers (10). Do not tighten bolts (9).

3. Then, align the other mounting holes using the lifting device and
install the tank onto support (8) using bolt (7), washers (6), and nut
(5). Do not tighten bolt (7).

4. Then fasten the front corners of the tank to the machine using bolts
(3), washers (2), and nuts (1). Tighten the bolts.

5. Tighten bolts (9) and (7).

6. Install oil temperature sensors (1) and (2) onto the bottom of the
tank. Push the metal clip in to plug connector (1) onto the sensor.

7. Install all the hydraulic hoses onto the bottom of the tank.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
8. Install the oil level sensor (1).

9. Plug the connector for the oil level sensor (1) into the harness.

10. Install all the fittings and hoses onto the return filter assemblies.

11. Open all shut-off valves on the suction lines.

12. Tie wrap wires and hoses as required.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Filling the Hydraulic Tank

WARNING! Hydraulic oil straight from the drum may contami-

nate the hydraulic system, resulting in possible
pump failure.

WARNING! Use pre-filtered hydraulic oil only.

WARNING! Added hydraulic oil must pass through the return

filters. 
If not filtered, hydraulic system contamination and
possible pump failure may result.

WARNING! Never add oil through the hydraulic tank

access cover.

Re-fill the hydraulic tank with the same type of oil already being used in the hydraulic system.
Open the tank vent (located on the top front of the tank, behind air cleaner)
or the hydraulic tank vent (1) in the engine compartment, depending on
which type of tank vent is on the machine. This must be done before add-
ing oil.
External Pump

Hydraulic oil can be added with an external pump at a quick-coupling (2)

provided on the manifold located in the engine compartment. Add pre-fil-
tered oil until level in the tank is within the green zone of the sight gauge
at operating temperature or within the yellow zone when cold.

Electric Fill Pump

Remove the fill pump suction hose (4) from the hydraulic pump compart-
ment. Place the fill pump suction hose (4) into a container filled with pre-
filtered oil. Press and hold the fill pump actuation button (3) located in the
engine compartment. Add oil until level in the tank is within the green
zone of the sight gauge at operating temperature or within the yellow zone
when cold.

Hydraulic System Start-Up

See “Vent Air From Hydraulic System” on page 50-41.

Check for any leaks and repair as required.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Auxiliary Oil Cooler
Removal (Hydraulic Driven Fan)
★ The auxiliary oil cooler is located in the top of the rear right side guard door. There are two types of hydraulic oil coolers:
hydraulic driven fan or two electric driven fans. The electric driven fans have been replaced by one hydraulic driven fan.
The same oil cooler is used for both types of auxiliary oil coolers. Both cooler assemblies are removed form the guard
door the same.

WARNING! Release pressure in the hydraulic oil tank by opening the hydraulic tank vent. Pressure on the hydraulic tank
must be released before beginning any work on the hydraulic system

1. Remove three bolts (1), washers (2), and guard (3)

from the guard door.
Remark
Tag and mark hoses before removal to
ensure correct assembly. Cap or plug hoses
and fittings.

2. Remove three hoses (4) (5) and (6) from their fit-
tings.
Remark
The cooler assembly is awkward, two techni-
cians are required to remove the cooler
assembly.

3. Remove four bolts (7), eight washers (8), and slide the cooler assembly (9) out of the guard door.

4. See “Auxiliary Oil Cooler Fan Pump” in this manual to replace the hydraulic pump.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Hydraulic Tank Vacuum Pump
Removal

WARNING! Release pressure in the hydraulic oil tank by

opening the hydraulic tank vent. Pressure in
the hydraulic tank must be released before
beginning any work on the hydraulic system.

1. Remove four bolts (1), washers (2), and cover (3) from the top of
the hydraulic tank.

2. Remove nine bolts (4), washers (5), and filter cover (6) from the
top of the hydraulic tank.

3. Disconnect electrical connector (a) from the wiring harness con-

nector.

4. Remove vacuum hose (A) from check valve B).

5. Remove four bolts (C), washers (D), brackets (E), vacuum pump
assembly (F), and gasket (G) from the hydraulic tank.
Installation
★ Replace the gasket if it is damaged.

1. Place gasket (G) onto the hydraulic tank and install vacuum pump
assembly and brackets (E) using four washers (D) and bolts (C).

2. Install vacuum hose (A) onto check valve (B).

3. Reconnect electrical connector (a) to its wiring harness connector.

4. Install hydraulic filter cover (6) on top of the tank using nine washers (5) and bolts (4).

5. Install vacuum pump cover (3) onto the vacuum pump assembly using four washers (2) and bolts (1).

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Machine Start-Up After Hydraulic Component Replacement
Vent Air From Hydraulic System

WARNING! Make sure to read and understand all operational warnings shown in the General
Information Section of this manual. 
Additional safety precautions will be included in this section as required by the operation being dis-
cussed.

WARNING! Make sure ALL suction line shut-off valves to hydraulic pumps are open. 
Starting the machine with a suction line shut-off valve closed will destroy the pump.

WARNING! The air that is trapped in the hydraulic system after component replacement or repairs must be
removed. Follow the hydraulic system start-up procedures to remove the air.

Hydraulic System Start-Up for Machines With A Vacuum Pump

1. Open the hydraulic tank vent in the engine compartment.

2. Start and run engine at low idle for 30 minutes while cycling all the
hydraulic functions before closing the hydraulic tank vent T-valve.
Remark
Air pockets are created in the hydraulic system when
major service is done. 
These air pockets will damage pumps. 
Running the engine and cycling hydraulic functions with
the vent open allows the air pockets to vent out of the
hydraulic tank.

3. Then close the T-valve vent to build pressure in the hydraulic tank
when the engine is started.

4. Start the engine and operate at idle for a few minutes to cycle the pumps. Listen for any unusual sounds coming from the
pump area that could indicate a problem. If you think a possible problem exists, shut down the engine immediately, inves-
tigate and correct the problem before continuing.

5. Operate a few implement functions slowly for about one minute to get the oil cooler return oil flowing into the tank. If
equipped, activate the disc saw circuit for a few moments to get the disc saw circuit return oil flowing into the tank.

6. Shut down the engine and turn on the hydraulic tank vent for 60 seconds.
Remark
Air bubbles are created in the oil when the return oil first spills into the tank. 
These air bubbles will damage pumps.
Turning on the hydraulic tank vent will remove the air bubbles.

7. Check the hydraulic oil level in the tank and add oil if required.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-41
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Rotary Manifold
Removal
★ The rotary manifold is removed through the opening in the bottom of the car body. All of the hydraulic hoses must be
removed. All of the hydraulic fittings except the fittings on top of the manifold must be removed.

1. Park the machine on a level surface and block the tracks to keep
the machine from moving.
Remark
Release pressure in the hydraulic oil tank by opening the
hydraulic tank vent. 
Pressure on the hydraulic tank must be released before
beginning any work on the hydraulic system.

2. Remove the access panel (1) from the bottom of the car body.

Remark
The rotary manifold is located under the boom. 
The boom must be raised and secured in the up position
to access the top of the rotary manifold.

WARNING! Secure the boom lift cylinder in the raised posi-

tion with a suitable metal pipe that will support
the weight of the boom. Failure to comply
could cause serious injury or death.

3. Raise boom (1) up and block the lift cylinder (2) with a suitable
metal bar (3) that will support the weight of the boom. Then let
boom (1) down until it is resting on the metal pipe (3) and the lift
cylinder (2).

Remark
Tag all the hoses on top of manifold (1) with the manifold
port number.
Remark
Plug all the hoses after removal to keep debris (that could
contaminate the hydraulic oil) out of the hoses.

4. Disconnect the rotary manifold wire harness from the fuel pump
harness located at the rear of the engine.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
5. Remove all the hoses from the top of the manifold above the
mounting bracket (2).
Remark
The hydraulic fittings above the mounting bracket on the
top sides of the manifold must be removed. 
The fittings on the top of the manifold do not need to be
removed.

6. Remove the fittings on the top sides of the manifold above the
mounting bracket (1).
Remark
Tag all the hoses and fittings on the manifold with the
manifold port number to ensure correct assembly.

7. Remove all the hoses and fittings from the manifold below the
mounting bracket.
Remark
Make an eye bolt or hook that can be screwed into one of
the ports on top of the manifold for attaching a winch.

WARNING! Make sure the winch is tight enough to 

support the rotary manifold before removing
the bolts that fasten the 
manifold to the bracket. 
Failure to comply could cause serious injury.

8. Attach a suitable winch to the top of the rotary manifold and

secure it to the boom above the manifold.

9. Remove four locknuts (1), eight washers (2), and four bolts (3).
Lower rotary manifold (4) down into the car body with the winch.
Remark
The rotary manifold does not line up directly above the
car body access opening. 
Two technicians will be required to maneuver the mani-
fold through the opening using the winch.

10. Remove the rotary manifold from the car body through access
opening (1) using the winch.
Inspection
★ Inspect the hoses and fittings that were removed.
★ If the hose end connectors are damaged, replace the hoses.
★ Damaged, dented, crushed, or leaking fittings and hoses restrict oil
flow and degrade operation of the equipment.
★ Use new O-rings on all disconnected hydraulic fittings.
★ Be sure the hoses are in good condition. If in doubt, replace them.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Installation

1. Install the rotary manifold through the car body access opening
using a winch to pull it up into position.

2. Position the rotary manifold with the block (1) to the front of the
machine.

3.Install the rotary manifold on the bracket with four bolts (1), eight
washers (2), and four locknuts (3). Assemble with one washer on
top and one on the bottom.
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

4. Install the fittings as marked before removal. Refer to pictures

below for the orientation of the fittings.

Right Side Left Side

5. Install the hoses as marked before removal.

6. Connect the rotary manifold wire harness to the fuel pump harness located at the rear of the engine.

7. Start the engine and raise the boom to remove the support bar from the lift cylinder.

8. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
9. Operate the hydraulic controls to check for proper operation and any leaks from the fittings and hoses. 
Tighten any leaking fittings or hoses.
Remark
If any of the controls do not function correctly, check to make sure the correct hose is connected to the port
in the rotary manifold.

10. Check the oil level in the hydraulic tank and add hydraulic oil if necessary.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-45
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Swing Motor
Removal

1. Raise the boom with the attachment and bring the attachment back
towards the machine. Then lower the boom so the attachment is on
the ground. This will give you room to remove the swing motor.
Remark
Tag and mark hoses before removal to ensure correct
assembly.
Remark
Plug all hydraulic hoses and fittings after removal.

2. Release pressure from the hydraulic oil tank by opening the

hydraulic tank vent. Pressure on the hydraulic tank must be
released before beginning any work on the hydraulic system.

3. Remove three hoses (1), (2) and (3) from the anti-cavitation valve
(4).

4. Remove hose (5) and elbow (6) from the swing motor (7).

5. Remove two bolts (1) and swing motor (2) with the anti-cavitation
valve attached (not shown) from the gearbox (3).

6. Remove motor pilot O-ring (4).

Remark
The parts in the following step are included with the new
swing motor.

7. Remove shaft seal (5), O-ring (6), cover (7), and retaining ring (8)
from gearbox (3).

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
8. Remove eight Allen head capscrews (1) and the anti-cavitation
valve (2) from the swing motor (3).

9. Remove two O-rings (4) from the anti-cavitation valve (2).

Installation
Remark
Clean the surfaces where the O-rings seat before assem-
bly. 
Always install new O-rings during assembly.
★ Refer to the List of Adhesives for sealants used on the fittings.
★ If the anti-cavitation valve that was removed does not look like the
anti-cavitation valve in the photo, order the new anti-cavitation
valve and replace the old one. 
The older anti-cavitation valve does not prevent hydraulic pressure
spikes that can cause excessive torque to the swing drive compo-
nents.

1. Install two O-rings (4) on the anti-cavitation valve (2).

2. Install the anti-cavitation valve (2) onto the swing motor (3) using
eight Allen head capscrews (1).
Remark
Parts 8, 7, 6, and 5 in the following step are included with
a new swing motor.

3. Install retaining ring (8), cover (7), O-ring (6), and shaft seal (5) in
gearbox (3).

4. Install O-ring (4) and swing motor (2) onto gearbox (3) using two
bolts (1).

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
5. Install three hoses (1), (2), and (3) onto anti-cavitation valve (4).

6. Install elbow (6) and hose (5) onto swing motor (7).

7. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Swing Motor Anti-Cavitation Valve
★ All 56 cc swing motor anti-cavitation valves should be replaced with new ones. The older anti-cavitation valve does not
prevent hydraulic pressure spikes that can cause excessive torque to the swing drive components.

Removal
1. Swing cab side engine compartment guard (1) open to access the
Allen head capscrews that fasten the anti-cavitation valve (2) to the
swing motor (3).
Remark
Tag and mark hoses before removal to ensure correct
installation. Plug the hoses after removal.

2. Open the hydraulic tank vent to release the pressure in the tank.

3. Remove three hoses (4), (5), and (6) from anti-cavitation valve (2).

4. Remove eight Allen head capscrews (7) and the anti-cavitation

valve (2) from the swing motor (3).

5. Remove two O-rings (1) from the anti-cavitation valve (2).

Installation
Remark
Clean the surfaces where the O-rings seat before 
assembly. 
Always install new O-rings during assembly.
★ Refer to the List of Adhesives for sealants used on the fittings.

★ Refer to Standard Tightening Torque for torque specification

charts.

1. Remove the three hydraulic fittings from the old valve and install
them on the new valve.

2. Install new O-rings (1) on the anti-cavitation valve (2).

3. Install anti-cavitation valve (2) on swing motor (3) with eight allen
head capscrews (7).

4. Install three hoses (4, 5, and 6) onto anti-cavitation valve (2).

5. Close the cab side engine compartment guard.

6. See “Vent Air From Hydraulic System” on page 50-41.

Komatsu recommends setting the IQAN swing parameters to the following:
Start Slope 200 ms or greater

Stop Slope 600 ms or greater

Minimum Current 330 mA

Maximum Current 600 mA or less

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-49
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

12
Swing Motor Gearbox Brake
Disassembly

1. Refer to “Swing Motor, Removal” procedure in this section of the

manual and remove the swing motor from the brake housing (1).

2. Secure a fixture as shown.

Remark
The bottom plate of the adjustable center screw com-
presses the brake back-up plate (3) until the snap ring (4)
is axially unloaded. The adjustable center screw is
threaded through the center of the crossbar mounted to
the drive using the existing motor mounting holes.

3. Free the snap ring (4), remove the fixture and disassemble the
brake.
Remark
The piston (5) releases easily by applying air pressure to
the brake release port.

Remark
The exploded view of the brake parts is shown.

4. Remove the brake housing (1) from the gearbox to replace the components shown below the
brake housing. This should not be required unless the O-ring is leaking.

Assembly
Remark
Lubricate the piston seals, back-up rings, and their contact areas with gear oil
before assembly. 
Assemble the back-up rings prior to the piston seals.

1. Assemble using the fixture as shown in disassembly to compress the spring.

2. Refer to the “Swing Motor, Installation” procedure and install the swing motor.

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DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM

Swing Motor/Gearbox Assembly, XT430-3

Removal

1. Raise the boom with the attachment and bring the attachment back
towards the machine. Then, lower the boom so the attachment is
on the ground and the revolving frame is not allowed to rotate.
This will give you room to remove the swing motor/gearbox.
Remark
Tag and mark hoses before removal to ensure correct
assembly. 
Plug all hydraulic hoses and fittings after removal to pre-
vent contamination.

2. Open the hydraulic tank vent to release the pressure in the tank.
3. Remove three hoses (1), (2), and (3) from the anti-cavitation valve
(4).
4. Remove hose (6) from the swing motor (5).
5. Remove hose (7) from the brake housing (8).
6. Attach a suitable lifting device to the swing motor/gearbox (9).

7. Remove twenty-four bolts (10) and washers (11) from the swing
motor/gearbox (9).
8. Remove the swing motor/gearbox (9) from the mounting plate (12)
using a suitable lifting device.

Swing motor/gearbox: 145 kg (320 lb)

Installation

1.Transfer the anti-cavitation valve and hydraulic fittings from the

old swing motor/gearbox to the new swing motor/gearbox.
★ Refer to the List of Adhesives for sealants used on the fittings.
2. Remove drain hose and fittings from old swing motor/gearbox (9).
Install them on the new swing motor/gearbox.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-51
DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM
3. Place swing motor/gearbox (9) onto mounting plate (12) locating
the eccentric mark on the gearbox flange, toward the right side of
the machine (sixth hole back CW).
4. Install swing motor/gearbox (9) onto mounting plate (12) using
twenty-four bolts (10) and washers (11).
5. Install hose (7) onto brake housing (8).
6. Install hose (6) onto swing motor (5).
7. Install three hoses (1), (2), and (3) onto anti-cavitation valve (4).
8. Fill to the full mark on the dipstick with gear oil. Fill the gearbox
through the dipstick opening (13).

Shell Omala S4 GX 220 or equivalent. 4.3 l (4.5 US qt)

★ See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

SWING BEARING

WARNING! Read and follow the safety instructions in this manual before performing these 
procedures. Failure to comply could cause injury or death.

WARNING! Relieve hydraulic pressure before servicing any hydraulic component. 

Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.

WARNING! Wait for the hydraulic fluid to cool before servicing any hydraulic component. 
Hot hydraulic fluid can cause severe burns.

WARNING! The entire upper part of the machine must be removed from the car body to replace the swing bear-
ing. 
Use a suitable lifting device, lifting bar, and chains or straps that can support 20,000 lb (9,072 kg).

Removal
1. Refer to Stick Arm Removal, and remove the stick arm from the boom.
Remark
Remove the guard in the next step so a lifting strap or
chain can be attached to the rear top corner of the engine
compartment frame (1).

2. Remove three bolts (2) and washers (3), and guard (4) from the top
rear of the hydraulic tank (5)

3. Attach a lifting bar (1) to a suitable lifting device and attach chains
or straps that can support 20,000 lb (9,072 kg) in three places as
shown. 

Entire upper part of the machine:

20,000 lb (9,072 kg)

Attach one chain to the front right of the cab (2), one chain to the
rear of the engine compartment frame (3), and one chain to the
base end guard of the boom (4).

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-53
DISASSEMBLY AND ASSEMBLY SWING BEARING

4. Refer to Rotary Manifold Removal, and remove the hydraulic

hoses from the rotary manifold on the leveling machines. Remove
the hydraulic hoses required to separate the upper from the car
body on the non-leveling machines.

5. Remove 30 socket head capscrews (1) from the swing bearing (2).

6. Remove the upper machine from the car body with the lifting
device and set it on supports that can support 20,000 lb (9,072 kg).

7. Remove twenty-four bolts (3), washers (4), and spacers (5) from
swing bearing support (6).
Remark

Swing bearing: 725 lb (329kg)

The swing bearing weighs approximately 725 lb (329 kg). Use a suitable lifting device to remove the swing
bearing in the next step.

8. Attach three eyebolts to the swing bearing (2) and remove the swing bearing from support (6).

9. Dispose of grease remaining in the grease bath.

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DISASSEMBLY AND ASSEMBLY SWING BEARING
Installation

WARNING! The entire upper part of the machine must be installed on the car body.
Use a suitable lifting device, lifting bar, and chains or straps that can support 20,000 lb (9,072 kg).

Entire upper part of the machine: 20,000 lb (9,072 kg)

★ No inner or outer swing bearing bolt may be reused, it must be

replaced with a new bolt. The thread hole must be cleaned with
degreaser to remove oil and grease.
Remark
The bolt hole pattern on the swing bearing must meet the
bolt hole pattern on the swing bearing support and upper
revolving frame.

1. Refer to Removal and set the swing bearing (1) onto support (5)
with the lifting device and fasten it to support with spacers (2),
washers (3), and bolts (4).

Mating face of swing circle support: LG-6

Threads of swing circle mounting bolts: LT-2

Remark
Follow the torque chart to fasten the swing bearing to the
support (car body or revolving frame casting). Use Grade
9 hex head capscrews with a minimum tensile of 180,000
psi. Torque the first 8 bolts in a crossing star pattern
according to the Figure.

Swing bearing to the support: 930 lbf ft (1,261 N•m)

Mating face of swing circle: LG-6

2. Attach a lifting bar (1) to a suitable lifting device and attach chains
or straps that can support 20,000 lb (9,072 kg) in three places as
shown in Removal. Attach one chain to the front right of the cab
(2), one chain to the rear of the engine compartment frame (3), and
one chain to the base end guard of the boom (4).
3. Set the upper machine on the swing bearing with the lifting device
and align the bolt holes.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-55
DISASSEMBLY AND ASSEMBLY SWING BEARING

Remark
Follow the torque chart to fasten the swing bearing to the
revolving frame. Use ASTM A574 socket head cap-
screws with a minimum tensile of 170,000 psi (11,952.58
km/cm2). Torque to 900 lbf ft. Torque the first eight bolts
in a crossing star pattern according to the chart.

Swing bearing to revolving frame: 900 lbf ft (1,220.24

N•m)

Threads of revolving frame mounting bolts: LT-2

4. Fasten the swing bearing to the bottom of the revolving frame with
30 socket head capscrews (1). Refer to Removal.

5. Remove the chains from the machine and the lifting device.

6. Refer to “Rotary Manifold, Removal” and install the hydraulic hoses on the rotary manifold on the leveling machines.
Install the hydraulic hoses required on the non-leveling machines.

7. Install guard (4) on the top of hydraulic tank (5) with three washers
(3) and screws (2).

8. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Fill and Check Swing Pinion Grease Level
Quantity of grease in grease bath: G2-L1
11.5 l (3 US gal)

1. Remove panel from the side of the dash console. Locate cover (4) at
the front underneath the console.

4
SR0071
2. Remove two bolts (3) on the top of the revolving frame and remove
cover (4).

3. Insert scale (5) into the grease through inspection and adjustment
hole (A). Check that the height of grease (S) in the area passing the
pinion is at least 9 mm (0.355 in). Add grease if the level is low.
4. Install cover (4) with bolts (3).
5. Install foam (2) and floor mat (1).

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Revolving Frame Casting
Removall

WARNING! The entire upper part of the machine must be removed from the car body to replace the swing bear-
ing. 
Use a suitable lifting device, lifting bar, and chains or straps that can support 20,000 lb (9,072 kg).

1. Refer to Swing Bearing Removal and remove upper machine and Swing Bearing.

2. Dispose of grease and remove grease bath from swing bearing support.
Remark
Tag and mark the hoses before removal to ensure correct
installation.

3. Remove the hydraulic hoses from the bottom of the rotary mani-
fold (1).

4. Attach suitable chains or lifting straps to the rotary manifold (1).

5. Remove four locknuts (2), eight washers (3), and four bolts (4),
and remove the rotary manifold (1) from the revolving frame cast-
ing with a suitable lifting device.
Remark
The revolving frame casting weighs 1,100 lb (499 kg).
Attach a suitable lifting device to support the revolving
frame casting in the following steps.

Revolving frame casting: 1,100 lb (499 kg)

6. See the “Leveling Cylinder, Removal” in this section of the manual and remove the rod end of the leveling cylinders from
the revolving frame casting.

7. Remove the front pin grease lines (1).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
8. Remove two jam nuts (1) and screws (2) from the
intermediate leveler (3).

9. Remove the locknut (4) and washer (5) from the

front pin (6).

10. Remove six bolts (7), washers (8), and center bolt
lock (9) from the tapered hub (10).

11. Remove the center bolt (11) and tapered hub cap
(12).

12. Use a chisel and remove the tapered hub (10) from
the pin.

13. Repeat the above steps to remove the rear tapered hub assembly.

14. Remove the front pin (6) and slack adjuster plate (12) from the
assembly. Tap on the threaded end to remove pin.

15. Remove the rear pin (13) from the assembly. Tap on the threaded
end to remove pin.
Remark
The revolving frame casting weighs 1,100 lb (499 kg).
Use a suitable lifting device to remove the revolving
frame casting in the following step.

Revolving frame casting: 1,100 lb (499 kg)

16. Remove the revolving frame casting (14) from the intermediate leveler (3) with the lifting device.

17. Inspect the bushings (15 and 16) for wear and replace if required.

18. Clean and inspect all parts for wear and replace if required.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Installation

1. Apply grease to the center area of the pins (6) and (13). Apply anti-seize to the pin threads.

Apply grease to the center area of the pins (6) and (13). 
Apply anti-seize to the pin threads.

Remark
The revolving frame casting weighs 1,100 lb (499 kg). Use a suitable lifting device to place the revolving
frame casting on the intermediate leveler in the following step.

Revolving frame casting: 1,100 lb (499 kg)

2. Attach suitable chains or lifting straps to the revolving frame casting (14) and place the casting on the intermediate leveler
(3) with a suitable lifting device.

3. Install the tapered hub (10) on pin (6). Use a chisel to spread the hub.

4. Place the slack adjuster plate (12) between the front of the revolving frame casting (14) and the intermediate leveler (3) as
shown. Then install the front pin (6) and fasten with washer (5) and locknut (4).

5. Install the tapered hub cap (12) on the tapered hub with five of the washers (8) and bolts (7). Leave one bolt out for the
center bolt lock (9) to be installed.

6. Install the center bolt (11).

Torque all the bolts to 100 lbf ft (136 N•m).

7. Install center bolt lock (9) with washer (8) and bolt (7).

Torque the bolt to 100 lbf ft (136 N•m).

8. Repeat the above steps to install the rear pin (13) and the rear tapered hub assembly.
Remark
There is no slack adjuster in the rear pin assembly.

9. Install the slack adjuster screws (2) and tighten until there is no slack between the revolving frame casting (14) and the
intermediate leveler (3). Then install the jam nuts (1).

10. See the “Leveling Cylinder, Installation” and install the rod end of the leveling cylinders on the revolving frame casting.

11. Install the front pin grease lines (1).

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12. Attach suitable chains or lifting straps to the rotary manifold (1)
and place the manifold on the revolving frame casting with a suit-
able lifting device.

13. Install the rotary manifold (1) on the revolving frame casting with
four bolts (2), eight washers (3), and locknuts (4).

14. Install the hydraulic hoses on the lower portion of the rotary mani-
fold.

WARNING! The entire upper part of the machine must

be removed from the car body to replace
the swing bearing. 
Use a suitable lifting device, lifting bar, and
chains or straps that can support 20,000 lb
(9,072 kg).

15. Install grease bath onto swing bearing support.

16. See "Swing Bearing Installation" and install swing bearing and upper machine.

Mating face of swing bearing support: LG-6

17. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Intermediate Leveler
Removal

1. See “Revolving Frame Casting, Removal” and remove the revolv-

ing frame casting.

2. Remove all the grease lines from the intermediate leveler (1).

3. Remove two jam nuts (2) and slack adjuster screws (3).

Remark
The intermediate leveler is attached with two pins with
tapered hubs on each side of the pins. Both pin assem-
blies are removed the same. The left side has a slack
adjuster.

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12

Use a suitable lifting device and chains or straps that can support 1,210 lb (549 kg) before removing the pin
assemblies from the intermediate leveler. Failure to comply could result in personal injury or death.
4. Attach chains or lifting straps from a suitable
lifting device to the intermediate leveler (10).

Intermediate leveler: 1,210 lb (549 kg)

5. Remove six bolts (1), washers (2), and center

bolt lock (3) from the tapered hub (4).

6. Remove the center bolt (5) and tapered hub cap

(6).

7. Use a chisel and remove the tapered hub (4)

from the pin (7).

8. Repeat the above steps to remove the tapered

hub assembly from the inside of pin (7).

9. Repeat the above steps to remove the tapered

hub assemblies from the left side pin (8).
Remark
Make sure the chains and/or straps are
tight enough to support the intermediate
leveler before performing the following
step.

10. Remove both pins (7) and (8), and slack adjuster
plate (9), from left side pin (8).

11. Remove intermediate leveler (10) with the lifting device.

12. Clean and inspect all parts for wear and replace if required.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Installation
Apply Mobilgrease XHP 322 Mine grease to the pins before installation.

1. Spread the tapered hub (1) with a screwdriver and install the hub
on pin (2).
Remark
Leave a 3/16 inch (4.8 mm) gap from the face of the
tapered hub to the end of the pin as shown.
Remark
The pin cannot be tight against either end of the pin or
there will be no space for adjustment of wear in the
assembly. The tapered pin assemblies must be torqued
to 100 lbf ft (135 N•m) at the intervals specified in the
Operation and Maintenance Manual or shown on the
decal in the rear pump compartment.

2. Install the tapered hub cap (1) with center bolt (2) on pin (3).
Remark
Only tighten the center bolt so the tapered hub cap is
snug. 
Do not tighten any more than snug or the gap will be
removed between the pin and the tapered hub cap.

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3. Install the pin (8) with the tapered hub into the
left side pin hole from the out side of the car
body (11) and through the slack adjuster (9) and
intermediate leveler (10).

4. Repeat steps 1, 2, and 3 for the right side of the

intermediate leveler (10).
Remark
The slack adjuster (9) is only on the left
side.

5. Install the tapered hubs and center bolts on the

inside of the pins on both sides.
Remark
Alternately tighten the center bolt on the
inside and outside tapered hub equally to
leave a gap between the tapered hub
caps and each end of the pin.

6. Install the center bolt lock (3), six washers (2),

and bolts (1) on all the tapered hub assemblies.
Torque the six tapered hub bolts (1) to 100 lb ft
(135 N•m).

Six tapered hub bolts (1):

100 lbf ft (135 N•m)

7. Install the slack adjuster screws (12) into the car

body (11) and alternately screw them into the slack adjuster plate (9) until the intermediate leveler is moved to the right
side and the slack is removed. Then lock them with the jam nuts (13).

8. Install the grease lines (1) on the intermediate leveler and slack
adjuster.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

9. See “Revolving Frame Casting, Installation” and install the revolv-

ing frame 
casting and the upper portion of the machine.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Auxiliary Pump
★ Depending on the machine attachment, a 45 or 71 cc pump may be
used as an auxiliary pump on the machine.

45 cc Auxiliary Pump Removal

1. Open the hydraulic tank vent to release the pressure in the tank.

2. Close the auxiliary pump suction line shut-off valve (1) (shown in
the open position).

Remark
Tag and mark hydraulic hoses and fittings before removal
to ensure correct assembly. 
Plug hoses and fittings after removal.

3. Remove the case drain hose (1) from the auxiliary pump (2).

4. Remove suction hose (3) from the auxiliary pump (2).

5. Remove the pressure hose (4) from the auxiliary pump (2).

6. Remove two tees (1) and (2) with hoses attached from auxiliary
pump (3).

7. Remove two bolts (4), washers (5), and auxiliary pump (3) from
implement pump flange (6).

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DISASSEMBLY AND ASSEMBLY SWING BEARING

45 cc Auxiliary Pump Installation

★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

1. Remove O-ring (1) from the implement pump flange (2) and
replace with a new O-ring.

2. Check thru drive coupling (3) and replace if required.

Remark
Note the orientation of the fittings on the auxiliary pump
before removal to ensure the correct installation on the
new auxiliary pump. 
Replace O-rings during installation.

3. Remove all the fittings from the auxiliary pump and install the fit-
tings on the new auxiliary pump.

4. Install the auxiliary pump (3) on the implement pump flange (6)
with two washers (5) and bolts (4).

5. Install the two tees (1) and (2) with hoses attached on the auxiliary
pump (3).

6. Install pressure hose (4) on auxiliary pump (2).

7. Install suction hose (3) on auxiliary pump (2).

8. Install case drain hose (1) on auxiliary pump (2).

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9. Open the auxiliary pump suction line shut-off valve (1) (shown in
the open position).

10. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

11. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

12. Refer to “Auxiliary Implement Pump Pressure Settings” to set the

stand-by and PCO pressures.

71 cc Auxiliary Pump Removal

1. Open the hydraulic tank vent to release the pressure in the tank.

2. Close the auxiliary pump suction line shut-off valve (1) (shown in the open position).

3. Remove the case drain hose (1) from auxiliary pump (2).

4. Remove the suction hose (3) from the auxiliary pump (2).

5. Remove the pressure hose (4) from the auxiliary pump (2).

6. Remove load sense hose (1) from auxiliary pump (2).

7. Remove two bolts (3), washers (4), and auxiliary pump (2) from
implement pump flange (5).

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
71 cc Auxiliary Pump Installation
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

1. Remove O-ring (1) from implement pump flange (2) and replace
with a new O-ring.

2. Check thru drive coupling (3) and replace if required.

Remark
Note the orientation of the fittings on the auxiliary pump
before removal to ensure the correct installation on the
new auxiliary pump. Replace O-ring during installation.
Remark
Follow the “Hydraulic Fitting Torque Values” in Section 30
of this manual to torque the fittings.

3. Remove all the fittings from the auxiliary pump and install the fit-
tings on the new auxiliary pump.

4. Install the auxiliary pump (2) on the implement pump flange (5)
with two washers (4) and bolts (3).

5. Install the load sense hose (1) on the auxiliary pump (2).

6. Install the pressure hose (1) on the auxiliary pump (2).

7. Install the suction hose (3) on the auxiliary pump (2).

8. Install the case drain hose (4) on the auxiliary pump (2).

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9. Open the auxiliary pump suction line shut-off valve (1) (shown in
the open position).

10. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

11. Refer to “Auxiliary Implement Pump Pressure Settings” to set the

stand-by and PCO pressures.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Implement Pump
Removal

1. Open the hydraulic tank vent to release the pressure in the tank.

2. Refer to “Auxiliary Pump, Removal” and remove auxiliary pump

(1) from implement pump (2).

3. Close the implement pump suction line shut-off valve (3) (shown
in the open position).

4. Remove case drain hose (4) from implement pump (2).

5. Remove test gauge hose (5) from implement pump (2).

6. Remove suction hose (6) from implement pump (2).

7. Remove load sense hose (1) from the other side of the implement
pump (2).

8. Remove pressure hose (3) from implement pump (2).

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9. Remove four Allen head capscrews (1) and implement pump
flange (2) from implement pump (3).

10. Remove thru drive coupling (4) from implement pump (3).

Remark
Note the orientation of the fittings before removal to
ensure correct assembly.

11. Remove all the fittings from implement pump (1).

12. Wrap a lifting strap around the implement pump and attach the
strap to a suitable lifting device. Raise the lifting device so the
strap is tight to prevent the implement pump from falling when the
attaching hardware is removed.

13. Remove four nuts (2) and washers (3) from implement pump (1).

14. Remove implement pump (1) from transmission (2) using the lift-
ing device.

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12
Installation

1. Install new O-ring (1) on implement pump (2) and place the imple-
ment pump on the transmission using a suitable lifting device. Use
a pliers to turn the shaft to align the spline.

2.Install the implement pump to the transmission with four washers

(3) and nuts (2).
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

3. Install all the fittings on the implement pump in the orientation

noted before removal.

4. Install new O-rings (1) on the implement pump flange.

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5. Install implement pump flange (2) on implement pump (3) with
four Allen head capscrews (1).

6. Install thru drive coupling (4) onto implement pump (3).

7. Install load sense hose (3) and pressure hose (1) on implement
pump (2).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
8. Install load sense hose (5), case drain hose (4), and suction hose (6)
on implement pump (2).

9. See the “Auxiliary Pump, Installation” procedure and install the

auxiliary pump (1) onto implement pump (2).

10. Open implement pump suction line shut-off valve (3). Shown in
the open position. Also open the auxiliary pump suction line shut-
off valve.

11. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

12. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

13. Refer to “Implement Pump Pressure Settings”. Set the stand-by

and PCO pressures.

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12
Auxiliary Oil Cooler Fan Pump
Removal

1. Open the hydraulic tank vent to release the pressure in the tank.

2. Close the auxiliary oil cooler fan pump suction line shut-off valve
(1). Shown in the open position.

3. Remove hose (1) from fitting (2).

4. Remove hose (3) from fitting (4).

5. Remove two bolts (5), washers (6), and fan pump (7) from left
track drive pump (8).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
6. Remove coupler (1). Clean and inspect for wear. Replace if
required.

Installation

1. Grease and install the drive coupling (1) on the left drive pump
shaft.
Remark
Installing new O-rings is recommended during installa-
tion.
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.

2. Remove O-ring (2) and replace it with a new one.

3. Install new hydraulic fittings (2) and (4), on the new fan pump in
the orientation shown.

4. Install fan pump (7) on left drive pump (8) with two washers (5)
and bolts (6).

5. Install hose (1) on fitting (2).

6. Install hose (3) on fitting (4).

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7. Open auxiliary oil cooler fan pump suction line shut-off valve (1)
(shown in the open position).

8. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

9. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

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12
Charge Pump
Removal
★ The charge pump is located on the bottom right side of the pump
compartment and is attached to the right side drive pump.
Remark
Tag and mark, plug or cap all hydraulic hoses and fittings
after removal.

1. Open the hydraulic tank vent to release the pressure in the tank.

2. Close charge pump suction line shut-off valve (1) (shown in the
open position).

3. Remove pressure hose (1) from fitting (2).

4. Remove pressure hose (3) from elbow (4).

5. Remove suction hose (5) from fitting (6).

6. Remove the hydraulic fittings from charge pump (3).

7. Remove two bolts (1), washers (2) and charge pump (3) from right
drive pump (4).

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8. Remove coupler (1). Clean and inspect for wear. Replace if
required.

Charge Pump Installation

1. Grease and install drive coupling (1) on the right drive pump shaft.
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.
Remark
Apply a light coat of grease to O-ring (2) before installa-
tion.

2. Remove O-ring (2) and replace with a new O-ring.

3. Install charge pump (3) onto right side drive pump (4) with two
washers (1) and bolts (2).

4. Install the hydraulic fittings on the charge pump in the orientation

shown.

5. Install suction hose (5) on fitting (6).

6. Install pressure hose (3) on elbow (4).

7. Install pressure hose (1) on fitting (2).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
8. Open charge pump suction line shut-off valve (1) (shown in the
open position).

9. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

10. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

Right Side Drive Pump

Removal

1. Refer to “Charge Pump, Removal” and remove the charge pump

from the right side drive pump.

2. Remove the pump access cover from the bottom of the upper
revolving frame.
Remark
Tag and mark hoses before removal to ensure correct
installation. Plug or cap all hydraulic hoses and fittings
after removal.

3. Remove top right side pressure hose (1) from fitting (2).

4. Remove bottom left side pressure hose (1) from fitting (2). Access
this hose from the bottom of the pump.

5. Remove charge hose (3) from elbow (4). Access this hose from the
bottom of the pump.

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6. Remove case drain hose (1) from fitting (2). Access this hose from
the bottom of the pump.

7. Remove pressure test hose (1) from fitting (2). Access this hose
from the top of the pump.

8. Remove all the fittings from the pump before removing the pump
from the transmission.

9. Attach a suitable lifting strap to the pump and attach the strap to a
suitable lifting device.

10. Ensure the straps to the lifting device are tight enough to support
the pump when the bolts are removed. Remove four bolts (1) and
washers (2).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
11. Remove the pump from the transmission with the lifting device.

12. Remove O-ring (1) from the pump.

Installation
Remark
The new pump includes the adapter and coupling to
attach the charge pump. The pump does not include the
O-ring that is installed between the pump and the 
transmission. 
The O-ring should be replaced with a new O-ring.
★ Refer to the List of Adhesives for sealants used on the fittings.
★ Refer to Standard Tightening Torque for torque specification
charts.
Remark
Install new O-rings during installation.

1. Apply a light coat of multi-purpose grease to the mounting surface

of transmission and O-ring (1).

2. Install O-ring (1) onto the pump.

3. Position the pump (with port Fa up) on the transmission using the
lifting device.

4. Remove relief valve (1) from port Fa to allow an elbow to be

installed.

5. Install elbow onto pump next to port Fa.

6. Then re-install relief valve (1) into port Fa.

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7. Rotate the pump as required to install the hydraulic fittings before
attaching the pump to the transmission.

8. Remove plug (1) from the M1 port on the pump.

9. Install elbow (2) in the M1 port and position as shown.

10. Remove plastic plug (1) from port T1.

11. Remove plug from port T2 and install plug (2) into port T1.

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DISASSEMBLY AND ASSEMBLY SWING BEARING
12. Install fitting (1) into port T2.

13. After the fittings are installed in the positions shown, install the
pump to the transmission in position shown with four washers (1)
and bolts (2).

14. Install pressure test hose (1) into elbow (2) in the M1 port. Access
this port from the top of the pump.

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15. Install case drain hose (1) onto fitting (2) in port T2.

16. Install bottom left side pressure hose (1) onto fitting (2).

17. Install charge hose (3) onto elbow (4).

18. Install top right side pressure hose (1) onto fitting (2).

19. Refer to “Charge Pump Installation” procedure in this section of

the manual and install the charge pump on the right side drive
pump.

20. Open the charge pump suction line shut-off valve.

21. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

22. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

23. Refer to “Hydraulic Main Track Drive Relief Adjustment” and

“Track Drive Pump Null Adjustment”.

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DISASSEMBLY AND ASSEMBLY SWING BEARING

12
Left Side Drive Pump
Removal

1. If equipped with an auxiliary oil cooler fan pump, refer to “Auxiliary Oil Cooler Fan Pump” procedure and remove the
fan pump from the left side drive pump.

2. Remove the pump access cover from the bottom of the upper revolving frame.
Remark
Tag and mark hoses before removal to ensure correct installation.
Plug or cap all hydraulic hoses and fittings after removal.
Remark
Release pressure in the hydraulic oil tank by opening the hydraulic tank vent.
Pressure on the hydraulic tank must be released before beginning any work on the hydraulic system.

3. Remove top right side pressure hose (1) from fitting (2).

4. Remove bottom left side pressure hose (1) from fitting (2). 
Access this hose from the bottom of the pump.

5. Remove charge hose (3) from elbow (4). 

Access this hose from the bottom of the pump.

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DISASSEMBLY AND ASSEMBLY SWING BEARING
6. Remove case drain hose (1) from fitting (2). 
Access this hose from the bottom of the pump.

7. Remove pressure test hose (1) from fitting (2). 

Access this hose from the top of the pump.

8. Remove all the fittings from the pump before removing the pump
from the transmission.

9. Attach a suitable lifting strap to the pump and attach the strap to a
suitable lifting device.

10. Ensure the straps to the lifting device are tight enough to support
the pump when the bolts are removed. 
Remove four bolts (1) and washers (2).

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DISASSEMBLY AND ASSEMBLY SWING BEARING
11. Remove the pump from the transmission with the lifting device.

12. Remove O-ring (1) from the pump.

Installation
Remark
The new pump includes the adapter and coupling to
attach the charge pump. The pump does not include the
O-ring that is installed between the pump and the trans-
mission. The O-ring should be replaced with a new O-
ring.
Remark
Refer to “General Instructions” for the type of sealant to
use on the fittings and torque specification charts. 
Installing new hydraulic fittings is recommended if the 
fittings have O-rings.

1. Apply a light coat of multi-purpose grease to the mounting surface

of the transmission and O-ring (1).

2. Install O-ring (1) onto the pump.

3. Position the pump (with port Fa up) on the transmission using the lifting device.

4. Remove relief valve (1) from port Fa to allow an elbow to be

installed.

5. Install elbow (1) onto the pump next to port Fa.

6. Then re-install relief valve (1) into port Fa.

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7. Rotate the pump as required to install the hydraulic fittings before
attaching the pump to the transmission.
Remark
Apply a light coat of grease or oil to O-rings before 
installation. Installing new hydraulic fittings is recom-
mended if the fittings have O-rings.

8. Remove plug (1) from the M1 port on the pump.

9. Install elbow (2) into port M1 and position as shown.

10. Remove plastic plug (1) from port T1.

11. Remove the plug from port T2 and install plug (2) into port T1.

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DISASSEMBLY AND ASSEMBLY SWING BEARING
12. Install fitting (1) into port T2.

13. After the fittings are installed in the positions shown, install the
pump onto the transmission (as shown) with four washers (1) and
bolts (2).

14. Install pressure test hose (1) onto elbow (2) in port M1. 
Access this port from the top of the pump.

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DISASSEMBLY AND ASSEMBLY SWING BEARING
15. Install case drain hose (1) onto fitting (2) in port T2.

16. Install bottom left side pressure hose (1) onto fitting (2).

17. Install charge hose (3) onto elbow (4).

18. Install top right side pressure hose (1) onto fitting (2).

19. Refer to the “Charge Pump Installation” and install the charge
pump on the right side drive pump.

20. Open the charge pump suction line shut-off valve.

21. Refer to “Machine Start-Up After Hydraulic Component Replace-

ment” to remove air from the hydraulic system.

22. Check the oil level in the hydraulic tank and add hydraulic oil if
necessary.

23. Refer to “Hydraulic Main Track Drive Relief Adjustment” and

“Track Drive Pump Null Adjustment” and set the adjustments.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

12
FINAL DRIVE ASSEMBLY
Removal
Remark
The drive motor and the final drive planetary are one assembly and must be removed as an assembly. 
The left side is shown. The right side is removed the same as the left side final drive.
Remark
Tag and mark the hydraulic hoses before removing to ensure correct installation.

1. Remove seven bolts (1), washers (2), and cover (3) from housing
(4).

2. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent.

WARNING! Pressure on the hydraulic tank must be

released before beginning any work on the
hydraulic system.

3. Remove five hydraulic hoses (1), (2), (3), (4), and (5) from the fit-
tings.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
4. Remove two split flange fittings (1) from the top and bottom of the
drive motor.

5. Remove elbow (2) form the drive motor.

6. Remove elbow (3) from the drive motor.

7. Remove fitting (4) from the drive motor.

8. Refer to “Drive Sprocket Removal” and remove the drive

sprocket.

Remark
The final drive assembly weighs:
500 kg (1,103 lb) for XT430-3 and XT430L-3, 
700 kg (1544 lb) for XT445L-3 and XT460L-3. 
Use a suitable lifting device and strap that can handle this
weight.

9. Remove twenty four bolts (6) and use a suitable lifting strap and
lifting device to remove the final drive assembly (7) from the track
frame.

10. The final drive can be serviced. 

The drive motor cannot be serviced and must be replaced with a
rebuilt motor from Komatsu.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

12
Disassembly

WARNING! Make sure to read and understand all operational warnings shown in the Safety Section of this
manual. Additional safety precautions will be included in this section as required by the operation
being discussed.

Remark
The drive motor cannot be removed until the final drive gears are removed from the final drive. 
The bearing nut can only be accessed after the gears are removed.

1. Drain the oil from the final drive hub.

2. Secure the final drive in a fixture as shown so the final drive can be
rotated as required.
Remark
Place the final drive on blocks with the final drive cover
up as shown if a fixture is not available.

3. Remove 16 bolts (1) from the final drive cover. Screw in two tees
(2) for attaching lifting straps.

4. Remove the cover from the final drive.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
5. Remove spacer.

6. Remove number 1 carrier assembly (1).

7. Remove spacer (1), number 1 sun gear shaft (2), and number 2 sun
gear (3).

8. Remove thrust washer (1).

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
9. Remove number 2 carrier assembly.

10. Remove two bolts and bearing nut lock plate (1).

Remark
The bearing nut has three holes (1) on the top for pins on
the bearing nut tool to fit into for removal.

Bearing nut tool.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

12
11. Place the bearing nut tool on the bearing nut. Ensure that the three
pins on the bottom of the tool are in the holes on the nut.

12. Clamp the tool in place with bar (1) and a tee threaded into one of
the holes on the motor.

13. Loosen the bearing nut.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
14. Remove the bearing nut.

15. Lift the planetary hub off of the motor.

16. Remove seal and O-ring, (1) and (2) from the planetary hub.

17. Remove bearing (3) from hub.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
18. Remove bearing (1) and collar (2) from the motor.
Remark
In some cases a puller will be required to remove the
bearing and collar.

19. Remove O-ring and seal, (3) and (4).

20. Remove bearings (1) and (2) from the hub.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

12
Disassembly of Number 1 Carrier

1. Push in pin (5) to drive out shaft (6) from carrier (7). 
Remove pin (5) after removing shaft (6).

2. Remove thrust washer (8), gear (9), bearing (10), and thrust
washer (11).

Assembly of Number 1 Carrier

Remark
A mark was made when the pin was inserted at the end
of the carrier side hole h. The inside wall of the hole is
swelled at that mark. Flatten the swelled part before
assembly.

1. Install bearing (10) in gear (9) and fit top and bottom thrust wash-
ers (8) and (11), and then set the gear assembly to carrier (7).

Remark
When installing the shaft, revolve the planetary gear and
take care not to damage the thrust washers.

2. Align the pin holes of shaft (6) and carrier, then lightly hit the shaft
with a plastic hammer to install.

3. Insert pin (5). Caulk the pin part of the carrier after inserting the
pin.

4. Check that gear (9) turns smoothly.

Disassembly of Number 2 Carrier

1. Push in pin (16) to drive out shaft (17) from carrier (18). Remove
pin (16) after removing shaft (17).

2. Remove thrust washer (19), gear (20), bearing (21), and thrust
washer (22).

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

12
Assembly of Number 2 Carrier
Remark
A mark was made when the pin was inserted at the end
of the carrier side hole h. The inside wall of the hole is
swelled at that mark. Flatten the swelled part before
assembly.

1. Install bearing (21) in gear (20) and fit top and bottom thrust wash-
ers (19) and (22). Then, set the gear assembly to carrier (18).

Remark
When installing the shaft, revolve the planetary gear and
take care not to damage the thrust washers.

2. Align pin holes of shaft (17) and carrier, then lightly hit the shaft
with a plastic hammer to install.

3. Insert pin (16). Mark the pin part of the carrier after inserting the
pin.

4. Check that gear (20) turns smoothly.

Assembly
Remark
Clean all the parts and check them for dirt or damage. 
Replace damaged parts with new parts. 
Coat the sliding surfaces of the parts with engine oil
before assembly.

Hub Assembly

1. Using the push tool (part # 85478), press fit bearings (1) and (2)
into the hub.
Remark
Thoroughly degrease and dry the O-ring and O-ring fitting
surface of the seal before installing.

2. Install O-ring (1) into seal (2) and install the O-ring and seal onto
the hub.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
3. After installing the O-ring and seal, check that the slant is less than
0.039 inches (1 mm).

4. Apply a thin coat of engine oil to the sliding surfaces of the seal.

Remark
Thoroughly degrease and dry the O-ring and O-ring fitting
surface of the seal before installing.

5. Install O-ring (1) into seal (2) and install the O-ring and seal onto
the motor.

6. After installing the O-ring and seal, check that the slant is less than
0.039 inches (1 mm).

7. Apply a thin coat of engine oil to the sliding surfaces of the seal.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
8. Install collar onto motor.

9. Apply engine oil on the motor where the bearing will be installed.

10. Install the bearing on the motor. 

Tap the bearing with a plastic rod and hammer until the bearing is
seated on the collar.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
11. Check that the bearing is seated on the collar all the way around
with a feeler gauge. 
There should be no gaps between the bearing and collar.

12. Lower the hub onto the motor.

13. Apply oil to the sides of the motor.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
14. Install the bearing onto the motor and tap it into place with a plas-
tic rod and hammer.

15. Apply engine oil on the bearings. All the rollers should well lubri-
cated and the sliding surface of the bearing where the bearing nut
seats should have a thin coat of oil.

16. Install the bearing nut (1).

Remark
The bearing nut has three holes (1) on the top for pins on
the bearing nut tool to fit into for installation.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

17. Place the bearing nut tool on the bearing nut. Make sure that the
three pins on the bottom of the tool are in the holes on the nut.

18. Clamp the tool in place with a bar (1) and a tee threaded into one
of the holes on the motor.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
19. Tighten the bearing nut with a torque wrench.

Bearing nut: 620 lbf ft (840.6 N•m)

20. Rotate the hub 2 to 3 turns in one direction.

Remark
In the following step, measure from top of motor (1) down
through the threaded hole in bearing nut to the top of the
bearing (2) using a digital gauge as shown. Place the
needle end of the gauge through the hole in the bearing
nut to the top of the bearing (2). And place the caliper end
on the top of the motor (1).

21. Measure from top of motor (1) to top of bearing (2) for
dimension b.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
22. Then, tighten until the bearing nut will not turn anymore while the
hub is being rotated at least 5 turns in one direction.

Bearing nut: 620 lbf ft (840.6 N•m)

Remark
In the following step, measure the same as in the previ-
ous step.

23. Measure from top of motor (1) to top of bearing (2) for
dimension a.

24. Subtract dimension b from dimension a to get dimension c.

Dimension c should be – 0.001 to +0.003 inch (–0.03 to +0.07
mm). This is the preload on the bearings.

25. Rotate the hub and check that all the rollers in the bearing are
rotating and that the bearing cage does not bind.

26. Using a push-pull gauge, measure the tangential force of the hub in
its revolving direction on the motor case. Maximum force is 172 lb
(78 kg).
Remark
The tangential force means the maximum force at the
beginning of rotation.

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27. Install the bearing lock (1). Use Loctite 262 on bolts.

Bearing lock bolts: 50 lbf ft (67 N•m)

28. Install the number 2 carrier assembly.

29. Install the thrust washer (1) and number 2 sun gear (2).

30. Install spacer (1) on sun gear.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
31. Install the number 1 carrier assembly.

32. Install spacer (1) and number 1 sun gear shaft (2).

33. Apply Komatsu Silicone Gasket LG-6 to the hub before installing
cover.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
34. Install the cover.

Torque the cover bolts.

Cover bolts: 85 lbf ft (115 N•m)

Installation

Remark
Refer to “General Instructions” for the type of sealant to
use on the fittings and torque specification charts. 
Installing new hydraulic fittings is recommended if the 
fittings have O-rings.

1. Install the final drive assembly onto the track frame in the reverse
order of removal.

Apply LT-2 to the mounting bolts and torque to 

361 to 448 lbf ft (490 to 608 N•m).

2. Install the new hydraulic fittings as shown in the removal proce-

dure.

3. Install five hydraulic hoses (1), (2), (3), (4), and (5) on the fittings.

4. See “Vent Air From Hydraulic System” on page 50-41.

5. Check the oil level in the hydraulic tank and add hydraulic oil if necessary.

6. Install the drive motor cover.

7. Refer to “Drive Sprocket Installation” and install the drive sprocket.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
8. Locate the final drive oil fill and level plugs (1) as shown.

WARNING! Overfilling the track final drive will cause the

track motor seals to allow hydraulic oil or water
to enter and contaminate the track drive motor.

9. There are two plugs (1). Add oil through the one that is easier to
fill and no internal gears are seen.

10. Remove the plug from the level port (1).

11. Fill with oil until the level is 0.4 inches (10 mm) below the bottom
of the plug hole (1).

12. Clean the port plugs. Inspect the O-ring seals and replace if dam-
aged.

13. Reinstall the port plugs.

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

12
MAIN CONTROL VALVE
Removal
Main control valve sections can be replaced without disconnecting all the hoses and removing the control valve from the
machine.

1. Hook a winch (1) to one of the holes in the upper rear cover of the
cab and attach a strap around main control valve (2) to hold the
valve in position when the mounting bolts are removed.
Remark
Tag and mark hydraulic hoses before removal to ensure
correct installation.
Remark
Remove all the hydraulic hoses from the main control
valve before removing the mounting bolts if you are
replacing the complete control valve assembly. Leave the
hoses attached and only remove the hoses required if
you are replacing a valve section.

2. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent. Pressure on the hydraulic tank must be released before
beginning any work on the hydraulic system.

3. Remove four bolts (1) and locknuts (2) from the control valve
bracket (3). 
Note: There are two bolts on top and two on the bottom of the
bracket.

4. Remove two nuts (1) from the right side bracket (2) of the control
valve.

5. Pull the control valve out from the mounting bracket.

Remark
Remove the hoses required to disassemble the valve
sections. Most of the hoses can stay attached.

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DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
6. Remove the three nuts (1) from the right or left side of the control valve and slide the sections off of the studs (2) to
replace valve sections.

Torque Nuts 1a to 33 lbf ft (45 N•m)

Torque Nuts 1b to 59 lbf ft (80 N•m)

Installation
Remark
See “General Instructions” for the type of sealant to use on the fittings and torque specification charts.
Installing new O-rings is recommended.
1. Assemble the valve sections with new O-rings.
2. Mount the main control valve on the mounting bracket.
3. Install all the hoses.
4. See “Vent Air From Hydraulic System” on page 50-41.
5. Check the oil level in the hydraulic tank and add hydraulic oil if necessary.
6. See “Control Valve Circuit Pressure Adjustments” to adjust the control valve pressure.

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DISASSEMBLY AND ASSEMBLY FILL PUMP

12
FILL PUMP
Removal
The fill pump assembly is bolted onto the revolving frame next to the
right side of the engine. The pump can be removed from the electric
motor, or the assembly can be removed from the revolving frame.

1. Access fill pump assembly (1) by pivoting the cab side engine
guard up.

2. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent. 
Pressure in the hydraulic tank must be released before beginning
any work on the hydraulic system.

3. Disconnect the power connector from the engine harness (not

shown).

4. Remove two hoses (1) and (2) from the fill pump (3).

5. Remove four bolts (4), washers (5), and fill pump assembly (6)
from the engine compartment.

6. Remove the fill pump from the electric motor and replace the
motor or pump. Remove the hydraulic fittings from the pump.
Installation
Remark
See “General Instructions” for the type of sealant to use
on the fittings and torque specification charts. Installing
new hydraulic fittings is recommended if the fittings have
O-rings.

1. Assemble the motor and pump.

2. Install the hydraulic fittings on the pump.

3. Install fill pump assembly (6) in the engine compartment on the revolving frame with four washers (5) and bolts (4).

4. Install two hoses (1) and (2) on the fill pump (3).

5. Connect the power connector from the pump to the engine harness.

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DISASSEMBLY AND ASSEMBLY CHARGE MANIFOLD HEATER

12
CHARGE MANIFOLD HEATER
Removal
The charge heater (1) is an option that is used to assist in warming the
hydraulic oil in cold weather. The charge heater is mounted on the
charge filter manifold (2), located on the rear hydraulic tank support.
Refer to the Operation and Maintenance Manual for the correct use of
this option.

1. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent. 
Pressure on the hydraulic tank must be released before beginning
any work on the hydraulic system.

2. Remove hose (1) from elbow (2).

3. Remove wire (1) from the coil (2).

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DISASSEMBLY AND ASSEMBLY CHARGE MANIFOLD HEATER
4. Remove four allen head capscrews (3), lockwashers (4), and
charge heater (1) from the charge filter manifold (2).

5. Remove two O-rings (not shown) from the charge heater (1).
Installation
Remark
See “General Instructions” for the type of sealant to use
on the fittings and torque specification charts. Installing
new hydraulic fittings is recommended if the fittings have
O-rings.

Remark
If you are installing a new charge heater for the first time,
you must install the orifice that is in the charge heater kit
in the top of the charge filter manifold (see Step 1). You
must also remove the two plugs (2) from the surface of
the charge filter manifold where the charge heater is
installed.

1. Remove plug (1) from the top of the charge filter manifold (2).
Install orifice (3) down into charge filter manifold (2). 
Then reinstall plug (1).

2. Remove the elbow from the charge heater and install the elbow on
the new charge heater.

3. Install two new O-rings on the charge heater mounting surface.

4. Install charge heater (1) on the charge filter manifold (2) with four
lockwashers (4) and allen head capscrews (3).

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DISASSEMBLY AND ASSEMBLY CHARGE MANIFOLD HEATER
5. Install wire (1) onto coil (2).
Remark
This wire is on the same harness as the connector that
attaches to the charge filter manifold.

6. Install hose (1) on elbow (2).

7. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY CHARGE FILTER MANIFOLD

12
CHARGE FILTER MANIFOLD
Removal
The charge filter manifold is located on the inside of the rear hydraulic
tank support.
Remark
The hydraulic oil charge filter should be changed every
other time that the hydraulic return filters are changed.

1. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent. 
Pressure on the hydraulic tank must be released before beginning
any work on the hydraulic system.

2. Unscrew the filter canister (1) and remove the filter, O-ring, and
back-up ring.

3. If an optional charge heater is installed on the charge filter mani-

fold, follow the “Charge Filter Manifold Heater Removal” proce-
dure and remove the charge heater from the charge filter manifold.
Remark
Tag and mark the hoses before removal to ensure correct
installation.

4. Remove four hoses (1), (2), (3), and (4), from their fittings.

5. Remove three hoses (5) from tee fittings (6).

6. Remove tee fitting (6) from the elbow.

7. Remove screw (7) and connector (8) from the charge filter mani-
fold.

8. Remove two hoses (1) from elbows.

9. Remove two bolts (2), washers (3), and charge filter manifold from
the rear support.

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DISASSEMBLY AND ASSEMBLY CHARGE FILTER MANIFOLD

12
Installation
Remark
See “General Instructions” for the type of sealant to use on the fittings and torque specification charts. 
Installing new hydraulic fittings is recommended if the fittings have O-rings.

1. Install the hydraulic fittings on the new charge filter manifold in

the same positions so the hoses will install easily.

2. Remove the bracket from the manifold removed and install the
bracket on the new manifold.

3. Install the charge filter manifold on the rear support with two
washers (3) and bolts (2).

4. Install two hoses (1) on their elbows.

5. Install two tees (6) on the elbow.

6. Install three hoses (5) on the tees (6).

7. Install four hoses (1), (2), (3), and (4) on the appropriate fittings.

8. Install connector (8) on the manifold with screw (7).

9. Place a new charge filter in canister (1).

10. Apply grease to the threads of the canister and install the O-ring,
back-up ring, and canister (1) onto the manifold.

11. If an optional charge heater was installed on the charge filter mani-
fold, follow the “Charge Filter Manifold Heater Installation” pro-
cedure and install the charge heater on the charge filter manifold.

12. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY PILOT PRESSURE MANIFOLD

12
PILOT PRESSURE MANIFOLD
Removal and Installation
The pilot pressure manifold is located on the right side of the boom
base inside the rear right guard door.
Refer to the Parts Book for the replacement parts to the pilot pressure
manifold.
Remark
Tag and mark the hoses and connectors before removal
to ensure correct installation. The solenoids are from left
to right as follows: 
Track Brake Release (1), 
Shift (2), and 
Swing Brake Release (3).

1. Release pressure in the hydraulic oil tank by opening the hydraulic

tank vent.

★ Pressure on the hydraulic tank must be released before beginning

any work on the hydraulic system.

2. Follow illustration to disassemble and assemble.

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DISASSEMBLY AND ASSEMBLY RETURN OIL MANIFOLD (LOGIC BLOCK)

12
RETURN OIL MANIFOLD (LOGIC BLOCK)
The return oil manifold (1) is located above the right side of the trans-
mission under the hydraulic tank.

The return oil manifold should not require replacement.

Only pilot relief valve (1) and spike relief check valve (2) may require replacement.
See the Parts Book if replacement is required.
Remark
Release pressure in the hydraulic oil tank by opening the hydraulic tank vent. 
Pressure on the hydraulic tank must be released before beginning any work on the hydraulic system.

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DISASSEMBLY AND ASSEMBLY SAW STOP VALVE

12
SAW STOP VALVE
Removal and Installation
The saw stop valve (1) is only used on machines that were manufac-
tured for a disc saw attachment. The valve is located on the rear of the
machine attached to the left side of the boom base weldment. On older
machines the valve is located in the engine compartment near the radia-
tor.
The function of the valve is to stop the disc saw blade so it does not
continue to rotate after the Disc Saw Off switch is pressed.
See the Parts Book for the replacement parts to the saw stop valve. 
Cartridges and seal kits are available.
Remark
Release pressure in the hydraulic oil tank by opening the
hydraulic tank vent. 
Pressure on the hydraulic tank must be released before
beginning any work on the hydraulic system.

Follow the illustration for disassembly and assembly.

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DISASSEMBLY AND ASSEMBLY ENGINE FLEXPLATE

12
ENGINE FLEXPLATE

WARNING! Make sure to read and understand the Safety Notice in this manual. 
Additional safety precautions will be included in this section as required by the operation being dis-
cussed.

Remove Hydraulic Pumps

The auxiliary pump, implement pump, charge pump, hydraulic cooler
fan pump, and track drive pumps must be removed from the transmis-
sion (1). Refer to the individual topics to remove the pumps.

Separate Transmission From Engine

1. Pivot open the cab side engine guard to access the engine.
Remark
The rear engine mounts are fastened to the transmission.
The engine must be blocked in place before removing the
transmission.

2. Block the bottom rear of the engine on both sides.

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DISASSEMBLY AND ASSEMBLY ENGINE FLEXPLATE
3. Remove 12 nuts (1) and washers (2) from studs (3).

Remark
Tag and mark the hydraulic hoses before removal to
ensure correct installation.

4. Remove four hydraulic hoses (1) from the return manifold (2).
Remark
Do not remove the transmission mounts from the 
transmission.

5. Remove locknut (3), washer (4), bolt (5), and isolator (6) from the
transmission mount (7). Repeat for the other transmission mount.

WARNING! Use a suitable lifting device to slide the trans-

mission back away from the engine. This will
require two technicians. The transmission is
heavy and awkward. Be careful not to tip the
transmission over. Failure to comply could
cause injury to personnel.

6. Slide the transmission back away from the engine with a suitable lifting device. Slide the transmission back enough to
access the engine flexplate.

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DISASSEMBLY AND ASSEMBLY ENGINE FLEXPLATE

Flexplate Removal

1. Remove eight screws (1), washers (2), and flexplate (3) from
engine.

Flexplate Installation

1. Apply moly paste to engine and flex plate on areas (1).

2. Apply Loctite® 271 to eight screws (1) and install flex plate (3) on
engine with eight washers (2) and screws (1).

Torque screws to 40 lbf ft (54 N•m)

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DISASSEMBLY AND ASSEMBLY ENGINE FLEXPLATE
3. Apply moly paste to spline on the flex plate. Also apply moly paste
to spline shaft on the transmission (2).

Transmission Installation
Remark
The shaft seal on the transmission should be replaced
when the flexplate is replaced.

1. Replace the shaft seal (1) before installing the transmission on the
engine.

2. Apply LT-2 to the 12 studs (1).

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DISASSEMBLY AND ASSEMBLY ENGINE FLEXPLATE

WARNING! Use a suitable lifting device to slide the trans-

mission in place on the engine. 
This will require two technicians. 
The transmission is heavy and awkward. Be
careful not to tip the transmission over. Failure
to comply could cause injury to personnel.

Remark
You may need to turn the engine over slowly by turning
the front of the crankshaft to line up the spline on the
engine to the spline on the transmission.

1. Use a suitable lifting device and place the transmission on the

engine.

2. Install clamp (2) on stud (3) and fasten the transmission to the
engine with 12 washers (4) and nuts (5).

Torque the nuts to 40 lbf ft (54 N•m)

3. Install four hydraulic hoses (1) onto the return manifold (2).

4. Install the transmission mount (7) on the revolving frame with iso-
lator (3), washer (4), bolt (5), and locknut (6). Repeat for the other
transmission mount.

Torque the bolts to 325 lbf ft (440 N•m).

Install Hydraulic Pumps

1. Install the track drive pumps, hydraulic cooler fan pump, 

implement pump, auxiliary pump, and charge pump onto the
transmission (1). Refer to the individual topics to install the
pumps.

2. See “Vent Air From Hydraulic System” on page 50-41.

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DISASSEMBLY AND ASSEMBLY ENGINE

12
ENGINE

Removal

WARNING! Make sure to read and understand the Safety Notice in this manual. 
Additional safety precautions will be included in this section as required by the operation being dis-
cussed.

★ The engine is removed from the front of the machine. The top components of the engine compartment and radiator, oil
cooler, and charge air cooler assembly must be removed before the engine can be removed.

1. Remove two bolts (1), four washers (2), and right side engine
guard (3) from the machine.

2. Remove six bolts (1), washers (2), and cover (3) from guard (4).

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DISASSEMBLY AND ASSEMBLY ENGINE
3. Remove nine bolts (1), washers (2), and guard (3) from panel (4).
Remark
If the machine is not equipped with a pre-cleaner, there is
a flat panel in place of the pre-cleaner guard that needs
to be removed.

4. Screw an eyebolt into the threaded hole on top of the guard (3) and
remove the guard with a lifting device.

5. Lift the pre-cleaner (1) straight up to remove.

Remark
There is a clamp under the pre-cleaner that can be
loosened if necessary for removal from the air cleaner
extension.

6. Remove four bolts (1), washers (2), and air cleaner extension
guard (3) from panel.

7. Disconnect the wire connectors (1) from two lights (2), and
remove the light harness (3) from the top guard panel.

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DISASSEMBLY AND ASSEMBLY ENGINE
8. Remove two bolts (1) and washers (2) from the front of the top
guard panel (3).

9. Remove four locknuts (4), eight washers (5), and four bolts (6)
from the top guard panel (3).

10. Screw eyebolt (1) into top guard panel (2) and remove with a suit-
able lifting device.

11. Drain the radiator coolant. Remove the drain plug (1) from the
radiator (2) and install a fitting with a drain hose attached to drain
the radiator.

12. Remove clamp (1) and hose (2) from under the radiator over-flow
tank (3).

13. Remove two hoses (1), hose (2), and hose (3) from radiator over-
flow tank (4).

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DISASSEMBLY AND ASSEMBLY ENGINE
14. Remove six bolts (1) and washers (2) from the over-flow tank
panel (3).

15. Remove the lower muffler fire guard (4) from the over-flow tank
panel (3).
Remark
The lower muffler fire guard is siliconed to the over-flow
tank panel.

16. Slide the over-flow tank panel (3) from under the muffler and
remove it from the frame.

17. Remove two clamps (1) and elbow (2) from air cleaner (3) and
turbo charger (4).

18. Remove two locknuts (1), four washers (2), two bolts (3), and the
air cleaner panel (4) (with the air cleaner attached) from the frame.

19. Remove two locknuts (1), four washers (2), two bolts (3), and
retainer (4) from the muffler bracket (5).

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12
Remark
Turn on the hydraulic vacuum pump before removing
hydraulic hoses from the oil cooler. Have #24 and #20
caps and plugs ready to cap and plug the hydraulic fit-
tings and hoses.
Remark
Place a container under the hydraulic connections if the
machine is not equipped with a vacuum pump. Cap and
plug the hydraulic hoses and fittings immediately.

20. Remove hydraulic hose (1) from fitting (2).

21. Remove hydraulic hose (1) from fitting (2).

22. Remove hydraulic hose (3) from fitting (4).

Remark
Turn the vacuum pump OFF and turn ON the hydraulic
tank vent switch for at least 60 seconds.

23. Remove the negative battery cable (1) from the rear battery (2) and
remove two positive battery cables (3) from the disconnect
switch (4).

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DISASSEMBLY AND ASSEMBLY ENGINE
24. Remove two locknuts (1), four washers (2), two bolts (3), and
ground cable (4). Then slide the battery assembly out from the
engine.

25. Remove two clamps (1 and 2), tube (3) and hose (4) from charge
air manifold (5) and charge air cooler hose (6).

26. Remove clamp (1) and tube (2) from hose (3)

27. Remove clamp (1) and tube (2) from turbo charger hose (3).

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DISASSEMBLY AND ASSEMBLY ENGINE

Remark
Place a container under the engine coolant hoses before
disconnecting.

28. Remove clamp (1) and heater hose (2) from engine.
Remark
Depending on the options on the machine, there may be
another heater hose to remove from the fittings.

29. Remove clamp (3) and hose (4) from tube (5).

30. Remove clamp (6) and tube (5) from hose (7).

31. Remove clamp (8) and hose (9) from engine.

32. Remove oil cooler (1).

33. Remove coolant hose (2).

34. Remove reversing fan air hose (3).

35. Remove fan guard (4).

36. Fan Guard Exploded View: use for Removal and Installation.

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DISASSEMBLY AND ASSEMBLY ENGINE

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12
37. Remove air tube (1) from reversing fan air tube (2). Then remove
air tube (1) from the cooler assembly.

Remark
Do not remove air conditioner hoses from the 
compressor. If the hoses are removed, the air 
conditioning system will need to be evacuated and
charged with freon.

38. Remove the ground wire (1) and power wire connector (2) from
the compressor (3).

39. Loosen the compressor belt tightener (4) and mounting bolt (5),
and remove the drive belt from the compressor and engine.

40. Remove bolt (1) from the bracket.

41. Remove nut (2), bolt (3), and compressor (4) from the engine.
Place the compressor to the side so it is not in the path of engine
removal.

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DISASSEMBLY AND ASSEMBLY ENGINE
42. Remove one bolt (1), washer (2), and isolator (3) from each side of
the bottom support (4).

43. Remove four bolts (1), washers (2), and crossmember (3) from the
radiator support.

44. Remove the foam (1) from top of the radiator if it needs to be
replaced. Otherwise leave the foam on the radiator.

45. Remove the hose (2) from between the cooler assembly and the
radiator support on both sides.

46. Remove two locknuts (1), washers (2), and isolator (3) from each
top side of the assembly.

47. Remove the top two bolts (4) and washers (5) on each side of the
assembly. Screw two eye bolts into the top of each side of the
assembly where the bolts (4) were removed. Then use a suitable
lifting device to remove the cooler assembly from the machine.

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DISASSEMBLY AND ASSEMBLY ENGINE
48. Remove turbo boost air hose (1) from regulator (2).

Remark
Tag and mark all the connectors from the engine harness
before disconnecting to ensure correct installation.

49. Remove engine harness connectors (1) from the left side of the
engine.

50. Remove the wire clamps (2) and engine harness from the engine.

51. Remove tank vent hose (1) from fitting (2).

52. Remove fill hose (3) from fitting (4).

53. Remove two locknuts (5), four washers (6), two bolts (7), and
hydraulic fill hose/tank vent bracket (8) from engine bracket (9).

54. Lay the hydraulic fill hose/tank vent bracket (8) and engine har-
ness away from the engine.

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DISASSEMBLY AND ASSEMBLY ENGINE
55. Remove ground cable (1) from the lower rear left side of the
engine.

56. Place a container under the fuel lines (1) and (2) and remove fuel
lines from the rear left side of the engine.

57. Remove heater hose (1) from the rear right side of the engine.
Remark
There may be more fittings and hoses depending on the
heater option of the machine.

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DISASSEMBLY AND ASSEMBLY ENGINE
58. Remove oil pressure gauge hose (1) from the right side of the
engine.

Remark
Tag and mark the wires and cables attached to the starter
before removal to ensure the correct assembly. Do not
remove wire (4).

59. Remove the wires (except wire (4)) and cables from starter (1).

60. Remove diode (2) and bracket (3) from the engine.

61. Remove cover (1) and engine harness cable (2) from alternator
fuse (3).

62. Remove all connectors, cable ties, wire clamps, and engine harness
from the engine.

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DISASSEMBLY AND ASSEMBLY ENGINE

Remark
If the machine is equipped with a transmission cooler, 
follow the following step. If not, go to the next step.

63. Remove the transmission cooler assembly (1) from the engine. Set
the assembly away from the engine.

64. Remove locknut (1), two washers (2), bolt (3), and top half of the
motor mount (4) from each front engine mount bracket.

Remark
Attach chains from a suitable lifting device to the engine
lifting brackets to hold the engine while removing the
engine from the transmission.

65. Remove 12 nuts (1) and washers (2) from studs (3).

66. Using a lifting device and remove the engine (with the muffler
attached) from the machine.

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DISASSEMBLY AND ASSEMBLY ENGINE

12
Installation Preparation
★ Transfer the parts from the removed engine to the engine to be installed.

Apply Loctite® 565 Thread Sealant on all pipe fittings

without O-rings before installation

Apply Loctite® 545 Thread Sealant on all JIC hydraulic

fittings before installation.

Apply oil on all O-rings before installation.

1. Apply Copper Anti-Seize to the engine and install the ground cable
(1) with a washer and bolt. This ground cable is from the cab.

2. Apply Copper Anti-Seize to the engine and install the ground cable
(2) with a washer and bolt. This ground cable will connect to the
starter negative terminal.

3. Apply Copper Anti-Seize to the engine and install the ground cable
(1) with a washer and bolt. This ground cable will connect to the
rear battery assembly mounting bracket.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-145
DISASSEMBLY AND ASSEMBLY ENGINE
4. Remove two bolts (1), washers (2), clamp (3) and exhaust pipe
elbow (4) (with muffler attached) from the old engine.

5. Apply LT-2 to two bolts (1) and install the exhaust pipe elbow (4)
with muffler attached on new engine and turbo charger with bolts
(1), washers (2), and clamp (3). Do not tighten bolts (1) until
clamp (3) is tightened.

6. Install the top engine radiator pipe and bracket (1) on engine with
washer (2) and bolt (3).

7. Install hose (4) on pipe (1) and engine with two clamps (5).

8. Install hose (6) on engine with clamp (7).

9. Remove two clamps (1) and hose (2) from turbo charger.

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DISASSEMBLY AND ASSEMBLY ENGINE
10. Collapse the lock ring (1) on the bottom back side of the turbo
charger so the turbo charger can be rotated.

11. Rotate the turbo charger so the pipe (1) is eight inches from the
manifold.

12. Install hose (1) on turbo charger with two clamps (2).

13. Ensure the lock ring (1) is seated. Tap the tabs of the lock ring
apart with a hammer.

14. Apply LT-2 to four bolts (1) and install the front right engine
mount (2) onto the engine with four bolts (1) and washers. Do not
tighten the bolts.

15. Square right front motor mount (2) to the engine with a square
placed as shown.

16. Tighten the four bolts (1). .

Torque the bolts to 92 lbf ft (125 N•m)

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-147
DISASSEMBLY AND ASSEMBLY ENGINE
17. Apply LT-2 to four bolts (1) and install the front left engine mount
(2) onto the engine with four bolts (1) and washers. Do not tighten
bolts (1).

18. Square the right front motor mount (2) to the engine with a square.

19. Tighten the four bolts (1).

Torque the bolts to 92 lbf ft (125 N•m).

20. Set the engine on a flat surface with a block under each front motor
mount and under the rear of the engine.

21. Remove the engine oil cap (1) and fill the engine with 21 quarts of
oil.

Engine oil: 21 qt (19.87l)

Remark
Refer to the Engine Oil Selection Guide decal on the
inside of the hydraulic pump guard door for the correct
engine oil viscosity for the ambient temperature.

Remark
Perform the following four steps only if your engine is
equipped with a block heater. The alternator must be
rotated up if installing a block heater.

22. Remove the drive belt (1) from the engine using a breaker bar
(½ inch drive) to loosen tensioner (2).

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DISASSEMBLY AND ASSEMBLY ENGINE

Remark
Before installation, apply Loctite® 565 Thread Sealant on
all fittings without O-rings.

23. Remove the block heater (1) from the old engine and install it on
the new engine under the alternator.

24. Remove the fittings (2) for the heater lines from the front of the old
engine and install them on the new engine.
Remark
These fittings will vary depending on the heater options
of the machine.

25. Install the alternator back and the drive belt.

26. Remove the fittings (1) for the heater line from the rear of the old
engine and install it on the new engine.
Remark
These fittings will vary depending on the heater options
of the machine.

Remark
If installing a new turbo boost regulator, set the regulator
at 8 psi (0.56 kg/cm2).

27. Remove the turbo boost regulator (1) and install it on the new
engine.

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DISASSEMBLY AND ASSEMBLY ENGINE
28. Remove two fittings (1) (for the engine coolant filter) from the old
engine and install them onto the new engine.

29. Remove the engine coolant filter assembly (2) and install the
assembly on the new engine.

30. Install two hoses (3) onto the engine and engine coolant filter
assembly.
Remark
Replace the filter with a new filter.

31. Remove fitting (4) (for the oil pressure gauge hose) and install it
on the new engine.

32. Remove the paint from the mounting surface where engine bracket
(1) will be installed.

33. Apply Copper Anti-Seize to the engine and install bracket (1) and
diode (2) (from the old engine) onto the new engine, next to the
starter.
Remark
Install the other end of the diode wire to the starter sole-
noid (along with the other wires) after the engine is
installed in the machine.

Remark
Remove the fuse from the alternator on the old engine.

34. Remove two screws (1) from the alternator rear cover (2) and
install the fuse assembly (3) (from the old alternator) onto the new
alternator with screws.

35. Install cable (4) from fuse assembly (3) onto positive terminal (5)
of the alternator.

36. Install cable (6) from the negative terminal of the starter onto the
negative terminal (7) of the alternator.
Remark
Terminal (8) of the alternator is not used. Leave the 
protective cap on the terminal.

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DISASSEMBLY AND ASSEMBLY ENGINE
37. Install radiator hose (1) onto the bottom of the engine (below the
alternator), with clamp (2).

Remark
If the machine is equipped with a transmission cooler, 
follow the next step. If not, skip the next step.

38. Apply LT-2 to two bolts (1), install transmission cooler bracket (2)
onto the front left engine mount using two bolts (1), four washers
(3), and two locknuts (4).

Bolts: Apply LT-2

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DISASSEMBLY AND ASSEMBLY ENGINE

12
Installation
Remark
You may need to turn the engine over slowly by turning
the front of the crankshaft to line up the spline on the
engine to the spline on the transmission.

1. Attach a suitable lifting device to the engine and install the engine
in the machine on the transmission (1) and onto the front motor
mounts.

2. Install clamp (2) on stud (3) and fasten the transmission to the
engine with 12 washers (4) and nuts (5).

Torque the nuts to 40 lbf ft (54 N•m).

Remark
Install one washer at the bolt end and one washer at the
nut end in the following step. 
Assemble the motor mounts as shown in the figure.

3. Install the top half of the motor mount (4) onto each front motor
mount bracket with bolt (1), two washers (2), and nut (3).

Torque the bolts to 325 lbf ft (440 N•m).

4. Install the cables and wires (1) onto the terminals of starter (2) as
marked before disassembly.

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5. Install cable (1) from engine harness onto alternator fuse (2).

6. Install five connectors (1) from the engine harness on left side of
engine as shown.

7. Install oil pressure gauge hose (1) on the right side of the engine
above the coolant filter assembly.

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DISASSEMBLY AND ASSEMBLY ENGINE
8. Install the heater hose (1) on the shutoff valve (2) on the rear of the
engine.
Remark
The fittings and hoses will vary depending on the heater
options of the machine.

9. Remove the fuel fitting (1) from the old engine and install it on the
new engine.

10. Install the fuel lines (2) and (3) on the rear of the engine.

11. Install turbo boost hose (1) from the hydraulic tank to
regulator (2).

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12. Remove screws (1) and reversing fan (2) from adapter (3) on the
old engine.

13. Remove four capscrews (1) from the fan pulley (2) on the new
engine. Discard capscrews (1).

14. Remove four capscrews (1) and fan adapter (2) from the old
engine.

Apply LT-2 to the four capscrews (1) just removed.

15. Apply LT-2 to the four capscrews (1) just removed and install
reversing fan adapter (2) onto the pulley of the new engine with
these four capscrews (1).

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DISASSEMBLY AND ASSEMBLY ENGINE
16. Install compressor on engine mount as shown.

17. Install belt on compressor.

18. Install the adjustment hardware (1) on the compressor.

19. Adjust the belt tension.

20. Install ground connector (1) and power connector (2).

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Apply LT-2 to six screws (1).

21. Apply LT-2 to six screws (1) and install reversing fan (2) onto
adapter (3) of the new engine.

22. Screw two eye bolts into the top of each side of the cooler assem-
bly (2) where the bolts were removed. Then use a suitable lifting
device to install the cooler assembly in the machine.

23. Install two locknuts (1), washers (2), and isolator (3) on each top
side of the cooler assembly.

24. Install top two bolts (4) and washers (5) on each side of the cooler
assembly.

25. Install one bolt (1), washer (2), and isolator (3) on each side of the
bottom support (4).

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12
26. Spray high strength adhesive on the foam (1) and install the foam
on top of the cooler assembly.

27. Install a hose (2) in the gap on both sides of the cooler assembly
and the frame.
Remark
The diameter of the hose will depend on the size of the
gap between the cooler assembly and the frame.

28. Apply black silicone adhesive on the hoses (2) after installation.

29. Install crossmember (3), with four bolts (1), and washers (2) onto
the radiator support.

30. Install air tube (1) on reversing fan air tube (2).

31. Install engine fan guard.

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12
32. Install coolant hose (2).

33. Install reversing fan air hose (3).

34. Install oil cooler (1).

35. Make sure engine fan guard (4) is secure.

36. Install heater hose (2) on engine with clamp (1).

Remark
Depending on the options on the machine, there may be
another heater hose to install on the fittings.

37. Install hose (9) and tube (5) on engine with clamp (8).

38. Install tube (5) on hose (7) with clamp (6).

39. Install hose (4) on tube (5) with clamp (3).

40. Install tube (2) onto turbo charger hose (3) with clamp (1).

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DISASSEMBLY AND ASSEMBLY ENGINE
41. Install tube (2) onto hose (3) with clamp (1).

42. Install tube (3) onto hose (6) with clamp (1).

43. Install hose (4) onto manifold (5) with clamp (2).

Remark
Install one washer on the bolt end and one washer on the
locknut end in the following two steps.

44. Apply Copper Anti-Seize to the rear battery mount and revolving
frame. Install ground cable (4) onto the rear mount of the battery
assembly with bolt (1), two washers (2) and locknut (3).

45. Install the battery assembly front mount on the revolving frame
with bolt (1), two washers (2), and locknuts (3).

46. Install the negative battery cable (1) from the starter to the rear 
battery.

47. Install one positive cable (2) from the starter and one positive
cable (3) from the main fuse onto the disconnect switch (4).

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48. Install hydraulic hose (1) onto fitting (2).

49. Install hydraulic hose (3) onto fitting (4).

50. Install the right side hydraulic hose (1) on fitting (2).

Remark
Install one washer on the bolt end and one washer on the
locknut end in the following step.

51. Install muffler bracket (5) to isolator (6) with retainer (4), using
two bolts (1), four washers (2), and two locknuts (3).

Remark
Install one washer on the bolt end and one washer on the
locknut end in the following step.

52. Install the air cleaner panel (4) with air cleaner attached to the
frame with two bolts (1), four washers (2), and two locknuts (3).

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DISASSEMBLY AND ASSEMBLY ENGINE
53. Install elbow (2) onto turbo charger (4) and air cleaner (3) with two
clamps (1).

2, 3

S1010
Figure 50-1 Radiator Overflow Tank
Panel

54. Slide the overflow tank panel (3) under the muffler and position it
for installation.

55. Apply silicone to the muffler fire guard (4) and attach the fire
guard to panel (3).
Remark
One bolt (1) will go through the muffler fire guard in the
following step.

56. Attach the overflow tank panel (3) to the frame with six bolts (1)
and washers (2).

57. Install two hoses (1), hose (2), and hose (3) onto radiator overflow
tank (4).

58. Attach a suitable lifting device to eye bolt (1) on top guard
panel (2).

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59. Install the top guard panel (3) onto the frame with four bolts (4),
eight washers (5), four locknuts (6), also with two bolts (1) and
washers (2).

60. Connect the machine light harness (3) to the light connectors (1).

61. Install the air cleaner extension guard (3) onto the top guard panel
with four bolts (1) and washers (3).

62. Install the pre-cleaner (1) onto the air cleaner extension.

63. Install the pre-cleaner guard (3) on the top guard panel (4) with
nine bolts (1) and washers (2).

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64. Install cover (3) on the pre-cleaner guard (4) with six bolts (1) and
washers (2).

65. Install the right side engine guard (3) onto the machine with two
bolts (1) and four washers (2).

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12
TRACK SYSTEM
Track Tension
WARNING! Read and follow the safety instructions in this manual before performing these 
procedures. Failure to comply could cause injury or death.

Check Track Tension

1. Raise Track Frame off ground and block for safety.
2. Rotate the track in forward and reverse directions multiple times to
free debris.
3. Stop rotation in reverse travel direction to maintain tension of top
chain. This will allow slack to be on the underside of track frame
assembly.

4. Track Sag to be as per following table. Measure from bottom of

rock guard to surface of shoe plate at lowest point. This point is
centered between idler and sprocket.

Dimension
Machine Model
Min. mm (in) Max. mm (in)

XT430-3/XT430L-3 110 (4.33) 150 (5.90)

XT445L-3/XT460L-3 110 (4.33) 150 (5.90)

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Increasing Track Tension

WARNING! Only properly trained maintenance personnel

should adjust the track tension.

The track tension valve cover (1) is located on the side of the track
assembly.

Add grease through the fill valve fitting (1) until the correct track ten-
sion is reached. A difference in track tension should be noticed after 4
or 5 strokes of grease. If a change in track tension is not noticed, check the idler unit
slides for wear or contamination.
Decreasing Track Tension

WARNING! The grease in the track tension system is under high pressure.
Stand to one side when releasing grease. 
Never loosen the relief valve nut more than one turn. 
The valve nut could fly out if loosened more than one turn. 
Failure to comply could cause serious injury.

If the grease does not come out, move the machine backwards and forwards.

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12
Track Shoe Removal and Installation
1. Remove four nuts (1), bolts (2), and track shoe (3) from track
chain.

2. Install track shoe (3) on track chain with four bolts (2) and nuts (1).

3. Torque all track shoe mounting bolts (1).

Track shoe mounting bolts:

330 lbf ft (440 N•m) plus 1/3 turn

Track Removal and Installation

1. Locate the master pin (1) on the track chain. The master pin has a
hole in the center of the pin.

2. Drive the machine onto a flat surface and locate the master pin (1)
at the front of the idler wheel.

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3. Follow the “Decreasing Track Tension” procedure and completely
remove the tension from the track assembly.

4. Block the track up with wood blocks to keep the tension off the
master pin before removing the pin (1).

5. Attach a pin inserter to a suitable lifting device (2).

6. Line up the pin inserter to the pin.

7. Insert the pin inserter push pin (1) and press the pin out of the
track.

8. Drive the machine in reverse until the track end is on top of the
rear drive sprocket. Then use a suitable lifting device to remove
the track end from the sprocket so it is on the ground.

9. Lay the new set of track that is replacing the track on the machine
and pin the new track to the present track with the pin inserter.

10. Drive the machine in reverse until the machine is on the new track
and the master pin that joins the two sets of tracks is approximately
three feet in front of track idler (1).

11. Remove the old track from the new track.

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12. Use a suitable lifting device to lift and fold the end of the track so
the end is at the drive sprocket.

13. Attach a chain on the end of the track and run the chain over the
inside hub of the sprocket and over the front idler.

14. Place a block between the drive sprocket and track so the track
does not get caught on the drive sprocket.

15. Pull the track over the drive sprocket and up to the front idler.

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16. Place the pin bushings in the links and tie wrap in place. 
Cut the tails off of the tie wraps.

17. Use a suitable lifting device and lift the end of the track up.

18. Then use a sledge hammer and pound the chain links together so
the master pin can be installed.

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19. Block the track in place and align the chain links with a bar.

20. Pound the starter pin (1) into the links.

21. Insert the pin (1) into the pin inserter and press the pin into the
links.

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DISASSEMBLY AND ASSEMBLY TRACK SYSTEM
22. A flashlight can be used to look through the other side to line up
the pin inserter to the line-up pin.
★ Important: Once it is lined up, lower stop (1).

23. Press the pin into the links.

24. Adjust the track tension. Refer to “Track Tension” in this section
of the manual.

25. Repeat the procedure to replace the other track if required.

Idler Wheel, Recoil Spring and Track

Adjuster Assembly
Idler Wheel and Recoil Spring Removal

1. Refer to “Track Removal and Installation” and remove the master

pin from the track.

2. Using a suitable lifting device, lay the track down on the floor.

3. Remove the track adjuster lubricator assembly (2). Remove the

grease fitting and the bracket from the adjuster (1).

4. Using a pry bar, move the front idler, recoil spring and track adjuster assembly par-
tially out of the undercarriage frame.

The idler and recoil spring weigh 1,433 lb (650 kg).

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5. Attach lifting straps to the front idler, recoil spring and track
adjuster assembly (1) and attach to a suitable lifting device. 
Slide the assembly out of the undercarriage frame.

The weight of the idler wheel is 529 lb (240 kg).

The weight of the recoil spring is 816 lb (370 kg).

6. Support the assembly with blocks. Remove the four bolts (2) and
separate the recoil spring (4) from the idler wheel (3).

Idler Wheel and Recoil Spring Installation

1. Ensure the mating surfaces on the supports of the front idler and
the support of the recoil spring are clean and free of dirt and debris
prior to reassembly.
2. Carry out installation in the reverse order of removal.

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12
Idler Assembly
Special tools

Necessity
Symbol

Sketch
Part number Part name Qíty N/R Work Content

Installation of floating seal

1 796-570-1020 Installer ■ 1 XT430-3, XT430L-3
J
Installation of floating seal
2 791-575-1000 Installer ■ 1 XT445L-3, XT460L-3

Disassembly

1. Remove the support based upon the machine model.

• For XT430-3/XT430L-3 machines, remove dowel pin (1) to
remove support (2).

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• For XT430-3/XT430L-3 machines, remove nut and bolt (1) to
remove support (2).

2. Remove floating seals (3) from support (2) and idler (4).

3. Remove idler (4) from the shaft (5) and support assembly (7).

4. Remove the plug and drain oil at this time or spread cloths to absorb
it.

For XT430-3/XT430L-3: Oil of 230 ±10 cc (7.7 ±0.33

oz) is in the idler.

For XT445L-3/XT460L-3: Oil of 345 ±10 cc (21 ±0.61

oz) is in the idler.

5. Remove floating seals (6) on the opposite side from idler (4), shaft (5) and support assembly (7).

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DISASSEMBLY AND ASSEMBLY TRACK SYSTEM
6. Remove the shaft (5) based upon the machine type.
• For the XT430-3/XT430L-3 machines, remove dowel pin (8) to
remove support (7) from shaft (5).
• For the XT445-3/XT460L-3 machines, loosen and remove nut
and bolt (8) to remove support (7) from shaft (5).

7. Remove bushings (9) and (10) from idler (4).

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12
Assembly

1. Press fit bushings (9) and (10) to idler (4).

2. Install the shaft based upon the machine type.

• For the XT430-3/XT430L-3 machines, install shaft (5) with O-
ring (12) to support (2) using dowel pin (1).
• For the XT445-3/XT460L-3 machines, install shaft (5) with O-
ring (12) to support (2) with bolt and tighten with nut.

★ Be sure to assemble shaft (5) with the UP marking facing

upward.

3. Using the appropriate tool J for the machine type (J1 or J2), install
floating seal (3) to idler (4), and the shaft (5) and 
support (2).
★ Before installing the floating seal, completely clean, degrease
and dry contact surfaces of the O-ring and the floating seal
(hatched area in the illustration). Take care so that no dust will
stick to the contact surface of the floating seal.
★ Apply oil to the sliding surface of the floating seal, and take care
not to have any dirt stuck on it.

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★ After inserting the floating seal, check that inclination of the
seal is less than 1 mm {0.039 in} and that protrusion (a) of the
seal remains within the range of 5 - 7 mm {0.197 to 0.276 in}.

4. Install the shaft (5) and support (7) assembly to idler (4).

5. Turn it over, and supply oil between the shaft (5) and idler (4).

For XT430-3/XT430L-3: Oil of 230 ±10 cc (7.7 ±0.33

oz) is in the idler.

For XT445L-3/XT460L-3: Oil of 345 ±10 cc (21 ±0.61

oz) is in the idler.

6. Using appropriate tool J for the machine type (J1 or J2), install float-
ing seal (6) to idler (4) and support (7).
★ Completely clean, degrease and dry contact surfaces of the O-
ring and the floating seal (hatched area in the illustration). Take
care so that no dust will stick to the contact surface of the float-
ing seal.
★ Apply oil to the sliding surface of the floating seal, and take care
not to have any dirt stuck on it.

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★ After inserting the floating seal, check that inclination of the
seal is less than 1 mm {0.039 in} and that protrusion (a) of the
seal remains within the range of 5 - 7 mm {0.197 to 0.276 in}.

7. Install the support based upon the machine model.

• For the XT430-3/XT430L-3 machines, install shaft (5) and O-
ring (11) to support (7) using dowel pin (8).

• For the XT445L-3/XT460L-3 machines, install shaft (5) and O-

ring (11) to support (7) using bolt and tighten nut.

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DISASSEMBLY AND ASSEMBLY TRACK SYSTEM
8. Apply oil and tighten plug (13) with O-ring (14).

Plug (13): 130 - 180 N•m {96 to - 133 lbf ft}

★ When mounting the idler assembly on the machine, make sure

that plug (13) faces right side of the machine.

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12
Recoil Spring: XT430-3, XT430L-3
Special tools

Necessity

Sketch
Symbol Part number Part name Qíty N/R

791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
1 Cylinder
790-101-1600 ■ 1
(686 kN {70 t})
790-101-1102 Pump ■ 1
J
790-201-1500 Push tool kit ■ 1
790-201-1620 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1

Disassembly

1. Remove piston assembly (2) from recoil spring assembly (1).

2. Disassembly of recoil spring assembly.

A. Set recoil spring assembly (1) to tool.

WARNING! The spring is under large installed load, so be

very sure to set the tool properly. Failure to do
this is dangerous.

Installed load of spring: . . . . . . . . . . . . . . . 208.74 kN (46,926 lbf)

B. Apply hydraulic pressure gradually to remove lock plate (3)

then nut (4).
★ Compress the spring until the nut becomes loose.
★ Release the hydraulic pressure slowly and release the tension of the spring.
Free length of spring: . . . . . . . . . . . . . . . . . . .811.5 mm (31.94 in)

C. Remove yoke (6), cylinder (7), collar (8) and dust seal (9) from spring (5).

3. Disassembly of piston assembly.

A. Remove lock plate (11) from piston (10), then remove valve (12).

B. Remove snap ring (13), then remove U-packing (14) and ring (15).

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12
Assembly

1. Disassembly of piston assembly.

A. Assemble ring (15) and U-packing (14) to piston (10) and secure
with snap ring (13).

B. Tighten valve (12) temporarily, and secure with lock plate (11).

2. Disassembly of recoil spring assembly.

A. Using tool J2, install dust seal (9) to cylinder (7).

B. Assemble cylinder (7), collar (8) and yoke (6) to spring (5), and
set it on tool J1.

Cylinder sliding part: Grease (G2-LI)

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C. Apply hydraulic pressure slowly to compress the spring, and
then tighten nut (4) so that the installed length of the spring is
dimension (a) and secure it with lock plate (3).
Installed length (a) of spring: . . . . . . . . . . . . . . 659 mm (25.94 in)

D. Remove recoil spring assembly (1) from tool J1.

3. Assemble piston assembly (2) to recoil spring assembly (1).

Sliding part of piston: Grease (G2-LI)

Wear ring: Grease (G2-LI)

★ Install the piston assembly so the valve installing position is on the outside.
★ Fill the inside of the cylinder with 180 cc (6.08 oz) of grease (G2-LI), then bleed the air and check that grease comes
out of the grease hole.

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DISASSEMBLY AND ASSEMBLY TRACK SYSTEM

12
Recoil Spring: XT445L-3, XT460L-3
Special tools

Necessity

Sketch
Qíty

N/R
Symbol Part number Part name

791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
1 Cylinder
790-101-1600 ■ 1
(680 kN {70 t})

J 790-101-1102 Pump ■ 1
790-201-1500 Push tool kit 1
790-201-1660 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1

Recoil spring (Excluding idler): 900 kg (1,985 lb)

Disassembly

1. Remove piston assembly (2) from recoil spring assembly (1).

2. Disassembly of recoil spring assembly

A. Set tool J1 to recoil spring assembly (1).

WARNING! Since the installed load of the spring is large

and dangerous, set the tool securely.

Installed load of spring: . . . . . . . . . . . . . . 239.037 kN {24,375 kg}

B. Apply oil pressure gradually to compress the spring and remove

lock plate (3) and nut (4).
★ Compress the spring to a degree that you can loosen the nut.
★ Release the oil pressure gradually to reduce the spring tension to 0 (zero).
Free length of spring: . . . . . . . . . . . . . . . . . . . 845.3 mm (33.2 in)

C. Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5).

3. Disassembly of piston assembly

A. Remove lock plate (11) from piston (10), and then remove valve (12).

B. Remove snap ring (13), U-packing (14), and ring (15).

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12
Assembly

1. Assembly of piston assembly.

A. Install ring (15) and U-packing (14) to piston (10) and secure
them with snap ring (13).

B. Tighten valve (12) temporarily and secure it with lock plate

(11).

2. Assembly of recoil spring assembly.

A. Using tool J2, install dust seal (9) to cylinder (7).

B. Install cylinder (7), collar (8), and yoke (6) to spring (5), and
then set them to tool J1.

Sliding parts of cylinder: Grease (G2-LI)

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DISASSEMBLY AND ASSEMBLY TRACK SYSTEM
C. Apply oil pressure gradually to compress the spring and tighten
nut (4) so that installed length of the spring will be (a), and then
secure it with lock plate (3).
Installed length of spring (a): . . . . . . . . . . . . . . . 690 mm (27.1 in)

D. Remove recoil spring assembly (1) from tool J1.

3. Install piston assembly (2) to recoil spring assembly (1).

Sliding parts of piston: Grease (G2-LI)

Wear ring: Grease (G2-LI)

★ Install the piston assembly so that the position of the valve will be on outside.
★ Supply 320 cc (10.8 oz) of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease
hole.

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12
Track Roller
Removal

1. Loosen the track tension so the track will sag when the machine is raised to access the
track rollers.

WARNING! The grease in the track tension system is

under high pressure. 
Stand to one side when releasing grease.

2. Loosen the relief valve nut (2) one turn only to allow grease (1) to escape. 
If the grease does not come out easily, move the machine backwards and forwards.

3. With the machine on a level surface and the tracks on the ground, remove the roller
mounting bolts (1).

4. Then rotate the boom 90° and raise the tracks with the boom and remove the roller from the outside of the track assembly.

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Installation
1. Carry out the installation in the reverse order of removal.

Apply LT-2 to the bolts before installation.

Torque the roller mounting bolts:

XT430-3, XT430L-3; 406 ±11 lbf ft (550 ±15 N•m)
XT445L-3, XT460L-3; 682 ±11 lbf ft (925 ±15 N•m).

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12
Final Drive Sprocket
Removal

1. See the “Track Removal and Installation” procedure in this section

of the manual and remove the track from the sprocket.

2. Using a suitable lifting device, lay the track down on the floor to
access the sprocket.

3. Swing the boom to the side of the machine and lift the track frame
with the boom.

4. Place blocks (1) between the track frame and the track. Place blocks
(1) under the planetary housing also.

5. Remove the mounting bolts (2) from the sprocket.

6. Install an eye bolt in one of the top sprocket holes and remove the sprocket with a suitable lifting device.

Installation
1. Thoroughly clean the mating surfaces of the sprocket and final drive before installing the sprocket.

2. Fasten an eye hook to one of the bolt holes of the sprocket and attach a chain or a lifting strap to a suitable lifting device.

3. Place the sprocket on the final drive with the lifting device.

Apply LT-2 to the bolts.

4. Install the sprocket to the final drive with the bolts.

Torque the bolts to 475 to 580 lbf ft (640 to 785 N•m)

5. Remove the blocks and lower the track frame onto the track.

6. See the “Track Removal and Installation” procedure in this section of the manual and install the track on the sprocket.

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12
Track Slider
Removal

1. Use a suitable lifting device and lift the track up off of the track
slider.

2. Remove sixteen bolts (2), washers (3). Use a suitable lifting device
to remove track sliders (1) from the track frame.

Installation

1. Place the track sliders (1) on the track frame with a suitable lifting
device.

Apply LT-2 to the bolts before installation.

2. Install the track sliders onto the track frame with sixteen washers (3) and bolts (2).

3. Lower the track onto the track slider with the lifting device.

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12
Carrier Roller (Optional)
Removal
1. Use a suitable lifting device and lift the track up off of the track
roller.

2. Remove four bolts (6), washers (5), and use a suitable lifting
device to remove the track roller (2) from the track frame.

Installation
1. Place the track roller (2) on the track frame with a suitable lifting
device.

Apply LT-2 to the bolts before installation.

2. Install the track roller on the track frame with four washers (5) and
bolts (6).

3. Lower the track onto the track roller with the lifting device.

Track Frame
Removal

WARNING! Use a suitable lifting device that handle 14,000

lbs (6,350 kg) when lifting the track frame. 
Failure to comply could cause injury to person-
nel.

WARNING! Use suitable jack stands that can support

63,000 lbs (28,580 kg) under the car body.

1. Remove fourteen bolts (1), washers (2), and spacers (3).

2. Raise the car body (4) and support it with jack stands.

Car body: 63,000 lbs (28,580 kg)

3. Remove the track frame (5) from the car body (4) with a suitable
lifting device.

Track frame: 14,000 lbs (6,350 kg)

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-191
DISASSEMBLY AND ASSEMBLY TRACK SYSTEM

12
Installation

WARNING! Use a suitable lifting device that handle 14,000

lbs (6,350 kg) when lifting the track frame. 
Failure to comply could cause injury to person-
nel.

WARNING! Use suitable jack stands that can support

63,000 lbs (28,580 kg) under the car body.

1. Place the track frame (5) under the car body (4) with the lifting
device and align the mounting holes.

Apply LT-2 to the bolts before installation.

2. Install the track frame (5) to the car body (4) with fourteen spacers
(3), washers (2), and bolts (1).

Torque the bolts to 1,200 lbf ft (1,627 N•m).

3. Remove the jack stands from under the car body (4).

50-192 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY TRACK SYSTEM

12

MEMORANDUM

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-193
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

12
LEVELING CYLINDER

WARNING! Read and follow the safety instructions in this manual before performing these procedures. Failure
to comply could cause injury or death.

WARNING! Relieve hydraulic pressure before servicing any hydraulic component. 

Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.

WARNING! Wait for the hydraulic fluid to cool before servicing any hydraulic component.
Hot hydraulic fluid can cause severe burns.

WARNING! The entire upper part of the machine must be supported before removal of a leveling cylinder.
Support the upper portion of the machine with suitable supports and/or lifting devices. Failure to
comply can cause personal injury or death.

Cylinder Removal for XT430L-3, XT445L-3

Remark
Remove and reinstall one cylinder at a time so the upper portion of the machine is always supported on one
side by the other leveling cylinder.

1. Tilt the cab forward, fully extending the arm and boom.
2
2. Place blocks (2) on the tracks, under the cab frame to support the
cab.
Be careful to place the block under the cab frame, not touching the
radiator access door.

KPXT0140
3. Remove the skirting (2) from the top of the car body (3) to access
the leveling cylinder (4).

50-194 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

Remark
Mark the hydraulic hoses and grease lines before
removal to ensure correct installation.

4. Remove two hydraulic hoses and elbows (1 and 2) from leveling

cylinder (3) and cap off.

5. Remove grease line (4) from the bottom of leveling cylinder (3)
and cap off.

6. Remove grease line (1) from the rod end of the cylinder and cap
off.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-195
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

12
7. Remove locknut (1), washer (2), pin (3), and spacers (4) from the
revolving frame casting and rod end of the cylinder.

Remark
Hydraulic oil will squirt out the cylinder ports in the following step. Catch the oil with a container.

8. Carefully push the rod end into the cylinder with a forklift.

9. Fasten a lifting strap to the cylinder and to a forklift.

Leveling cylinder: XT430L-3 and XT445L-3: 352 lb (160 kg)

10. Remove bolt (5), washer (6), washer (7), shim (8), tapered cup (9), shim (10), and spacer (11) from each side of pin (12)
on bottom of cylinder.

11. Remove pin (12).

12. Lay a pad on the car body for the cylinder to rest against as it is removed from the body.

13. Carefully lift the cylinder out of the car body with the forklift, pulling the cylinder up and out, tilting toward the rear of the
car body to clear the cab.

50-196 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

Cylinder Installation for XT430L-3, XT445L-3

1. Apply antiseize compound to the inside surface of cylinder bush-
ings (1). 
Do not let antiseize get on other parts.

2. Use the forklift to slowly lift the leveling cylinder and place into
the car frame.

KPXT0145
3. Center lower end of cylinder between the frame mounting plates
(3).

3 KPXT0170
4. Position grease fitting port (2) to face inboard on the rod end of
cylinder.
2

KPXT0154

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-197
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
5. Add tapered spacers (11), with tapered side in on both sides of cyl-
inder end.

6. Install pin (12), pushing it all the way through the opening, coating
it with antisieze as it moves. Realign the pin within opening so that
it is centered evenly.

7. Install the thick notched shim (10) on the inside of cylinder.

8. Install thinner full shim (10) on the outside of cylinder.

9. Check for any play. 

If needed, add shims to fill any gaps starting on the inside first.
Install additional shim (8) as required to provide a minimum clearance of 0.06 in (1.524 mm) between washers (7) and
tapered cup (9). 
Maximum clearance not to exceed 0.15 in (3.81 mm).

10. Install tapered cap (9) on both ends, tapping in with hammer.

11. Install bolt (5), washer (6) and (7), and any additional shim (8),
and insert at both inside and outside of cylinder.

Two bolts (5) XT430-3, XT430L-3, XT445L-3: 

incremental torque, alternating sides to
900 lbf ft (1,220 N•m)

12. Rotate rod end (2) of the cylinder so that it will properly align with
revolving frame casting.

13. Attach rod end of the cylinder to the revolving frame with locknut
(1), washer (2), pin (3), and two spacers (4).
Tighten with impact wrench.

14. Apply a light coating of LM-P grease to the inner surface of cylin-
der spherical bearing (rod and base).

50-198 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
15. Install grease line (1) on rod end of cylinder.

16. Install grease line (4) on base end of cylinder (3).

17. Install two hydraulic hoses (1) and (2) on cylinder (3).

18. Install the skirting (2) on the car body (3).

19. See “Vent Air From Hydraulic System” on page 50-41.

Cylinder Removal for XT460L-3

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-199
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

Remark
Remove and reinstall one cylinder at a time so the upper portion of the machine is always supported on one
side by the other leveling cylinder.

1. Tilt the cab forward, fully extending the arm and boom.
2
2. Place blocks (2) on the tracks, under the cab frame to support the
cab.
Be careful to place the block under the cab frame, not touching the
radiator access door.

KPXT0140
3. Remove the skirting (3) from the top of the car body (4) to access
the leveling cylinder (5).

Remark
Mark the hydraulic hoses and grease lines before
removal to ensure correct installation.

4. Remove two hydraulic hoses and elbows (1 and 2) from leveling

cylinder (3) and cap off.

5. Remove grease line (1) from the rod end of the leveling cylinder
and cap off.

50-200 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
6. Remove locknut (2), washers (7 and 3), cap (4), pin (5), and spac-
ers (6 and 15) from the revolving frame casting and rod end of the
cylinder.

Remark
Hydraulic oil will squirt out the cylinder ports in the following step. Catch the oil with a container.

7. Carefully push the rod end into the cylinder with a forklift.

8. Fasten a lifting strap to the cylinder and to a forklift.

Leveling cylinder: XT460L-3: 400 lb (181.43 kg)

9. Remove bolts (8), washers (9), plate (10), tapered cup (11), and spacer (12) from each side of pin (13) on bottom of cylin-
der.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-201
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

10. Remove pin (13).

11. Lay a pad on the car body for the cylinder to rest against as it is removed from the body.

12. Carefully lift the cylinder out of the car body with the forklift until you can reach the lower grease line.

50-202 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
13. Remove grease line (4) from the bottom of cylinder (3) and cap
off.

14. Continue to use the forklift to remove the cylinder carefully, pull-
ing the cylinder up and out, tilting toward the rear of the car body
to clear the cab.

Cylinder Installation for XT460L-3

1. Apply antiseize compound to the inside surface of cylinder bush-
ings (1). 
Do not let antiseize compound get on other parts.

KPXT0145

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-203
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
2. Use the forklift to slowly lift the cylinder toward the car frame,
positioning grease fitting port on the cylinder to face outward.

3. Install lower grease line (4) on base end of cylinder (3).

4. Slowly continue to lower the cylinder (2) fully into the car body,
centering the bottom end of cylinder between the frame mounting
plates. 2

KPXT0154

5. Add tapered spacers (12) on both sides of the bushing, with

tapered side in.
9 8
6. Install pin (13), pushing it all the way through the opening, coating 12 11
it with antisieze as it moves. Realign the pin within opening so that 13
it is centered evenly.
12
11
10
9
8
7. Check for any play. 
If needed, add shims to fill any gaps starting on the inside first.
KPXT0162
Install additional shim (14) as required to provide a minimum
clearance of 0.06 in (1.524 mm) between washer (9) and plate
(10). Maximum clearance not to exceed 0.15 in (3.81 mm).

8. Install tapered cap (11) on both sides, tapping in with hammer.

50-204 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
9. Install 3 bolts (8) and washers (9), with plate (10) and insert on
both ends.

10. Tighten the two outer bolts (with locktite applied) onto keeper
plate (10).
10
11. Tighten center bolt (8) (NO locktite) onto the same keeper plate KPXT0167
(10).

12. Torque the two outer bolts (8) in increasing step increments, alternating between each side, until 130 lbf ft (176.26 N•m)
is obtained.

Two outer bolts (8) XT460L-3: incremental torque, alternating sides to 130 lbf ft (176.26 N•m)

13. Torque the center bolt (8) in increasing step increments until 860 lbf ft (1,166 N•m) is obtained.

Center bolt (8) XT460L-3: incremental torque, alternating sides to 860 lbf ft (1,166 N•m)

14. Rotate rod end (2) of the cylinder so that it will properly align with
revolving frame casting.

15. Attach rod end of the cylinder to the revolving frame with locknut
(2), washers (7 and 3), cap (4), pin (5), and two spacers (6 and 15).

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-205
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER
16. Tighten with impact wrench.

17. Apply a light coating of LM-P grease to the inner surface of cylin-
der spherical bearing (rod and base).

18. Install the grease line (1) on rod end of cylinder.

19. Install the two hydraulic hoses (1) and (2) on cylinder (3).
The lower grease line (4) was attached in Step 3 above.

20. Once both rod cylinders (5) have been installed, install the skirting
(3) on the car body (4).

21. See “Vent Air From Hydraulic System” on page 50-41.

50-206 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY LEVELING CYLINDER

12

MEMORANDUM

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-207
DISASSEMBLY AND ASSEMBLY CAB

12
CAB

WARNING! Read and follow the safety instructions in this manual before performing these 
procedures. Failure to comply could cause injury or death.

Removal
Remark
Mark all wires and hoses before removal to ensure correct re-installation.
Remark
Hydraulic oil will leak out in the following step. Place a container to catch the oil.

1. Open the rear guard door of the cab and remove the following
hoses from the auxiliary hydraulic cooler.
• Logic block hose (1)
• Hydraulic tank hose (2)
• Coolant pump hose (3)

2. Remove the fan motor line (3) from the fan motor (4) located in
the top of the guard door above the fan.

50-208 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB

KPXT0171

Remark
Collect the refrigerant from the air conditioner system before removing any hoses. 
Refer to Section 80, Air Conditioner.
Remark
Engine coolant will leak out of the hoses and the heater in the following step. Place a container to catch the
oil. Cap off hoses after draining.

3. Close the heater hose shut-offs at the front and rear of the engine to minimize coolant loss.

4. Remove the air conditioner hoses (7) from the compressor, at top
front of engine.

5. Remove the air coolant lines (1) from the top of the air conditioner
condenser.

SR0136A

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-209
DISASSEMBLY AND ASSEMBLY CAB

6. Remove heater hose connection (3) from the rear of the cab.

1 LOWER REAR CAB EXTERIOR

5 KPXT0158
7. Remove lower air conditioning hose (5) from the cab.

8. Remove coolant hose (6).

9. Remove the operator’s seat from the cab. See “OPERATOR’S SEAT” on page 50-224 for instructions.

50-210 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
10. Disconnect all electrical fire suppression cable connections from
the Ansul control module (1) inside the rear of the cab, using your
hand to loosening the swivel nut and pull apart the connections.

11. Disconnect two fire suppression cable connections (2 and 3) from

the rear of the cab in the same manner.

Remark
Mark all wires and hoses before removal to ensure correct installation.

12. From inside the cab next to the seat, remove the electrical front console panel by unscrewing 7 screws.

13. Access the bracket on the back wall under the electrical panel.
Remove engine ground wire (6) and 3 other ground wires (7) from
top two bolts on the bracket. 6
14. Remove engine ground wire (6) from cab by pulling it through the
exterior side opening.

SR0124

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-211
DISASSEMBLY AND ASSEMBLY CAB
15. Remove connections from the following ports:

A. Remove horn harness (2) from the first port.

B. Remove starter harness (3) from the third port (black wire).

C. Remove fill pump (4) from the fourth port (white wire). This
connection includes a ground wire.

D. Remove ROPS light wiring harness (5) from the sixth and
seventh ports. This connection includes a ground wire.

Remove the harnesses from the cab by pulling them through the
exterior side opening.

16. Remove the BLUE auto reversing fan wire (1) from the bottom of
the control box. Remove wire from cab by pulling it through the
exterior side opening.

17. Remove the engine harness (bulkhead):

A. Remove bolts (qty 4) from the bracket plate (1), then remove
plate from the inside of the cab.

B. Remove the load center harness (1) from the engine harness
(2).

50-212 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
C. Remove the engine harness (1) from the hole in the back of
the bracket plate.

D. Remove the engine harness from cab by pulling it through the

exterior side opening.

If it is necessary to remove the guard door, follow instructions 18-20. If it is not necessary, proceed to step 21.

18. Attach the chains to the guard door and to a suitable lifting device:

A. Screw the .5 inch C7 eye bolt (1) into the top of the guard
door.

B. Attach a strap (2) to the guard door handle and chain (3) to the
eye bolt (1), and lift with a suitable lifting device.

19. Remove the guard door from the door hinges (4).

20. Lift the guard door up out of the door hinges (4) and remove the
door from the machine.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-213
DISASSEMBLY AND ASSEMBLY CAB
21. Attach suitable chains and/or straps to three corners of the cab and
attach them to a suitable lifting device.

22. Remove the 6 attaching bolts, washers, and isolators from the cab
(6 and 7).

SR0117A

SR0070A

50-214 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
23. Remove the cab from the machine with the lifting device.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-215
DISASSEMBLY AND ASSEMBLY CAB

12
Installation
Remark
Check the isolators for wear and replace if required.

1. Attach chains to the guard door and suitable lifting device.

A. Screw the .5 inch C7 eye bolt (1) into the top of the guard
door.

B. Attach a strap (2) to the guard door handle and chain (3) to the
eye bolt (1), and lift with a suitable lifting device.

2. Install the guard door on the door hinges (4).

3. Prepare the isolators and washers (qty 6) on the revolving frame

(5).

SR0116A

50-216 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
4. Place washers (qty 6) and bolts (qty 6) in the bottom of the cab to
line up with the revolving frame.

SR0117A
5. Attach suitable chains and/or straps to three corners of the cab and
attach them to a suitable lifting device.

6. Attach the cab to the revolving frame, lining up the attaching bolts
and washers (7) to the revolving frame.

Torque the bolts (6) to 600 lbf ft (814 N•m).

SR0070A

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-217
DISASSEMBLY AND ASSEMBLY CAB
7. Route the heater hoses and wire harnesses from the engine to the
rear of the cab.

8. Connect heater hose (3) from the engine to the rear of the cab.

1 LOWER REAR CAB EXTERIOR

5 KPXT0158
9. Connect air coolant lines (1) to the air conditioner condenser on
top of the cab.

SR0136A

10. Connect lower air conditioning hose (5) to the rear of the cab.

11. Connect coolant hose (6).

50-218 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
12. The main valve harness has a fan motor line (1) that runs behind
the valves to the rear guard door (2).

Connect the guard door end of fan motor line (3) to the fan motor
(4) located in top of guard door.

KPXT0171

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-219
DISASSEMBLY AND ASSEMBLY CAB
13. Route engine harness (bulkhead) from the engine through the
boom support and into the side of the cab.

KPXT0172

14. Remove bolts (qty 4) from the bracket plate (1), then remove plate
from the side of the cab.

15. Pull the end of engine harness (1) into the hole from the back of
the bracket plate.

16. Attach the bracket plate back onto the side of the cab using bolts.

17. Connect the load center harness (1) to the engine harness (2).

50-220 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
18. Route the BLUE auto reversing fan wire (1) from the engine
through the boom support into the cab, and connect to the bottom
of the control box. Cut to length before connecting, if required.

19. Route horn harness (2) to the cab, connecting to first port.

20. Route starter harness (3) to third port (black wire).

21. Route fill pump (4) from the engine into the cab at port 4 (white
wire). This connection includes a ground wire.

22. Route ROPS light wiring harness (5) from the boom support into
sixth and seventh ports. This connection includes a ground wire.

23. Route ground wire (6) from the engine into the cab.
7
24. Connect 3 ground wires onto bracket to the right of the control 6
box.

A. Remove the ground connectors for the top two connections.

B. On the top connection, place engine ground wire (6) then the 8
original ground for that connection.

C. On second connection, place fill pump and harness ground

wires (8). Then place original ground for that connection (9). 9

SR0124A

25. Connect all electrical fire suppression cable connections to the

Ansul control module (1) inside the rear of the cab, matching cable
colors. Gently connect the cables by pressing together, then hand-
tighten with the swivel nut.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-221
DISASSEMBLY AND ASSEMBLY CAB
26. Connect the two fire suppression connection plugs (2 and 3) on the
rear of the cab.

27. Check that the heater hoses are connected to the rear and front of
the engine compartment.

28. Check that the air conditioning hoses (7) are properly connected to
the compressor, at top front of engine.

29. Install the operator’s seat in the cab, routing air conditioning hoses under the seat to the front vent. See “OPERATOR’S
SEAT” on page 50-224 for instructions.

50-222 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY CAB
30. Install the following three hoses to the auxiliary hydraulic cooler
under the guard door.
• Logic block hose (1)
• Hydraulic tank hose (2)
• Coolant pump hose (3)

31. Charge the air conditioning system with R34a.

32. Check the coolant level in the radiator.

33. Add 40 ml (40cc) of air conditioning oil to the return port at the compressor connection. Use Sanden R134a PAG SP-15
Compressor Lubricant. After filling, rotate compressor to circulate oil.

Fill the compressor with 40ml (40 cc) of Red Dot - Sp15
Pag Oil for Sanden R134a Compressors.

Inject the oil in the suction port (blue) of the compressor.

See Section 80, Air Conditioner, for more information.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-223
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT

OPERATOR’S SEAT

Removal
1. Remove four cables (2), (3), (8) and (9) from the connections on
the control box behind the seat.

50-224 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT
2. Remove 4 bolts (4) from the front plate (3).

3. Pull the front plate (3) from the seat base and disconnect the air
conditioning hose.

4. Remove the air conditioning hose (1) from the under the seat base
(2), pulling it through the rear of the cab.
Remark
It is best to detach the hose from the base plate end
rather than the A/C unit end when removing the seat.

5. Remove the bolts from the base (1) of the operators seat. Then
remove the seat from the cab (2).

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-225
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT

Installation
1. After the seat is fully assembled, bolt the base (1) of the operators
seat to the bottom of the cab (2).

2. Route the air conditioning hose (1) from the rear of the cab, under
the seat through the back of the seat base (2).
Remark
It is best to reatttach the hose from the base plate end
rather than the A/C unit end when installing the seat.

3. Fasten the air conditioning hoses to the front plate of the seat base,
snapping the front plate together.

4. Fasten the front plate (3) onto the seat base with 4 bolts (4).

50-226 XT430-3,XT430L-3,XT445L-3,XT460L-3
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT
5. Connect four cables (2), (3), (8) and (9) from the back of the seat
to the rear of the cab.

The plugs go in corresponding connections (2), (3), (8) and (9) to

the control box.

XT430-3,XT430L-3,XT445L-3,XT460L-3 50-227
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT

50-228 XT430-3,XT430L-3,XT445L-3,XT460L-3
 80 AIR CONDITIONER

AIR CONDITIONER/HEATER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-3

AIR CONDITIONER / HEATER PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
A/C System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
AIR CONDITIONER/HEATER ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Technician Training and Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-1
AIR CONDITIONER
12

MEMORANDUM

80-2 XT430-3,XT430L-3,XT445L-3,XT460L-3
AIR CONDITIONER AIR CONDITIONER/HEATER CONTROLS
12IR COAIR CONDITIONER/HEATER
AIR CONDITIONER/HEATER CONTROLS
The air conditioner/heater unit controls the temperature and fan power
inside the cab. The AC/Heater control switch (1) is located on the dash
next to the hydraulic tank switches.

A/C controls:
• FAN CONTROL - Controls power level of fan. Ranges from OFF
 Low  Medium  High. The fan control must be ON for the
A/C and defrost modes to work.
• A/C HEAT - Toggle between air conditioner and heater modes.
• Left Position (Snowflake symbol)- Air Conditioner
• Center Position - Heat mode
• Right Position (Heatwave symbol) - Activate defrost mode.
• TEMP CONTROL - Controls level of cold or hot air depending
upon the mode. This switch operates the water valve.
Adjust the direction of the air flow by moving the adjustable air vents
located behind the operator’s seat.

The pressurized cab heater draws additional air into the cab through the
air intake duct. The air is filtered through an additional air filter that is
installed behind the louvered panel (1) located on the outside of the
cab, to the left of the cab door.
To change the filter, remove the eight bolts (2) to remove the louvered
panel and replace the filter. Make sure to replace the filter with the 
correct Komatsu air filter.

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-3
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

1. The fan does not a. No power to blower switch. Check the power to the blower.
work
b. No ground to blower motor. Check ground to the blower.
c. Blower fan stopped turning. Check power to the H-M-L (see “Control Panel Electrical
Diagram” on page 80-9).
2. The A/C works but a. No power to A/C panel switches. Check the power to the switch panel on the dash, checking
does not cool for A/C and Thermostat connections.
b. Condenser plugged with debris.

Air Conditioner Condenser

• Check and clean condenser (2).
c. Condenser fan fuse blown. • Check the condenser fan fuse. Replace if required.
d. Condenser fan relay fuse blown. • Check the condenser fan relay fuse. Replace if
required.
e. Condenser fan relay malfunction: • Check to be sure the condenser fan relay is seated
condenser fan relay loose or firmly in its mount.
malfunctioning. • Replace if required.

80-4 XT430-3,XT430L-3,XT445L-3,XT460L-3
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

f. Condenser fan malfunction.

Condenser Fan
• Check for damaged fan blades (1).
• Replace fan blades if required.
• Inspect wiring to motor assembly.
• Tighten any loose connections.
• Inspect motor assembly.
• Replace motor if required.
g. No power through binary switch • Check power through binary switch.
• Check refrigerant pressure.
h. Binary switch malfunction.

Binary Switch
• Replace binary switch (1).
i. Freon leak. • Check drier assembly sight glass (2) for signs of a
freon leak.
j. No power from binary to compressor Check power from binary to compressor clutch.
clutch.

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-5
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

k. Hot water shut-off valves at engine
are open.

Hot Water Shut-Off Valves

• Close both hot water shut-off valves (1 and 2) at
engine.

80-6 XT430-3,XT430L-3,XT445L-3,XT460L-3
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

l. Air conditioner compressor drive belt
loose.

Compressor Drive Belt (Typical)

• Tighten drive belt (1).
m. Loose electrical connection to air • Check all electrical connections from the cab to the
conditioner compressor. compressor.
• Tighten any loose wires.
n. Air conditioner compressor
malfunction.

Air Conditioner Compressor (Typical)

• Replace air conditioner compressor (1).

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-7
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

3. Heater works, but no a. Main water shut-off valve
warm air. malfunction.

Main Hot Water Shut-Off Valve

• Be sure the main hot water shut-off valve (1) is open.
• If not, open valve.
• Check main hot water shut-off valve.
• Re-connect pull cable or replace valve if required.
b. Hot water shut-off valves at engine
closed.

Hot Water Shut-Off Valve

• Open both hot water shut-off valves (1 and 2) at
engine.
c. No power and ground to Confirm power and ground to potentiometer.
potentiometer.

80-8 XT430-3,XT430L-3,XT445L-3,XT460L-3
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

PROBLEM PROBABLE CAUSE ACTION

d. Water valve not operating.

Check water valve operation by performing water valve

test:
• Power to Pin 1 - 12v or 24v
• Ground to Pin 4 - ground
• Put power to & take away from pin 2 and motor
should turn.
e. Water flow is wrong. Check plumbing to connection (see “Water Flow Dia-
gram” on page 80-10).

Control Panel Electrical Diagram

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-9
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

Water Flow Diagram

80-10 XT430-3,XT430L-3,XT445L-3,XT460L-3
AIR CONDITIONER AIR CONDITIONER / HEATER PROBLEMS

A/C System Diagnostics

Use this information to diagnose an expansion valve system for proper refrigerant pressure.

System Operating Normally - Fully Charged

Low Side High Side Sight Glass Evaporator Outlet Duct Temperature
5-30 PSI 150-285 Clear - any color other Cold - Lines sweating heavily, 40° - 50°
Pressure will be Low air flow than white or clear no frost
higher at higher past the indicates system
blower speeds condenser contamination
increases high
side pressures

Diagnostic Chart
Low Side High Side Symptoms Diagnosis Solutions
Low Low Poor or no cooling Low or improper refrigerant Check and repair any leaks in
5-30 PSI 110-150 PSI Foamy bubbles in the charge. the system.
sight glass. Compressor Recharge system as needed.
cycles rapidly. Warm
evaporator outlet line.

Low or Vacuum Low to Normal No cooling. Low or improper refrigerant. Check the expansion valve and
-20 to 5 PSI 115-160 PSI Sight class is clear. Bad expansion valve. screen.
Warm evaporator outlet Gauge reading may be higher if Look for icing on the high-side
line. the restriction is directly past lines.
service fitting. Clear the restriction or replace
necessary components.
Evacuate and recharge the sys-
tem.

Normal to Low Normal Unit works fine for a Evaporator freeze-up. Replace thermostatic switch,
0-25 PSI 150-285 PSI while, then begins to Bad thermostatic switch, clutch clutch or clutch relay.
blow warm air. or clutch relay.
Evaporator pipes frozen.
Compressor does not
cycle.

High or Equal to Low or Equal to No cooling. Expansion valve stuck open. Repair or replace compressor.
High Side Low Side Gauge Warm evaporator outlet Bad compressor. Replace expansion valve.
Gauge 90-110 PSI pipe. Evacuate and recharge the sys-
70-90 PSI Compressor will not tem.
cycle.

Normal to High High Fair to poor cooling. System overcharged. Recover excess R12 or R134a
30-80 PSI 250-350 PSI Sight glass clear to until system operation returns to
foamy. normal.
Evaporator outlet cool
to warm.

Normal to High High Fair to poor cooling. Restricted airflow past con- Check cooling fan operation.
30-60 PSI 250-400 PSI Sight glass clear. denser. High temperature air Clear radiator or condenser
Evaporator outlet cool across condenser. restriction.
to warm. Check for excess heat load if
near hydraulic oil cooler, etc.

XT430-3,XT430L-3,XT445L-3,XT460L-3 80-11
AIR CONDITIONER AIR CONDITIONER/HEATER ACCESS
Air Conditioning Configuration

AIR CONDITIONER/HEATER ACCESS

Control switches for the air conditioner, heater and defroster are located on the dash within the cab. Heater hoses are connected
to the back of the cab.

The air conditioning system is pre-assembled and located on the back of the cab behind the seat. This unit includes the evapo-
rator, fan motor and heater core. When a problem arises in air conditioning unit, all hoses are disconnected from the unit, and
the unit is removed from the back of the cab for replacement. All heater and air conditioning hoses are accessible from the
back of the cab.

Technician Training and Certification

Technicians who repair or service CFC-12 and HFC-134a motor vehicle air conditioners must be trained and certi-
fied by an EPA-approved organization. Training programs must include information on the proper use of equip-
ment, the regulatory requirements, the importance of refrigerant recovery, and the effects of ozone depletion. To be
certified, technicians must pass a test demonstrating their knowledge in these areas. A list of approved testing pro-
grams is available from the U.S. Environmental Protection Agency (EPA).

80-12 XT430-3,XT430L-3,XT445L-3,XT460L-3
 90 DIAGRAMS AND SCHEMATICS

Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

Track Drive (1/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5

Bar Saw (2/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Intermittent Disc Saw (3/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
Combination Bar Saw and Disc Saw (4/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Disc Saw (5/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
Split Flow Processor #2 (6/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Combined Flow Processor #3 (7/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
Combined Flow Processor #4 (8/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
Combined Flow Processor #5 (9/9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19

IQAN Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21

IQAN Control System Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
IQAN Control System Electrical Schematic (1/5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
IQAN Control System Electrical Schematic (2/5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
IQAN Control System Electrical Schematic (3/5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
IQAN Control System Electrical Schematic (4/5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
IQAN Control System Electrical Schematic (5/5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
IQAN Control System Enclosure Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33

Dash Panel Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35

Cummins Engine Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
Engine Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39
Cab Circuit Connections Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
Load Center Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43

XT430-3,XT430L-3,XT445L-3, XT460L-3 90-1

DIAGRAMS AND SCHEMATICS
12

MEMORANDUM

90-2 XT430-3,XT430L-3,XT445L-3, XT460L-3

XT430-3, XT430L-3, XT445L-3, XT460L-3

High pressure loop oil

Charge pressure
Brake release

Motor shift

Case return

Charge relief return

3
HYDRAULIC 29
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Bar Saw

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-5

HYDRAULIC 39
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Intermittent Disc Saw

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-7

HYDRAULIC 49
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Bar and Disc Saw Combo

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-9

HYDRAULIC 59
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Disc Saw

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-11

HYDRAULIC 69
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Split Flow, Processor #2

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-13

HYDRAULIC 79
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Combo Flow, Processor #3

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-15

HYDRAULIC 89
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Combo Flow, Processor #4

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-17

HYDRAULIC 99
XT430-3, XT430L-3, XT445L-3, XT460L-3

Hydraulic System - Combo Flow, Processor #5

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-19

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Connection Diagram

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-21

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Electrical Schematic (1/5)

See load center

IQAN connector

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-22

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Electrical Schematic (2/5)

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-25

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Electrical Schematic (3/5)

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-27

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Electrical Schematic (4/5)

See load center

IQAN connector

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-29

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Electrical Schematic (5/5)

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-31

IQAN CONTROL SYSTEM
XT430-3, XT430L-3, XT445L-3, XT460L-3

Enclosure Wiring Diagram

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-33

DASH PANEL SCHEMATIC
XT430-3, XT430L-3, XT445L-3, XT460L-3

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-35

Cummins Engine Schematic
XT430-3, XT430L-3, XT445L-3, XT460L-3

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-37

Engine Harness Schematic
XT430-3, XT430L-3, XT445L-3, XT460L-3

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-39

Cab Circuit Connections Diagram
XT430-3, XT430L-3, XT445L-3, XT460L-3

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-41

Load Center Electrical Schematic
XT430-3, XT430L-3, XT445L-3, XT460L-3
K-1 K-2 K-3 K-4

SWITCHED FOPS LIGHT IQAN RELAY DOOR & UP

PWR RELAY RELAY LIGHT RELAY
EK55099 EK55099 EK55099 EK55099

*CHARGE FILTER LIGHT INPUT -IQAN

HYD OIL LEVEL LIGHT INPUT -IQAN

CIRCULATION FAN POWER SUPPLY

WAIT TO START LAMP (RESERVED)

ARM SYSTEM 24v+ LATCH SUPPLY

REVERSE FAN OVERRIDE SIGNAL

DISC SAW OFF/ON SW'S SUPPLY
AK10025 AK10025 AK10025 AK10025

VEH KEY SWITCH "E' STOP OUT

VEH KEY SWITCH "E' STOP IN
HYD TANK VAC PUMP ON SIG
HYD TANK VAC SW'S SUPPLY

MASTER DISCONNECT LAMP

CHARGE RELIEF SW SUPPLY
LOWER LIGHTS ON SIGNAL
UPPER LIGHTS ON SIGNAL

BOOM LIGHTS ON SIGNAL

DISC SAW ON SIG & LAMP
CONDENSER FAN SIGNAL

DASH POWER 12V PORTS

VACUUM PUMP OUTPUT

DASH GROUND SUPPLY

VAC PUMP ON SIGNAL

84824 (EK55099)

Binary Switch Power +

THROTTLE POSITION
CAB REAR LIGHTS +

AIR CONDITIONER +
CONDENSER FANS +

IGN SWITCH SUPPLY

"ARM SYSTEM" +24v

CHARGE RELIEF ON
AK10011 AK10011

CAB SIDE LIGHTS +

THROTTLE RETURN
THROTTLE +5vDC
IGNITION SIGNAL

HYD TANK VENT

DOME LIGHT +

HORN SUPPLY
85 85 85 85

NOT USED
NOT USED

NOT USED
NOT USED

NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

NOT USED
NOT USED
VACANT

VACANT

VACANT

VACANT
VACANT

VACANT

VACANT
VACANT

VACANT
RADIO +

87

87

87

87
30 30 30 30

SPARE
FOR MAXI HEAD INSTALLATION USE:

START

HORN
SHIFT
86 86 86 86 P/N: 28542 (WT90237) HARNESS, MAXI INTERFACE.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12
INSERTION VIEW
FOR ROLLY II HEAD INSTALLATION USE:
SEE DASH PANEL CONNECTOR B
K-1 K-2 K-3 K-4

SEE CAB CIRCUIT CONNECTIONS (SHEET 2 OF 2) SWITCHED POWER

RELAY
FOPS LIGHT
RELAY
IQAN RELAY DOOR & UPPER
LIGHT RELAY
SEE DASH PANEL CONNECTOR A P/N: 28699-B (WT91267 Rev B) KIT, ROLLY II INTERFACE.
24V 24V 24V 24V
J-3 J-2
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 MAXI HEAD OPTION CONN.
J-4 30 85 86 87 30 85 86 87 30 85 86 87 30 85 86 87
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 RED/VIO 12g ATTATCHMENT BATT+ SUPPLY
1
J-1A

16g
18g

14g
16g
18g
16g

16g
18g
18g
16g
18g
16g
18g
18g
18g
18g
14g
18g
18g

18g
18g
18g

20g
20g
20g
14g

18g

XXg
XXg
18g
18g
18g
18g
18g

18g
18g

18g
20g
BLACK 12g 2 ATTATCHMENT GROUND SUPPLY

XXg
XXg

XXg
XXg
XXg
XXg
XXg
12g
16g
14g
14g
16g
14g

18g
18g

18g
14g

10g
16g
16g
10g

10g
16g
18g
10g

12g
16g
16g
10g

10g
16g
18g
10g

ORG/WHT

ORG/WHT

WHT/ORG

WHT/GRN
ORG/GRN
GRA/WHT
GRN/RED

WHT/BLK
GRA/RED

GRA/RED
ORG/BLU

PNK/RED

TAN/GRN
BLK/BRN
PNK/BLK
YEL/WHT

PNK/BLU
TAN/RED

ORANGE

RED/BLU
18g

BLU/RED
BLU/RED
ORG/BLU IGNITION SIGNAL

VIO/WHT

BLK/TAN
1

VIO/GRA

RED/YEL
YEL/TAN

VIO/YEL
GRN/WHT
BRN/WHT

BLACK

BLACK
BRN/ORG

RED/WHT
BRN/GRA
RED/ORG
BLU/WHT
GRN/BLK

WHITE

WHITE
ORG/BLK
BRN/BLU

ORG/BLU

ORG/BLU
PNK/RED

PNK/BLK
BRN/YEL
18g

XXXXX
XXXXX
VIO/TAN 2 IQAN V OUTPUT DOOR INTERLOCK

VACANT
VACANT

VACANT
VACANT
VACANT
VACANT
VACANT

GRAY

GRAY

PINK

RED
BLACK

BLACK

BLACK

BLACK
3 VACANT J-1B

RED

RED

RED

RED

RED

RED

RED
ORG/RED 16g 4 HBL MEMORY SUPPLY FROM BATTERIES
5 NOT USED
6 NOT USED

ORG/BLU 18g SPARE IGNITION SIGNAL WIRE

BLK/LTBLU 18g SPARE

BLK/GRN 14g TO ROTARY MANIFOLD WIRE #1 W/AA11853

ORG/VIO 18g AVAILABLE RELAY #86
GRN/VIO 14g AVAILABLE RELAY #87

BOTTOM VIEW K-9

SIGNAL
28430 24v

GND
3

86 30

85 87 87A
+1 2 5
CONTACT TERMINAL= AC12697-1 (8)

+
24v 5 2 4 1

+3 COIL TERMINAL= EK55041 (12)

4 24323 24v

K-5 K-6 K-7 K-9

BATT. DISC. LED HYD. VACUUM SYST. HYD. VACUUM SYST. T475 FUEL TRANSFER
ENABLE MICRO RELAY ENABLE MICRO RELAY DISABLE MICRO RELAY PUMP RELAY
24V 24V 24V 24V

86 85 30 87a 87 86 85 30 87a 87 86 85 30 87a 87 30 86 87a 87 85

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

16g
16g
18g
18g

16g
16g
18g
18g

18g
16g
18g

18g

14g
14g

14g
16g
RED
WHITE
BLACK

EH56066/AO14350
EH56066/AO14350

GROUND
BUSS

ORG/GRN

ORG/GRN
ORG/GRN

ORG/GRN

ORG/GRN
PNK/GRN
ORG/BLU

ORG/BLU
VIO/YEL
EH56067

EH56068

GREEN
BLACK

BLACK

BLACK

BLACK
WHITE
FAN CONTROLLER CONNECTOR

RED
20g
20g
20g

1 VACANT
RED 14g 2 SUPPLY
2 EA AO14350 1.2K Ohm, .05W, 2% RESISTOR
2 EA EH56066 4 POS DBL POTENTIAL BLOCK

BLACK 14g 3 GROUND

1 EA EH56068 END PLATE, ORANGE 2mm
DETAIL A

BLACK 14g 4 GROUND

1 EA EH56067 4 POS THRU BLOCK

24v
RED
WHITE
BLACK BATTERY +
20g
20g
20g

F(57)/50A

F(58)/40A

F(59)/30A

F(60)/40A

F(61)/40A

F(62)/30A

F(63)/30A

F(64)/40A
20g
20g
20g

DETAIL A

RED 10g 1 2 3 4 5 6 7 8
RED
WHITE
BLACK

RED 10g
RED 12g
RED 10g
RED 10g
A1 B1 C1 D1 A1 B1 C1 D1
RED 12g
BLU/YEL 12g

F-30 (10A)

F-31 (10A)

F-32 (20A)
F-2 (7.5A)

F-3 (15A)
F-1 (20A)

F-29 (3A)
F-4 (5A)
RED 12g

S1 16g RED "S" R1 12g RED "R" P1 16g WHT/ORG N1 14g RED "N" M1 14g RED "M" L1 14g RED "L"
S2 18g BLK/BRN R2 16g BRN/ORG P2 18g GRA/WHT N2 18g BLK/TAN M2 18g ORG/VIO L2 16g ORG/BLU
S3 R3 P3 N3 M3 L3
A2 B2 C2 D2 A2 B2 C2 D2
S4 16g GRN/TAN R4 12g GRN/BLK P4 18g GRA/WHT N4 14g GREEN M4 14g GRN/VIO L4 14g BLK/GRA
S5 16g BLACK R5 16g BLACK P5 16g BLACK N5 16g BLACK M5 16g BLACK L5 16g BLACK
20g
20g
20g

AC12508-2 16 POS SQUARE FLANGE RECEPTACLE

REQUIRES AC12699 PIN TERMINALS
IQAN
RED
WHITE
BLACK
TO IQAN HARNESS P/N: GS14123-300

CONNECTOR
J-5
VACANT XXg VACANT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

A3 B3 C3 D3 A3 B3 C3 D3

F-34 (10A)

F-35 (10A)

F-36 (10A)
F-8 (7.5A)
F-5 (__A)

F-6 (10A)

F-33 (3A)
MAXI DOOR INTERLOCK 18g VIO/TAN

F-7 (2A)
VAC PMP "ON" LIGHT INPUT 16g GRN/TAN
VAC PMP STRT INTRPT LT INPT 18g PINK/GREEN
DISC SAW SYSTEM ARM 18g PNK/BLU
A4 B4 C4 D4 A4 B4
DISC SAW SYSTEM SUPPLY 18g GRN/RED C4 D4

CHARGE RELIEF HEATER 18g WHT/BLK

S R P N M L
GROUND 16g BLACK
GROUND 16g BLACK 2 5 2 5 2 5 2 5 2 5 2 5

86 30

85 87
86 30

85 87

86 30

85 87
86 30

85 87

86 30

85 87

86 30

85 87 87A
1 4 1 4 1 4 1 4 1 4 1 4
XS2 MODULE POWER 24V 16g GRN/YEL
3 3 3 3 3 3
XA2 MODULE 24V 16g GRN/ORG 24323 24v 24323 24v 24323 24v 24323 24v 24323 24v 24323 24v
K-10 K-11 K-12 K-13 K-14 K-15
XA2 MD4 24V 16g GRN/GRA
HYD. TANK VACUUM CONDENSER DISC SAW REVERSE AVAILABLE KAB SEAT
REAL TIME CLOCK + 18g YEL/BLU A5 B5 C5 D5 A5 B5 C5 D5 PUMP RELAY FANS LATCHING FAN CONTROL RELAY RELAY

F-12 (10A)

F-38 (10A)

F-39 (10A)

F-40 (10A)
RELAY RELAY RELAY

F-11 (3A)
F-10 (3A)
F-9 (__A)

F-37 (3A)
CAN SHIELD 20g WHITE
CAN LO 20g GREEN
CAN HI 20g YELLOW
X W V U T
A6 B6 C6 D6 A6 B6 C6 D6
INTERLOCK 2 5 2 5 2 5 2 5 2 5

86 30

85 87
86 30

85 87

86 30

85 87
86 30

85 87

86 30

85 87
CONNECTOR 1 4 1 4 1 4 1 4 1 4

+
3 3 3 3 3
J-6 24323 24v 24323 24v 24323 24v 28232 12v 24323 24v
GROUND 14g BLACK
1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

K-16 K-17 K-18 K-19 K-20

VISOR LIGHT FUEL FUEL
VACANT XXg VACANT LOWER LIGHT
RELAY RELAY PUMP PUMP
BOOM LIGHTS
RELAY
RELAY LATCHING
VACANT XXg VACANT RELAY

VACANT XXg VACANT

A7 B7 C7 D7 A7 B7 C7 D7
T475 DISC SAW STOP 18g GRA/WHT
F-13 (15A)

F-42 (10A)

F-43 (15A)

F-44 (15A)
F-14 (3A)

F-15 (2A)

F-16 (5A)

F-41 (3A)
DOOR SWITCH SUPPLY 18g BLU/BLK
SHIFT COIL + 18g YEL/WHT
INTERLOCK SUPPLY 18g PNK/BLU
BRAKE COIL + 18g VIO/WHT A8 B8 C8 D8 A8 B8 C8 D8

AC12699-7 9 POS SQUARE FLANGE RECEPTACLE

X1 12g RED "X" W1 12g RED "W" V1 14g RED/GRN U1 14g RED/GRN T1 12g RED "T"
REQUIRES AC12512 PIN TERMINALS X2 18g PNK/BLK W2 18g PNK/RED V2 16g ORANGE U2 14g BLK/WHT T2 18g RED/YEL
X3 W3 V3 U3 T3
X4 12g ORG/YEL W4 12g YEL/BLK V4 14g BLK/WHT U4 14g BLK/WHT T4 12g BLU/YEL
X5 16g BLACK W5 16g BLACK V5 16g BLACK U5 16g BLACK T5 16g BLACK

A9 B9 C9 D9 A9 B9 C9
BATTERY +

F-47 (0-20A)

F-48 (0-20A)
F-17 (7.5A)

D9
F-20 (10A)

F-46 (10A)
F-18 (5A)

F-19 (3A)

F-45 (3A)

F(65)/20A

F(66)/30A

F(67)/30A

F(68)/30A

F(69)/20A

F(70)/40A

F(71)/50A

F(72)/30A
D10
A10 B10 C10 D10 A10 B10 C10

WHITE 8g
RED 12g 1 2 3 4 5 6 7 8

WHITE 8g
RED 12g
RED 12g
RED 12g
RED 10g
A11 B11 C11 D11 A11 B11 C11 D11
RED 8g
F-24 (10A)

F-52 (10/20A)
F-50 (10A)

F-51 (10A)
F-21 (2A)

F-22 (5A)

F-23 (5A)

F-49 (3A)

RED 8g

D12
A12 B12 C12 D12 A12 B12 C12

A13 B13 C13 D13 A13 B13 C13 D13

F-25 (7.5A)

F-26 (7.5A)

F-55 (10A)

F-56 (20A)
F-27 (__)

F-54 (7.A)
F-28 (5A)

F-53 (5A)

A14 B14 C14 D14 A14 B14 C14 D14

2 1

LOAD BATT+
8g BLK/YEL 8g RED

TEW TRIPLE TWIST WIRE

GROUND SWITCH
16g BLACK 16g ORANGE
WHT/GRN

ORG/GRN

BRN/ORG
BRN/GRN

GRA/WHT
PNK/GRN
BRN/ORG

BLK/WHT
BRN/PNK

BLU/WHT
BRN/GRA

TAN/GRN

BRN/RED
GRN/TAN

ORG/BLU

ORG/RED
WHT/BLK
BRN/BLK

GRA/RED
BRN/TAN
ORG/BLU

BLU/ORG

BLK/GRA

ORANGE
ORANGE

AO16104
BRN/BLU

BRN/YEL

BLK/RED

BLU/RED
VIO/GRA

VIO/GRA
BRN/VIO
BLK/YEL
BLU/YEL
VACANT

VACANT

VACANT

VACANT
VACANT
VACANT
VACANT

VACANT

VACANT

VACANT
VACANT
VACANT

VACANT
VACANT
VACANT
VACANT
VACANT
VACANT

VACANT

YELLOW

VACANT

VACANT
VACANT

VACANT
VACANT
VACANT
BROWN
DIODE

GREEN
BLACK

BLACK

BLACK

BLACK
BLACK

BLACK
WHITE

WHITE

WHITE

WHITE
BLACK

WHITE
WHITE

BLUE
BLUE

RED

RED
RED
Main Power supply +

Trombetta
XXg

XXg
XXg
XXg
XXg
XXg

XXg

XXg

XXg

XXg

XXg
XXg
XXg

XXg

XXg
16g

XXg
14g

12g

14g

14g

14g

18g

XXg
18g

XXg
XXg

XXg
18g

XXg
18g

18g
18g
18g

16g

16g
16g
18g
16g

12g

XXg

XXg
XXg
XXg
12g
12g

12g
12g
12g
12g

16g
18g
16g
16g

12g
12g

8g

8g

12g

16g
16g
18g
14g
16g
20g
20g
20g
20g
20g
20g
18g
18g
20g

18g

16g
16g
16g
16g
8g

8g

HYDRAULIC FILL
EA58003 PUMP RELAY
1 = #12 SIZE SITES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 1 2 3 4 1 2 3 4 5 6 1 2 EK55003 30 85 86 87 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
84823
J-7 #8 #4 #4 85 87
J-15 5 = #16 SIZE SITES
24v POWER RELAY
18 = #20 SIZE SITES
J-20 J-11 J-12 J-13 J-14
LOWER CAB HARNESS HORNS BOOM FOPS LIGHTS HYD. VACUUM SYST. VISOR
24322 HYDRAULIC FILL
PUMP RELAY
86 30
ENGINE HARNESS CONNECTOR
LIGHTS
START INTERRUPT LAMP OUTPUT

24V
CONNECTOR J-8 J-9 J-10
LIGHTS
K-21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
HORN HIGH TONE
HORN HIGH TONE GND
HIORN LOW TONE
HORN LOW TONE GND

LEFT OUTER
LEFT INNER
RIGHT INNER
RIGHT OUTER

LEFT
RIGHT
LEFT
RIGHT
HYD. FILL PUMP
24-12V CONVERTER

START SIGNAL
VACUUM PUMP ON SIGNAL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

HYD OIL LEVEL/CHARGE FILTER PSI LIGHT-DASH CONN.

VACUUM PUMP OUTPUT

START SINGAL OUTPUT

24V SUPPLY
START SIGNAL INPUT
RT FRONT LOWER LIGHT

LT FRONT LOWER LIGHT

12v+ FROM CONVERTER
RT SIDE DOOR LIGHT

GROUND SUPPLY
VENT OUTPUT
IGNITION SIGNAL

+ 24v SUPPLY
KAB SEAT 24v+

NOT USED

NOT USED

MAXI SYST. MEMORY +24v UNSWITCHED

NOT USED

NOT USED

NOT USED
NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED
NOT USED
NOT USED
VACANT

VACANT

WF94059

ENGINE HOUSE WORK LIGHT

HYD TANK VAC SYST CONTROLLER

DIAGNOSTIC TOOL 24v+

ECM +24v SUPPLY (30A)

HYD FILL PUMP SIGNAL

WAIT TO START LAMP

THROTTLE POSITION
A/C COMP. CLUTCH +

HYD VALVE HEATER

THROTTLE RETURN
THROTTLE 5vDC +
IGNITION SIGNAL
FUEL PUMP 12v +

DISC SAW STOP

J1939 DRAIN

E-STOP OUT
NOT USED
NOT USED
NOT USED

NOT USED

NOT USED
NOT USED
NOT USED

NOT USED
NOT USED
NOT USED
J1939 (+)
J1939 (-)

XT430-3, XT430L-3, XT445L-3, XT460L-3 90-43