Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual – PDF
$38.95
Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual SEN06593-16 – PDF DOWNLOAD
SERIAL NUMBERS
D37EXi-85001
D37PXi-85001
D39EXi-95001
D39PXi-95001
and up
Description
Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual SEN06593-16 – PDF DOWNLOAD
FILE DETAILS:
Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual SEN06593-16 – PDF DOWNLOAD
Language : English
Pages :3122
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual SEN06593-16 – PDF DOWNLOAD
SERIAL NUMBERS
D37EXi-85001
D37PXi-85001
D39EXi-95001
D39PXi-95001
and up
SERIAL NUMBERS 90001 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
TABLE OF CONTENTS:
Komatsu BULLDOZER D37EXi -24 D37PXi-24 D39EXi -24 D39PXi-24 Shop Manual SEN06593-16 – PDF DOWNLOAD
SERIAL NUMBERS
D37EXi-85001
D37PXi-85001
D39EXi-95001
D39PXi-95001
and up
Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 23
Foreword, Safety, Basic Information 29
How to Read the Shop Manual 29
Safety Notice for Operation 31
Precautions to Prevent Fire 39
Procedures If Fire Occurs 41
Precautions When You Discard Waste Materials 42
Procedures for Exhaust Gas Regulations 43
Precautions for DEF 44
General Character and Precautions for Handling 44
Precautions When You Add 44
Precautions for Storage 44
Precautions for Fire Hazard and Leakage 44
Other Precautions 44
Store DEF 45
Precautions When You Handle Hydraulic Equipment 46
Precautions When You Disconnect and Connect Pipings 49
Precautions When You Handle Electrical Equipment 56
Precautions When You Handle Fuel System Equipment 58
Precautions When You Handle Intake System Equipment 59
Practical Use of KOMTRAX 60
Disconnect and Connect Push-Pull Type Coupler 61
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 61
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 62
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 63
Precautions for Disconnection and Connection of Connectors 65
Disconnect and Connect Deutsch Connector 69
How to Disconnect and Connect Slide Lock Type Connector 70
Disconnect and Connect Connector with Lock to Pull 72
Disconnect and Connect Connector with Lock to Push 73
Disconnect and Connect Connector with Housing to Rotate 75
How to Read the Codes for Electric Cable 76
Explanation of Terms for Maintenance Standard 80
Standard Tightening Torque Table 83
Conversion Table 90
01 Specification 95
Table of Contents 96
Abbreviation List 97
Specifications 103
Specification Drawing 103
Specification Drawing: D37EXI-24 104
Specification Drawing: D37PXI-24 105
Specification Drawing: D39EXI-24 106
Specification Drawing: D39PXI-24 107
Specifications 109
Specification: D37EXI-24 110
Specification: D37PXI-24 115
Specification: D39EXI-24 119
Specification: D39PXI-24 124
Weight Table 132
Weight Table: D37EXI-24 133
Weight Table: D37PXI-24 135
Weight Table: D39EXI-24 137
Weight Table: D39PXI-24 139
Table of Fuel, Coolant, and Lubricants 143
10 Structure and Function 145
Table of Contents 146
Abbreviation List 150
Urea SCR System 156
Layout Drawing of Urea SCR System 156
Urea SCR System Diagram 158
Function of Urea SCR System 159
Function of DEF System 159
Inducement Strategy 161
Component Parts of Urea SCR System 175
DEF Mixing Tube 175
SCR Assembly 176
DEF Tank 178
DEF Pump 180
DEF Injector 181
DEF Hose 182
DEF Tank Heating Valve 183
Boot-up System 184
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 184
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 185
System Operating Lamp System 186
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 186
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 186
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 186
Function of System Operating Lamp System (Machine with Gateway Function Controller) 187
Battery Disconnect Switch 189
Function of Battery Disconnect Switch 189
Engine System 190
Layout Drawing of Engine System 190
Engine Control System 192
Layout of Engine Control System (Machine with KOMTRAX Terminal) 192
Layout of Engine Control System (Machine with Gateway Function Controller) 194
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 196
System Diagram of Engine Control System (Machine with Gateway Function Controller) 198
Function of Engine Control System (Machine with KOMTRAX Terminal) 200
Function of Engine Control System (Machine with Gateway Function Controller) 202
Automatic Idle Stop System 204
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 204
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 205
Function of Automatic Idle Stop System 205
Component Parts of Engine System 208
Damper 208
Variable Flow Turbocharger 209
EGR System 213
EGR Valve 216
EGR Cooler 218
KCCV System 220
KCCV Ventilator 223
Exhaust Throttle Valve 225
KDOC 226
Cooling System 229
Layout Drawing of Cooling System 229
Specifications of Cooling System 230
Cooling Fan Control System 231
System Diagram of Cooling Fan Control System 231
Function of Cooling Fan Control System 232
Component Parts of Cooling System 234
Cooling Fan Motor 234
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 239
Hydraulic Oil Cooler Bypass Valve 241
HST Charge Safety Valve 242
Control System 244
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 244
Layout Drawing of Control System (Machine with Gateway Function Controller) 245
Machine Monitor System 246
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 246
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 247
Function of Machine Monitor System 247
KOMTRAX System 248
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 248
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 248
Function of KOMTRAX System 249
Component Parts of Control System 250
Machine Monitor 250
KOMTRAX Terminal 265
Gateway Function Controller 267
Communication Terminal 270
HST Controller 272
Engine Controller 276
Fuel Control Dial 283
Decelerator and Brake Potentiometer 285
Hydraulic System 287
Layout Drawing of Hydraulic System 287
CLSS 288
Structure of CLSS 288
Function of CLSS 289
Component Parts of Hydraulic System 291
Hydraulic Tank 291
Work Equipment and Cooling Fan Pump 293
LS Valve 300
PC Valve 301
Control Valve 304
Power Train System 325
Layout Drawing of HST System 325
Operation of HST System 326
Steering and Brake Control System 328
Layout Drawing of Steering and Brake Control System 328
Function of Steering and Brake Control System 329
HST Control System 330
System Diagram of HST Control System 330
Gear Shift Control Function 331
Engine Low Speed Matching Control Function 335
HST Pump and Motor Sequence Control Function 336
Deceleration and Brake Control Function 338
Gear Shift Control Function by Load 340
Turn Control Function 341
Straight Travel Correction Control Function 342
Parking Brake Control System 343
System Diagram of Parking Brake Control System 343
Function of Parking Brake Control System 344
Operation of Parking Brake Control System 345
Component Parts of Power Train System 346
HST Pump 346
HST Charge Pump 363
HST Motor 364
Final Drive 376
Electric Steering Electric Lever 380
Work Equipment System 383
Work Equipment Control 383
Layout Drawing of Work Equipment Control 383
Function of Work Equipment Control 385
Layout Drawing of Front Work Equipment 387
Layout Drawing of Fixed Multi-Shank Ripper 388
Component Parts of Work Equipment System 389
Ripper PPC Valve 389
5-Spool EPC and Solenoid Valve 393
Pilot Circuit Accumulator 400
Angle Control EPC Valve 401
Piston Valve 404
Electric Blade Control Lever 405
ICT System 407
Layout Drawing of ICT System 407
System Diagram of ICT Control System 409
Blade Control System 411
Function of Blade Control System 411
Leveling Mode System Diagram 413
Function of Leveling Mode 415
Operation of Leveling Mode 416
Dozing Mode System Diagram 417
Function of Dozing Mode 418
Operation of Dozing Mode 419
Smooth Start System 420
Smooth Start System Diagram 420
Function of Smooth Start System 421
Operation of Smooth Start System 422
Slip Control System 423
Slip Control System Diagram 423
Function of Slip Control System 424
Operation of Slip Control System 425
Assist Control System 426
Assist Control System Diagram 426
Function of Assist Control System 427
Operation of Assist Control System 428
HST Speed Range Control System 429
HST Speed Range Control System Diagram 429
Function of HST Speed Range Control System 430
Operation of HST Speed Range Control System 431
Component Parts of ICT System 432
ICT Sensor Controller 432
Control Box 436
GNSS Receiver 439
GNSS Antenna 443
IMU Sensor 444
Stroke and Reset Sensor for Blade Lift Cylinder 448
Stroke Sensor for Blade Tilt Cylinder 451
Stroke Sensor for Blade Angle Cylinder 453
Undercarriage and Frame 455
Main Frame 455
Structure of Main Frame 455
Track Frame and Idler Cushion 456
Structure of Track Frame and Idler Cushion 456
Function of Track Frame and Idler Cushion 459
Work Equipment 460
Structure of Front Work Equipment 460
Structure of Fixed Multi-Shank Ripper 461
CAB Related Parts 462
ROPS CAB 462
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 462
Structure of ROPS CAB (Machine with Gateway Function Controller) 463
Function of ROPS CAB 464
CAB Mount 465
Structure of CAB Mount 465
Function of CAB Mount 466
20 Standard Value Table 467
Table of Contents 468
Abbreviation List 469
Standard Value Table for Engine 475
Standard Value Table for Engine: D37EXI-24 475
Standard Value Table for Engine: D37PXI-24 478
Standard Value Table for Engine: D39EXI-24 481
Standard Value Table for Engine: D39PXI-24 484
Standard Value Table for Machine 487
Standard Value Table for Machine: D37EXI-24 487
Standard Value Table for Machine: D37PXI-24 504
Standard Value Table for Machine: D39EXI-24 519
Standard Value Table for Machine: D39PXI-24 536
Machine Posture and Procedures to Measure Performance 551
30 Testing and Adjusting 553
Table of Contents 554
Precautions Before Work 558
Abbreviation List 559
Related Information on Testing and Adjusting 565
Tools for Testing and Adjusting 565
Sketch of Tools for Testing and Adjusting 573
Engine and Cooling System 578
Examine Engine Speed 578
How to Examine Engine Speed 578
Examine Exhaust Gas Color 580
How to Examine Exhaust Gas Color with the Handy Smoke Checker 580
How to Examine Exhaust Gas Color with Smoke Meter 581
Examine the Clearance of Exhaust Throttle Valve 582
Measure Clearance of the Exhaust Throttle Valve 582
Examine and Adjust Valve Clearance 584
Check Valve Clearance 584
Adjust Valve Clearance 585
Examine Compression Pressure 586
How to Examine Compression Pressure 586
Examine Blowby Pressure 589
How to Examine Blowby Pressure 589
Examine Engine Oil Pressure 591
How to Examine Engine Oil Pressure 591
Visual Check Inside of EGR Valve 593
How to do the Visual Check Inside of EGR Valve 593
Clean Inside of EGR Valve 595
How to Clean Inside of EGR Valve 595
Examine Fuel Pressure 598
How to Examine Fuel Pressure 598
Examine Fuel Return Rate and Leakage 600
How to Examine Fuel Return Rate and Leakage 601
Bleed Air from Fuel System 605
How to Bleed Air from Fuel System 605
Examine Fuel Circuit for Leakage 607
How to Examine Fuel System for Leakage 607
Handle Cylinder Cut-out Mode Operation 609
Handle No-Injection Cranking Operation 610
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 611
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage 611
Examine Installed Condition of Cylinder Heads and Manifolds 612
How to Examine Installed Condition of Cylinder Heads and Manifolds 612
Examine Engine Piping for Damage and Looseness 613
How to Examine Engine Piping for Damage and Looseness 613
Examine Alternator Belt 614
How to Examine Alternator Belt 614
Examine Automatic Tensioner 615
How to Examine Automatic Tensioner 615
Write Injector Compensation Value to Engine Controller 617
Write Injector Compensation Value 617
Examine SCR Related Functions 624
Examine DEF Pump Raised Pressure 628
Examine Injection Volume from DEF Injector 631
Examine DEF Line Heater Relay 1 636
Examine DEF Line Heater Relay 2 639
Examine DEF Pump Heater Relay 642
Examine DEF Tank Heater Valve 646
Examine SCR Denitration Efficiency 650
Clean DEF Tank 653
How to Clean DEF Tank 653
Clean DEF Tank Mounting Part 658
How to Clean DEF Tank Mounting Part 658
Clean DEF Pump 659
How to Clean DEF Pump 659
Power Train 665
Examine and Adjust HST Oil Pressure 665
Examine HST Oil Pressure 665
Adjust HST Oil Pressure 668
Bleed Air from HST Pump 670
How to Bleed Air from HST Pump 670
Bleed Air from Servo Valve of HST Pump 670
Examine Outlet Pressure of Solenoid Valve 672
How to Examine Outlet Pressure of Solenoid Valve 672
Examine Travel Deviation 677
How to Examine Travel Deviation 677
Examine Brake Performance Simply 679
How to Examine Brake Performance Simply 679
Examine and Adjust Deceleration/Brake Pedal 680
How to Examine Deceleration/Brake Pedal 680
How to Adjust Deceleration/Brake Pedal 682
Adjust Parking Brake Lever 684
How to Adjust Parking Brake Lever 684
Move Machine When It Cannot Travel 686
Move Machine with Hydraulic Type Parking Brake Release System 686
Move Machine After You Remove Final Drive Shaft 688
Undercarriage and Frame 690
Adjust Idler Clearance 690
How to Adjust Idler Clearance 690
Examine Sprocket Wear 691
How to Examine Sprocket Wear 691
Examine and Adjust Track Tension 692
How to Examine Track Tension 692
How to Adjust Track Tension 692
Hydraulic System 694
Release Remained Pressure in Hydraulic Circuit 694
How to Release Remained Pressure in Hydraulic System 694
Examine and Adjust Work Equipment Circuit Oil Pressure 695
How to Examine Work Equipment Circuit Oil Pressure 695
Adjust Work Equipment Circuit Oil Pressure 696
Examine and Adjust Oil Pressure in Control Circuit 698
Examine Oil Pressure in Control Circuit 698
Adjust Oil Pressure in Control Circuit 699
Examine Outlet Pressure of EPC Solenoid Valve 700
How to Examine Outlet Pressure of EPC Solenoid Valve 700
Bleed Air from Work Equipment and Cooling Fan Pump 702
How to Bleed Air from Work Equipment and Cooling Fan Pump 702
Examine Cooling Fan Speed 703
How to Examine Cooling Fan Speed 703
Examine Cooling Fan Circuit Oil Pressure 704
How to Examine Cooling Fan Circuit Oil Pressure 704
Examine Parts Which Cause Hydraulic Drift of Work Equipment 706
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 706
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 706
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 707
Examine Oil Leakage from Work Equipment Cylinder 708
How to Examine Internal Oil Leakage of Work Equipment Cylinder 708
Bleed Air from Work Equipment Cylinders 710
Bleed Air from Work Equipment Cylinder 710
Work Equipment 711
Adjust Work Equipment Lock Lever 711
How to Adjust Work Equipment Lock Lever 711
Examine and Adjust Play of Blade Electric Lever 713
How to Examine Play of Blade Electric Lever 715
Adjust Play of Blade Electric Lever 715
Replace Universal Joint 716
Electrical System 723
Set and Operate Machine Monitor 723
Operator Mode 727
Function to Show Technician Identification Status Screen 727
Function to Show Operator Identification Input Screen 727
Examine Function by LCD (Liquid Crystal Display) 728
Examine Function of Service Meter 728
Usage Limitation and Change Maintenance Password 728
Service Mode 731
How to Operate Service Mode 731
How to See Pre-defined Monitoring Information 733
How to Examine Self-Define Monitor Information 739
Abnormality Record Menu 750
How to See Maintenance Record 754
Maintenance Mode Setting 755
Set Phone Number Entry 759
Default Menu 761
Diagnostic Tests Menu 768
Adjustment Menu 776
No-Injection Cranking Operation 845
KOMTRAX Settings Menu 848
Show Service Message 852
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 854
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 859
Start Up KOMTRAX System (Machine with Gateway Function Controller) 861
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 867
Adjust After Replacement of HST Controller 869
How to Adjust After Replacement of HST Controller 869
Adjust After Replacement of Electric and Hydraulic Equipment 875
Adjust Rearview Camera Angle 877
How to Adjust Rearview Camera Angle 877
Handle Voltage Circuit of Engine Controller 879
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 880
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 881
Examine Diodes 882
Examine Diodes by Digital Tester 882
How to Examine Diodes by Analog Tester 882
ICT System 883
Set and Operate Control Box 883
Examine and Adjust ICT Related Devices 884
Calibrate Blade Edge Position 887
How to Operate Blade Calibration Menu (Pitch Rod Calibration) 888
How to Operate Blade Calibration Menu (Machine Cal Step A) 891
How to Operate Blade Calibration Menu (Machine Cal Step B) 896
Calibrate IMU Sensor 910
How to Calibrate IMU Sensor 910
Reset Cylinder Stroke End 917
Reset Lift Cylinder Stroke End 917
Reset Tilt Cylinder Stroke End 918
Reset Angle Cylinder Stroke End 918
How to Input Wear Volume of Blade Edge and Track Shoes 920
Examine and Adjust Blade Elevation 921
Examine Blade Elevation (For Old Control Box) 921
Examine Blade Elevation (For New Control Box) 923
Adjust Blade Elevation (For Old Control Box) 926
Adjust Blade Elevation (For New Control Box) 927
Examine Stroke Sensor for Lift Cylinder 929
How to Examine Stroke Sensor for Lift Cylinder 929
Examine Stroke Sensor for Tilt Cylinder 931
How to Examine Stroke Sensor for Tilt Cylinder 931
Examine Stroke Sensor for Angle Cylinder 933
How to Examine Stroke Sensor for Angle Cylinder 933
Examine and Adjust Reset Sensor for Lift Cylinder 935
How to Examine Reset Sensor for Lift Cylinder 935
Adjust Reset Sensor for Lift Cylinder 936
Adjust When ICT Sensor Controller is Replaced 937
How to Adjust When ICT Sensor Controller is Replaced 937
How to Adjust When ICT Related Devices are Repaired or Replaced 940
Pm Clinic 943
Pm Clinic Service 943
Pm Clinic Check Sheet: D37EXI-24 945
Pm Clinic Check Sheet: D37PXI-24 953
Pm Clinic Check Sheet: D39EXI-24 961
Pm Clinic Check Sheet: D39PXI-24 968
Pm Clinic Check Sheet for Undercarriage: D37EXI-24 975
Pm Clinic Check Sheet for Undercarriage: D37PXI-24 982
Pm Clinic Check Sheet for Undercarriage: D39EXI-24 989
Pm Clinic Check Sheet for Undercarriage: D39PXI-24 996
40 Troubleshooting1005
Table of Contents1006
Precautions Before Work1017
Abbreviation List1018
Related Information to Troubleshooting1024
General Troubleshooting Points1024
Troubleshooting Points for Urea SCR System1025
Sequence of Events in Troubleshooting1037
Checks Before Troubleshooting1039
Inspection Procedure Before Troubleshooting1041
Walk-Around Check1041
Test in Accordance with Testing Procedure1043
Examine Fuel Level and Type1043
Examine for Impure Ingredient in Fuel1043
Examine DEF Level and Type1044
Examine Fuel Prefilter1044
Examine Fuel Main Filter1046
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1048
Examine Coolant Level (Reservoir Tank)1049
Examine Air Cleaner Clogging1050
Clean Outer Element1050
Replace Element1052
Examine Hydraulic Oil Level1052
Examine Hydraulic Oil Strainer1053
Examine Oil Level in Final Drive Case1057
Bleed Air from Fuel System1057
Bleed Air from Hydraulic System1058
How to Examine Electric Equipment1058
Preparation for Troubleshooting of Electrical System1065
Procedure for Troubleshooting1072
Symptom and Troubleshooting Numbers1075
Information Shown in Troubleshooting Table1080
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness1082
Connector List and Layout (Machine with KOMTRAX Terminal)1085
Connector List and Layout (Machine with Gateway Function Controller)1102
Connector Contact Connection Table1119
T-Branch Box and T-Branch Adapter Table1159
Fuse Location Table (Machine with KOMTRAX Terminal)1165
Fuse Location Table (Machine with Gateway Function Controller)1169
Precautions When You Replace KDOC1173
Failure Code Table1174
Troubleshooting by Failure Code (Display of Code)1194
Failure Code [6091NX]1194
Failure Code [989L00]1196
Failure Code [989M00]1197
Failure Code [989N00]1198
Failure Code [A1U0N3]1199
Failure Code [A1U0N4]1201
Failure Code [A900FR]1203
Failure Code [A900N6]1204
Failure Code [A900NY]1205
Failure Code [AA10NX]1206
Failure Code [AB00KE]1208
Failure Code [AQ10MB]1210
Failure Code [AQ10N3]1212
Failure Code [AS00R2]1213
Failure Code [AS00R3]1214
Failure Code [AS00R4]1215
Failure Code [AS00R5]1216
Failure Code [AS00R6]1217
Failure Code [AS00ZK]1218
Failure Code [AS10KM]1219
Failure Code [AS10NR]1220
Failure Code [AS10NT]1221
Failure Code [AU10QA]1222
Failure Code [B@BAZG]1223
Failure Code [B@BCNS]1224
Failure Code [B@CRNS]1225
Failure Code [B@CRZG]1226
Failure Code [CA115]1227
Failure Code [CA122]1228
Failure Code [CA123]1230
Failure Code [CA131]1232
Failure Code [CA132]1234
Failure Code [CA144]1236
Failure Code [CA145]1238
Failure Code [CA153]1240
Failure Code [CA154]1243
Failure Code [CA187]1246
Failure Code [CA221]1248
Failure Code [CA222]1250
Failure Code [CA227]1252
Failure Code [CA234]1253
Failure Code [CA238]1254
Failure Code [CA239]1256
Failure Code [CA249]1258
Failure Code [CA256]1260
Failure Code [CA271]1262
Failure Code [CA272]1264
Failure Code [CA322]1266
Failure Code [CA324]1268
Failure Code [CA331]1270
Failure Code [CA332]1272
Failure Code [CA343]1274
Failure Code [CA351]1275
Failure Code [CA352]1276
Failure Code [CA356]1279
Failure Code [CA357]1281
Failure Code [CA386]1283
Failure Code [CA435]1284
Failure Code [CA441]1286
Failure Code [CA442]1288
Failure Code [CA449]1289
Failure Code [CA451]1290
Failure Code [CA452]1292
Failure Code [CA515]1294
Failure Code [CA516]1296
Failure Code [CA553]1298
Failure Code [CA555]1299
Failure Code [CA556]1300
Failure Code [CA559]1301
Failure Code [CA689]1305
Failure Code [CA691]1307
Failure Code [CA692]1309
Failure Code [CA697]1311
Failure Code [CA698]1312
Failure Code [CA731]1313
Failure Code [CA778]1315
Failure Code [CA1117]1320
Failure Code [CA1664]1321
Failure Code [CA1669]1323
Failure Code [CA1673]1324
Failure Code [CA1677]1325
Failure Code [CA1678]1326
Failure Code [CA1682]1327
Failure Code [CA1683]1332
Failure Code [CA1684]1334
Failure Code [CA1686]1336
Failure Code [CA1691]1337
Failure Code [CA1694]1339
Failure Code [CA1695]1341
Failure Code [CA1696]1342
Failure Code [CA1712]1344
Failure Code [CA1713]1347
Failure Code [CA1714]1349
Failure Code [CA1715]1350
Failure Code [CA1776]1351
Failure Code [CA1777]1354
Failure Code [CA1843]1357
Failure Code [CA1844]1359
Failure Code [CA1885]1362
Failure Code [CA1887]1364
Failure Code [CA1896]1366
Failure Code [CA1938]1370
Failure Code [CA1942]1372
Failure Code [CA1961]1373
Failure Code [CA2185]1374
Failure Code [CA2186]1376
Failure Code [CA2249]1378
Failure Code [CA2272]1379
Failure Code [CA2311]1382
Failure Code [CA2349]1383
Failure Code [CA2353]1385
Failure Code [CA2357]1387
Failure Code [CA2555]1388
Failure Code [CA2556]1390
Failure Code [CA2636]1392
Failure Code [CA2637]1395
Failure Code [CA2765]1397
Failure Code [CA2771]1398
Failure Code [CA2976]1404
Failure Code [CA3142]1406
Failure Code [CA3143]1407
Failure Code [CA3144]1408
Failure Code [CA3146]1410
Failure Code [CA3147]1411
Failure Code [CA3148]1412
Failure Code [CA3151]1414
Failure Code [CA3165]1420
Failure Code [CA3229]1422
Failure Code [CA3231]1424
Failure Code [CA3232]1426
Failure Code [CA3235]1430
Failure Code [CA3239]1432
Failure Code [CA3241]1435
Failure Code [CA3242]1438
Failure Code [CA3251]1441
Failure Code [CA3313]1443
Failure Code [CA3314]1444
Failure Code [CA3315]1445
Failure Code [CA3419]1447
Failure Code [CA3421]1449
Failure Code [CA3497]1451
Failure Code [CA3498]1452
Failure Code [CA3543]1453
Failure Code [CA3545]1459
Failure Code [CA3547]1461
Failure Code [CA3558]1462
Failure Code [CA3559]1464
Failure Code [CA3562]1466
Failure Code [CA3563]1468
Failure Code [CA3567]1471
Failure Code [CA3568]1474
Failure Code [CA3571]1479
Failure Code [CA3572]1481
Failure Code [CA3574]1483
Failure Code [CA3575]1486
Failure Code [CA3577]1488
Failure Code [CA3578]1490
Failure Code [CA3582]1492
Failure Code [CA3583]1500
Failure Code [CA3596]1502
Failure Code [CA3649]1506
Failure Code [CA3681]1508
Failure Code [CA3682]1513
Failure Code [CA3713]1518
Failure Code [CA3717]1521
Failure Code [CA3718]1522
Failure Code [CA3724]1523
Failure Code [CA3725]1524
Failure Code [CA3748]1527
Failure Code [CA3755]1530
Failure Code [CA3866]1532
Failure Code [CA3867]1536
Failure Code [CA3868]1539
Failure Code [CA3899]1543
Failure Code [CA3911]1545
Failure Code [CA3912]1549
Failure Code [CA3918]1551
Failure Code [CA3921]1553
Failure Code [CA3928]1554
Failure Code [CA3932]1555
Failure Code [CA3933]1557
Failure Code [CA3934]1559
Failure Code [CA3935]1562
Failure Code [CA3936]1564
Failure Code [CA4152]1566
Failure Code [CA4155]1570
Failure Code [CA4156]1573
Failure Code [CA4157]1576
Failure Code [CA4159]1578
Failure Code [CA4164]1579
Failure Code [CA4165]1581
Failure Code [CA4166]1583
Failure Code [CA4168]1584
Failure Code [CA4169]1587
Failure Code [CA4171]1589
Failure Code [CA4249]1593
Failure Code [CA4251]1595
Failure Code [CA4261]1597
Failure Code [CA4277]1600
Failure Code [CA4281]1604
Failure Code [CA4459]1608
Failure Code [CA4461]1611
Failure Code [CA4533]1614
Failure Code [CA4534]1615
Failure Code [CA4731]1616
Failure Code [CA4732]1617
Failure Code [CA4739]1618
Failure Code [CA4768]1619
Failure Code [CA4769]1621
Failure Code [CA4842]1623
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1627
Failure Code [CA4952] (Machine with Gateway Function Controller)1629
Failure Code [CA5115]1631
Failure Code [CA5179]1634
Failure Code [CA5181]1636
Failure Code [CA5271]1638
Failure Code [CA5272]1640
Failure Code [CA5273]1642
Failure Code [CA5274]1644
Failure Code [CA5275]1645
Failure Code [CA5276]1647
Failure Code [CA5387]1649
Failure Code [CA5388]1651
Failure Code [CA5389]1653
Failure Code [CA5391]1655
Failure Code [CA5392]1659
Failure Code [CA5393]1660
Failure Code [CA5394]1663
Failure Code [CA5395]1666
Failure Code [CA5396]1669
Failure Code [CA5631]1670
Failure Code [CA5938]1672
Failure Code [D130KA]1674
Failure Code [D130KB]1676
Failure Code [D130KY]1678
Failure Code [D19JKZ]1680
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1683
Failure Code [D811MC] (Machine with Gateway Function Controller)1684
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1685
Failure Code [D862KA] (Machine with Gateway Function Controller)1686
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1687
Failure Code [D8ALKA] (Machine with Gateway Function Controller)1689
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1691
Failure Code [D8ALKB] (Machine with Gateway Function Controller)1693
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)1695
Failure Code [D8AQKR] (Machine with Gateway Function Controller)1698
Failure Code [D8G1KT]1701
Failure Code [D8G6KT]1702
Failure Code [DAF0MB]1703
Failure Code [DAF0MC]1704
Failure Code [DAF8KB]1705
Failure Code [DAF9KQ]1707
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)1708
Failure Code [DAFGMC] (Machine with Gateway Function Controller)1709
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)1710
Failure Code [DAFLKA] (Machine with Gateway Function Controller)1712
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)1714
Failure Code [DAFLKB] (Machine with Gateway Function Controller)1716
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)1718
Failure Code [DAFQKR] (Machine with Gateway Function Controller)1722
Failure Code [DAJ000]1726
Failure Code [DAJ0KQ]1727
Failure Code [DAJ0KT]1728
Failure Code [DAJ0MC]1729
Failure Code [DAJ1KK]1730
Failure Code [DAJ2KK]1732
Failure Code [DAJ5KK]1734
Failure Code [DAJ6KK]1737
Failure Code [DAJLKA] (Machine with KOMTRAX Terminal)1739
Failure Code [DAJLKA] (Machine with Gateway Function Controller)1741
Failure Code [DAJLKB] (Machine with KOMTRAX Terminal)1743
Failure Code [DAJLKB] (Machine with Gateway Function Controller)1745
Failure Code [DAJPMA]1747
Failure Code [DAJQKR] (Machine with KOMTRAX Terminal)1748
Failure Code [DAJQKR] (Machine with Gateway Function Controller)1752
Failure Code [DAJRKR]1756
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)1760
Failure Code [DB2QKR] (Machine with Gateway Function Controller)1764
Failure Code [DB2RKR]1768
Failure Code [DBR0KT]1772
Failure Code [DBR0MC]1773
Failure Code [DBR1KK]1774
Failure Code [DBR2KK]1777
Failure Code [DBR5KK]1780
Failure Code [DBRLKA] (Machine with KOMTRAX Terminal)1782
Failure Code [DBRLKA] (Machine with Gateway Function Controller)1784
Failure Code [DBRLKB] (Machine with KOMTRAX Terminal)1786
Failure Code [DBRLKB] (Machine with Gateway Function Controller)1788
Failure Code [DBRPMA]1790
Failure Code [DBRQKR] (Machine with KOMTRAX Terminal)1791
Failure Code [DBRQKR] (Machine with Gateway Function Controller)1795
Failure Code [DBRRKR]1799
Failure Code [DBTSKR]1803
Failure Code [DBUTKA]1805
Failure Code [DD12KA]1806
Failure Code [DD12KB]1808
Failure Code [DD13KA]1810
Failure Code [DD13KB]1812
Failure Code [DD14KA]1814
Failure Code [DD14KB]1816
Failure Code [DDKAKA]1818
Failure Code [DDKAKB]1820
Failure Code [DDKFL4]1822
Failure Code [DDKGL4]1824
Failure Code [DDKHKA]1826
Failure Code [DDKHKB]1828
Failure Code [DDKQKA]1830
Failure Code [DDKQKB]1832
Failure Code [DDKRKA]1834
Failure Code [DDKRKB]1836
Failure Code [DDKSKA]1838
Failure Code [DDKSKB]1840
Failure Code [DDNLKA]1842
Failure Code [DDNLKB]1844
Failure Code [DDP6KA]1846
Failure Code [DDP6KB]1848
Failure Code [DDP6MA]1850
Failure Code [DDU1FS]1852
Failure Code [DDU1KA]1854
Failure Code [DDU1KY]1856
Failure Code [DFA4KX]1858
Failure Code [DFA4KZ]1859
Failure Code [DFA4L8]1860
Failure Code [DFA5KA]1861
Failure Code [DFA5KB]1863
Failure Code [DFA6KA]1865
Failure Code [DFA6KB]1867
Failure Code [DFA7KX]1869
Failure Code [DFA7KZ]1870
Failure Code [DFA7L8]1871
Failure Code [DFA8KA]1872
Failure Code [DFA8KB]1874
Failure Code [DFA9KA]1876
Failure Code [DFA9KB]1878
Failure Code [DGS1KA]1880
Failure Code [DGS1KX]1882
Failure Code [DH21KA]1884
Failure Code [DH21KB]1886
Failure Code [DHA4KA]1887
Failure Code [DHH7KA]1889
Failure Code [DHH7KB]1891
Failure Code [DHH8KA]1893
Failure Code [DHH8KB]1895
Failure Code [DHH9KA]1897
Failure Code [DHH9KB]1899
Failure Code [DHHAKA]1901
Failure Code [DHHAKB]1903
Failure Code [DK30KA]1905
Failure Code [DK30KB]1907
Failure Code [DK30KX]1909
Failure Code [DK30KZ]1910
Failure Code [DK30L8]1911
Failure Code [DK31KA]1914
Failure Code [DK31KB]1916
Failure Code [DK40KA]1918
Failure Code [DK40KB]1920
Failure Code [DK55KX]1922
Failure Code [DK55KZ]1923
Failure Code [DK55L8]1924
Failure Code [DK56KA]1926
Failure Code [DK56KB]1928
Failure Code [DK57KA]1930
Failure Code [DK57KB]1932
Failure Code [DK80KA]1934
Failure Code [DKS0L8]1936
Failure Code [DKS1KA]1937
Failure Code [DKS1KB]1939
Failure Code [DKS2KA]1940
Failure Code [DKS2KB]1942
Failure Code [DKS3KA]1943
Failure Code [DKS3KB]1945
Failure Code [DKS3MB]1946
Failure Code [DKS4L8]1948
Failure Code [DKS5KA]1949
Failure Code [DKS5KB]1951
Failure Code [DKS6KA]1952
Failure Code [DKS6KB]1954
Failure Code [DKS7MB]1955
Failure Code [DKSCL8]1956
Failure Code [DKSDKA]1957
Failure Code [DKSDKB]1959
Failure Code [DKSEKA]1960
Failure Code [DKSEKB]1962
Failure Code [DKSFKA]1963
Failure Code [DKSFKB]1965
Failure Code [DKSFMB]1966
Failure Code [DLM0KX]1967
Failure Code [DLM0MA]1968
Failure Code [DLM1KA]1969
Failure Code [DLM1KB]1971
Failure Code [DLM1MA]1973
Failure Code [DLM2KA]1974
Failure Code [DLM2KB]1976
Failure Code [DLM2MA]1978
Failure Code [DLM3KA]1979
Failure Code [DLM3KB]1981
Failure Code [DLM3MB]1983
Failure Code [DN21FS]1984
Failure Code [DR21KX]1986
Failure Code [DR31KX]1987
Failure Code [DV20KB]1988
Failure Code [DW4BKA]1990
Failure Code [DW4BKB]1992
Failure Code [DW4BKY]1994
Failure Code [DW7BKA]1995
Failure Code [DW7BKB]1997
Failure Code [DW7EKA]1998
Failure Code [DW7EKB]2001
Failure Code [DW7EKY]2004
Failure Code [DWN5KA]2006
Failure Code [DWN5KB]2008
Failure Code [DWN5KY]2009
Failure Code [DXA4KA]2010
Failure Code [DXA4KB]2012
Failure Code [DXA4KY]2014
Failure Code [DXA5KA]2015
Failure Code [DXA5KB]2017
Failure Code [DXA5KY]2019
Failure Code [DXA6KA]2020
Failure Code [DXA6KB]2022
Failure Code [DXA6KY]2024
Failure Code [DXA7KA]2025
Failure Code [DXA7KB]2027
Failure Code [DXA7KY]2029
Failure Code [DXHRKA]2030
Failure Code [DXHRKB]2032
Failure Code [DXHRKY]2033
Failure Code [DXHSKA]2034
Failure Code [DXHSKB]2036
Failure Code [DXHSKY]2037
Failure Code [DXHTKA]2038
Failure Code [DXHTKB]2040
Failure Code [DXHTKY]2041
Failure Code [DXHUKA]2042
Failure Code [DXHUKB]2044
Failure Code [DXHUKY]2045
Failure Code [DXJ4KA]2046
Failure Code [DXJ4KB]2048
Failure Code [DXJCKA]2050
Failure Code [DXJCKB]2052
Failure Code [DXJCKY]2053
Failure Code [DXJDKA]2054
Failure Code [DXJDKB]2056
Failure Code [DXJDKY]2057
Failure Code [DXK1KA]2058
Failure Code [DXK1KB]2060
Failure Code [DXK1KY]2061
Failure Code [DXK2KA]2062
Failure Code [DXK2KB]2064
Failure Code [DXK2KY]2065
Failure Code [F313KA]2066
Failure Code [F313KB]2067
Failure Code [F318KB]2068
Failure Code [F318KY]2069
Troubleshooting of Electrical System (E-Mode)2070
Engine Does Not Start (Engine Does Not Crank)2070
Manual Preheating System Does Not Operate2077
Automatic Preheating System Does Not Operate2080
While Preheating is in Operation, Preheating Monitor Does Not Come On2082
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing2084
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On2087
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation2088
Charge Level Monitor Comes On in Red While Engine is in Operation2089
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation2090
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation2091
HST Charge Pressure Monitor Comes On in Red While Engine Runs2092
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation2093
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs2094
Engine Coolant Temperature Gauge Does Not Show Correct Temperature2095
DEF Level is Not Shown Correctly2096
Fuel Gauge Does Not Show Normally2099
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature2102
Operation Mode Does Not Change2103
When You Operate Customize Switch Does Not Show Customize Screen2104
When You Change Setting on Customize Screen, Setting of Machine is Not Changed2105
Service Meter is Not Shown While Starting Switch is in OFF Position2106
Service Mode Cannot be Selected2107
Work Equipment Does Not Operate2108
Foot Heater Does Not Operate2110
Horn Does Not Sound2116
Horn Does Not Stop2118
Backup Alarm Does Not Sound2119
Backup Alarm Does Not Stop Operation2120
Headlamp Does Not Come On2121
Rear Lamp Does Not Come On2125
No Wiper Operates2128
Front Wiper Does Not Operate2130
Rear Wiper Does Not Operate2132
Left Door Wiper Does Not Operate2134
Right Door Wiper Does Not Operate2138
Front Washer Does Not Operate2142
Rear Washer Does Not Operate2144
Left Door Washer Does Not Operate2146
Right Door Washer Does Not Operate2148
KOMTRAX System Does Not Operate Correctly2150
Control Box Shuts Down After It Shows Messages [GPS receiver not connected!] and [Slope sensor not connected!]2151
Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !]2155
Control Box Shows Message [Waiting for radio link]2160
Control Box Shows Message [IMU sensor not connected] Show Production2161
Control Box Shows Message [Waiting for satellites]2162
Control Box Shows Message [GPS receiver not connected!] Show Production2163
Control Box Shows Message [Cylinder Stroke Reading Abnormal]2165
Control Box Shows Message [Komatsu CAN Comms Abnormal]2166
Control Box Shows Message [Komatsu Machine Trouble]2167
Control Box Shows Message [Waiting to initialize]2168
Control Box Shows Message [System initializing]2169
Control Box Shows Message [Initializing]2170
Control Box Shows Message [Configuring GPS]2171
Control Box Shows Message [No GPS Localization]2172
Control Box Shows Message [Low precisions]2173
Control Box Shows Message [Heading Initializing]2174
Control Box Displays [Out of design area]2175
Control Box Can Not be Turned on2176
Control Box Does Not Display Intelligent Machine Control Screen2177
Control Box Does Not Display Bulldozer Image2178
Control Box Does Not Display Design Surface2179
Control Box Touch Panel Does Not Respond2180
Control Box Touch Panel is Inaccurate2181
Cylinder Stroke Reset Indication Does Not Go Out2182
AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off)2183
Blade Automatic Lower Control Does Not Start While AUTO is Shown2185
Blade Automatic Raise Control Does Not Start While AUTO is Shown2186
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops)2187
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine2188
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface)2189
Finished Surface is Inaccurate (The Finished Surface is Not Smooth)2190
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction)2191
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips)2193
Machine Speed Does Not Increase While Blade Automatic Control is Activated2194
Blade Tilt Angle Does Not Align with Design Surface2195
Blade Tilts While Blade Automatic Control is Activated2197
When Starting Switch is Turned to ON Position, REVERSE Leveling Mode Switch LED Does Not Come On or Does Not Go Out2199
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2201
Information Shown in Troubleshooting Table (H-Mode)2201
Failure Mode and Cause Table2202
RH and LH Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate)2208
RH or LH Track Cannot Travel FORWARD and Reverse (One of RH or LH Travel Systems Cannot Operate)2210
RH or LH Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction)2212
Travel Speed or Power is Low2214
Speed Range Does Not Change2216
Shock is Large When Machine Moves Off or Stops2217
Travel Deviation is Large2218
Machine Drift on a Slope is Large2221
Engine Speed Drops Largely or Engine Stops2223
Unusual Noise is Heard from Around HST Pump or Motor2225
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High2227
All Work Equipment Do Not Operate2229
All Work Equipment Speed or Power is Low2231
Blade Lift Speed or Power is Low2232
Blade Tilt Speed or Power is Low2234
Blade Angle Speed or Power is Low2235
Time Lag of Blade Lift is Large2236
Hydraulic Drift of Blade Lift is Large2237
Hydraulic Drift of Tilted Blade is Large2238
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve2239
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2240
Unusual Noise is Heard from Around Fan2242
Troubleshooting of Engine (S-Mode)2243
Information Shown in Troubleshooting Table (S-Mode)2243
Engine Does Not Crank When Starting Switch is Turned to Start Position2244
Engine Cranks but No Exhaust Smoke Comes Out2245
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2246
Engine Startability is Unsatisfactory2247
Engine Does Not Pick Up Smoothly2249
Engine Stops During Operation2251
Engine Does Not Rotate Smoothly2253
Engine Lacks Output (or Lacks Power)2254
Exhaust Smoke is Black2256
Engine Oil Consumption is Excessive2258
Engine Oil Becomes Dirty Quickly2259
Fuel Consumption is Excessive2260
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2261
Engine Oil Pressure Drops2262
Fuel Mixes Into Engine Oil2263
Water Mixes Into Engine Oil (Milky)2264
Coolant Temperature Increases Too High (Overheat)2265
Unusual Noise is Heard2266
Vibration is Excessive2268
Air Cannot be Bled from Fuel Circuit2269
Active Regeneration is Done Frequently2270
Active Regeneration Continues Long2271
White Smoke is Exhausted During Active Regeneration2272
DEF Consumption is Excessive2273
There is an Unusual Smell (Irritating Odor)2275
Foreign Materials Enter DEF (DEF Increases)2276
50 Disassembly and Assembly2277
Table of Contents2278
Precautions Before Work2283
Abbreviation List2284
Related Information on Disassembly and Assembly2290
How to Read This Manual2290
Coating Materials List2291
Special Tool List2296
Sketches of Special Tools2315
Engine and Cooling System2331
Remove and Install Supply Pump Assembly2331
Remove Supply Pump Assembly2331
Install Supply Pump Assembly2335
Remove and Install Injector Assembly2339
How to Remove Injector Assembly2339
How to Install Injector Assembly2342
Remove and Install Cylinder Head Assembly2348
How to Remove Cylinder Head Assembly2348
How to Install Cylinder Head Assembly2362
Remove and Install EGR Valve Assembly2383
Remove EGR Valve Assembly2383
Install EGR Valve Assembly2384
Remove and Install EGR Cooler Assembly2386
How to Remove EGR Cooler Assembly2386
How to Install EGR Cooler Assembly2388
Remove and Install Starter Assembly2391
Remove Starting Motor Assembly2391
Install Starting Motor Assembly2392
Remove and Install Alternator Belt2394
Remove Alternator Belt2394
Install Alternator Belt2395
Remove and Install Automatic Tensioner2397
Remove Automatic Tensioner2397
Install Automatic Tensioner2397
Remove and Install Radiator Assembly2398
How to Remove Radiator Assembly2398
How to Install Radiator Assembly2401
Remove and Install Hydraulic Oil Cooler Assembly2405
How to Remove Hydraulic Oil Cooler Assembly2405
How to Install Hydraulic Oil Cooler Assembly2407
Remove and Install Aftercooler Assembly2411
Remove Aftercooler Assembly2411
Install Aftercooler Assembly2413
Remove and Install Cooling Fan Drive Assembly2417
Remove Cooling Fan Drive Assembly2417
Install Cooling Fan Drive Assembly2419
Remove and Install Cooling Fan Motor Assembly2421
Remove Cooling Fan Motor Assembly2421
Install Cooling Fan Motor Assembly2422
Remove and Install Engine and HST Pump Assembly2424
Remove Engine and HST Pump Assembly2424
Install Engine and HST Pump Assembly2430
Remove and Install Engine Front Oil Seal2438
How to Remove Engine Front Oil Seal2438
How to Install Engine Front Oil Seal2439
Remove and Install Engine Rear Oil Seal2441
How to Remove Engine Rear Oil Seal2441
How to Install Engine Rear Oil Seal2442
Remove and Install Engine Hood Assembly2445
How to Remove Engine Hood Assembly2445
How to Install Engine Hood Assembly2447
Remove and Install KDOC Assembly2451
How to Remove KDOC Assembly2451
How to Install KDOC Assembly2455
Remove and Install KDOC and SCR Assembly2462
Remove KDOC and SCR Assembly2463
Install KDOC and SCR Assembly2472
Remove and Install Bellows Pipe Assembly2482
Remove Bellows Pipe Assembly2482
Install Bellows Pipe Assembly2484
Remove and Install Fuel Tank Assembly2489
Remove Fuel Tank Assembly2489
Install Fuel Tank Assembly2492
Remove and Install DEF Tank Assembly2496
How to Remove DEF Tank Assembly2496
How to Install DEF Tank Assembly2502
Remove and Install DEF Tank Sensor Flange Assembly2508
How to Remove DEF Tank Sensor Flange Assembly2508
How to Install DEF Tank Sensor Flange Assembly2509
Remove and Install DEF Tank Sensor2513
Remove DEF Tank Sensor2513
Install DEF Tank Sensor2514
Remove and Install DEF Tank Strainer2521
Remove DEF Tank Strainer2521
Install DEF Tank Strainer2522
Remove and Install SCR Assembly2523
How to Remove SCR Assembly2523
How to Install SCR Assembly2527
Remove and Install KCCV Assembly2531
Remove KCCV Assembly2531
Install KCCV Assembly2532
Remove and Install Turbo Charger Assembly2533
How to Remove Turbo Charger Assembly2533
How to Install Turbo Charger Assembly2537
Remove and Install Exhaust Throttle Valve2543
Remove Exhaust Throttle Valve2543
Install Exhaust Throttle Valve2547
Remove and Install DEF Mixing Tube2553
Remove DEF Mixing Tube2554
Install DEF Mixing Tube2558
Remove and Install DEF Injector2566
Remove DEF Injector2566
Install DEF Injector2569
Remove and Install DEF Pump2573
Remove DEF Pump2573
Install DEF Pump2576
Remove and Install DEF Hose2579
Remove DEF Hose2579
Install DEF Hose2587
Remove and Install Air Cleaner Assembly2598
Remove Air Cleaner Assembly2598
Install Air Cleaner Assembly2599
Remove and Install Air Conditioner Compressor Assembly2601
Remove Air Conditioner Compressor Assembly2601
How to Install Air Conditioner Compressor Assembly2602
Power Train2604
Remove and Install Damper Assembly2604
How to Remove Damper Assembly2604
How to Install Damper Assembly2605
Remove and Install HST Pump Assembly2606
Remove HST Pump Assembly2606
Install HST Pump Assembly2609
Remove and Install HST Motor and Final Drive Assembly2612
Remove HST Motor and Final Drive Assembly2612
Install HST Motor and Final Drive Assembly2614
Disassemble and Assemble Final Drive Assembly2616
Disassemble Final Drive Assembly2616
Assemble Final Drive Assembly2622
Undercarriage and Frame2631
Remove and Install Idler and Recoil Spring Assembly2631
How to Remove Idler and Recoil Spring Assembly2631
How to Install Idler and Recoil Spring Assembly2631
Disassemble and Assemble Idler Assembly2633
Disassemble Idler Assembly2633
Assemble Idler Assembly2635
Disassemble and Assemble Recoil Spring Assembly2639
Disassemble Recoil Spring Assembly2640
Assemble Recoil Spring Assembly2641
Disassemble and Assemble Track Roller Assembly2643
Disassemble Track Roller Assembly2643
Assemble Track Roller Assembly2645
Disassemble and Assemble Carrier Roller Assembly2649
Disassemble Carrier Roller Assembly2649
Assemble Carrier Roller Assembly2650
Separate and Connect Track Assembly2653
Separate Track Assembly (Standard)2653
Install Track Assembly2654
Separate and Connect PLUS Type Track Assembly2657
Separate PLUS Type Track Assembly Generally2657
Install PLUS Type Track Assembly2657
Disassemble and Assemble Track Assembly Generally2659
How to Disassemble Full Track Shoes Assembly2660
How to Assemble Full Track Shoes Assembly2662
Disassemble and Assemble PLUS Type Track Assembly Generally2675
Disassemble PLUS Type Track Assembly Generally2676
How to Assemble PLUS Type Track Shoes Assembly Generally2677
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)2693
Disassemble One Track Link Assembly in Field (Track Assembly)2695
Assemble One Track Link Assembly in Field (Track Assembly)2696
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2704
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)2705
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2707
Hydraulic System2711
Remove and Install Hydraulic Tank Assembly2711
Remove Hydraulic Tank Assembly2711
How to Install Hydraulic Tank Assembly2716
Remove and Install Control Valve Assembly2721
How to Remove Control Valve Assembly2721
How to Install Control Valve Assembly2723
Work Equipment2726
Remove and Install Blade Assembly (Power Angle Power Tilt Dozer)2726
How to Remove Blade Assembly (Power Angle Power Tilt Dozer)2726
Install Blade Assembly2728
Remove and Install Work Equipment Assembly2732
Remove Work Equipment Assembly2732
Install Work Equipment Assembly2734
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly2737
Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly2737
Install Stroke and Reset Sensing Blade Lift Cylinder Assembly2738
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2741
Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2741
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2746
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly2753
Remove Stroke Sensing Blade Tilt Cylinder Assembly2753
Install Stroke Sensing Blade Tilt Cylinder Assembly2756
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly2760
Disassemble Stroke Sensing Blade Tilt Cylinder Assembly2760
Assemble Stroke Sensing Blade Tilt Cylinder Assembly2764
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly2769
Remove Stroke Sensing Blade Angle Cylinder Assembly2769
Install Stroke Sensing Blade Angle Cylinder Assembly2771
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly2775
Disassemble Stroke Sensing Blade Angle Cylinder Assembly2775
Assemble Stroke Sensing Blade Angle Cylinder Assembly2779
Remove and Install U-Frame Assembly2785
Remove U-Frame Assembly2785
Install U-Frame Assembly2787
CAB Related Parts2790
Remove and Install Operator Cab Assembly2790
How to Remove Operator Cab Assembly2790
Install Operator CAB Assembly2796
Remove and Install Wiper Arm2803
How to Remove Wiper Arm2803
How to Install Wiper Arm2804
Remove and Install Operator Cab Glass (Adhered Glass)2806
Remove Operator CAB Glass (Adhered Glass)2808
Install Operator CAB Glass (Adhered Glass)2808
Remove and Install Air Conditioner Unit Assembly2814
Remove Air Conditioner Unit Assembly2814
Install Air Conditioner Unit Assembly2820
Remove and Install Operator Seat2828
Remove Operator’s Seat2828
Install Operator’s Seat2829
How to Remove and Install Seat Belt2830
How to Remove Seat Belt2830
How to Install Seatbelt2830
Remove and Install Foot Heater Assembly2832
Remove Foot Heater Assembly2832
Install Foot Heater Assembly2834
Disassemble and Assemble Foot Heater Assembly2836
Disassemble Foot Heater Assembly2836
Assemble Foot Heater Assembly2837
Electrical System2838
Remove and Install Engine Controller Assembly2838
Remove Engine Controller Assembly2838
Install Engine Controller Assembly2841
Remove and Install HST Controller Assembly2844
Remove HST Controller Assembly2844
How to Install HST Controller Assembly2845
Remove and Install Machine Monitor Assembly2846
Remove Machine Monitor Assembly2846
Install Machine Monitor Assembly2847
Remove and Install Mass Air Flow and Temperature Sensor2849
How to Remove Mass Air Flow and Temperature Sensor2849
How to Install Mass Air Flow and Temperature Sensor2851
Remove and Install KCCV Crankcase Pressure Sensor2852
How to Remove KCCV Crankcase Pressure Sensor2852
How to Install KCCV Crankcase Pressure Sensor2853
Remove and Install SCR Temperature Sensor2855
Remove SCR Temperature Sensor2855
Install SCR Temperature Sensor2857
Remove and Install KOMTRAX Terminal Assembly2860
Remove KOMTRAX Terminal Assembly2860
Install KOMTRAX Terminal Assembly2861
Remove and Install Gateway Function Controller Assembly2862
How to Remove Gateway Function Controller Assembly2862
How to Install Gateway Function Controller Assembly2863
Remove and Install ICT Sensor Controller Assembly2864
Remove ICT Sensor Controller Assembly2864
Install ICT Sensor Controller Assembly2864
Remove and Install Control Box2866
How to Remove Control Box (For Old Control Box)2866
How to Remove Control Box (For New Control Box)2867
How to Install Control Box (For Old Control Box)2867
How to Install Control Box (For New Control Box)2868
Remove and Install GNSS Receiver2870
Remove GNSS Receiver2870
Install GNSS Receiver2870
Remove and Install GNSS Antenna2872
Remove GNSS Antenna2872
Install GNSS Antenna2873
Remove and Install IMU Sensor2878
Remove IMU Sensor2878
Install IMU Sensor2879
Remove and Install Communication Terminal2882
How to Remove Communication Terminal2882
How to Install Communication Terminal2885
60 Maintenance Standard2889
Table of Contents2890
Abbreviation List2891
Engine and Cooling System2897
Maintenance Standard for Engine Mount2897
Maintenance Standard for Damper2898
Maintenance Standard for Cooling System2899
Maintenance Standard for Cooling Fan Motor2901
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve2903
Power Train2904
Maintenance Standard for HST Pump2904
Maintenance Standard for EPC Valve of HST Pump2905
Maintenance Standard for Tow Receiving Valve of HST Pump2906
Maintenance Standard for HST Charge Pump2907
Maintenance Standard for HST Motor2909
Maintenance Standard for Final Drive2910
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D37EXI-24, D37PXI-242912
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D39EXI-24, D39PXI-242914
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D37EXI-24, D37PXI-242916
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D39EXI-24, D39PXI-242917
Undercarriage and Frame2918
Maintenance Standard for Track Frame and Idler Cushion2918
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D37EXI-24, D37PXI-242923
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D39EXI-24, D39PXI-242925
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)2927
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)2929
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes2931
Maintenance Standard for PLUS Type Track Shoes2933
Maintenance Standard for Single Shoes2937
Hydraulic System2938
Maintenance Standard for Hydraulic Tank2938
Maintenance Standard for Work Equipment and Cooling Fan Pump2939
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump2940
Maintenance Standard for Control Valve2942
Maintenance Standard for Ripper PPC Valve2949
Maintenance Standard for 5-Spool EPC and Solenoid Valve2951
Maintenance Standard for EPC Valve2952
Maintenance Standard for Angle Control EPC Valve2953
Work Equipment2954
Maintenance Standard for Front Work Equipment2954
Maintenance Standard for Cutting Edge and End Bit2957
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder2958
Maintenance Standard for Stroke Sensing Blade Tilt Cylinder2959
Maintenance Standard for Stroke Sensing Blade Angle Cylinder2960
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder2961
Maintenance Standard for Stroke Sensor for Blade Tilt Cylinder2962
Maintenance Standard for Stroke Sensor for Blade Angle Cylinder2963
Maintenance Standard for Fixed Multi-Shank Ripper2964
Maintenance Standard for Ripper Lift Cylinder2966
CAB Related Parts2967
Maintenance Standard for CAB Mount2967
Electrical System2968
Maintenance Standard for Steering Electric Lever2968
80 Appendix2969
Table of Contents2970
Precautions Before Work2971
Abbreviation List2972
Air Conditioner System2978
Precautions for Refrigerant2978
Air Conditioner Component2979
Specifications of Air Conditioner2982
Structure and Function of Refrigeration Cycle2983
Outline of Refrigeration Cycle2984
Component Parts of Air Conditioner System2986
Air Conditioner Unit2986
Configuration Diagram of Air Conditioner Unit2986
Function of Air Conditioner Unit2987
Component Parts of Air Conditioner Unit2988
Function of Evaporator as Air Conditioner Unit Component2988
Function of Heater Core as Air Conditioner Unit Component2988
Function of Thermostat as Air Conditioner Unit Component2988
Structure of Expansion Valve as Air Conditioner Unit Component2989
Function of Expansion Valve as Air Conditioner Unit Component2989
Operate Expansion Valve as Air Conditioner Unit Component2989
Function of Dual Pressure Switch2990
Function of Pressure Switch2990
Compressor2991
Structure of Compressor2991
Specifications of Compressor2991
Function of Compressor2991
Condenser2992
Structure of Condenser2992
Specifications of Condenser2992
Function of Condenser2993
Receiver Drier2994
Structure of Receiver Dryer2994
Specifications of Receiver Dryer2994
Function of Receiver Dryer2994
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2996
Circuit Diagram of Air Conditioner2999
System Diagram of Air Conditioner3000
Control Function of Air Conditioner3001
Locations of Air Conditioner Parts and Layout of Connectors3002
Examine Relay3006
How to Examine Relay3006
Air Conditioner Troubleshooting Chart 13008
Air Conditioner Troubleshooting Chart 23009
Information Shown in Troubleshooting Table3012
Troubleshooting for Condenser Fan3013
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)3016
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)3020
Troubleshooting for Temperature Control Function3023
Troubleshooting by Gauge Pressure3027
Connect Service Tool3029
How to Connect Service Tool3029
Precautions for Disconnection and Connection of Air Conditioner Piping3030
Handle Compressor Oil3032
90 Circuit Diagrams3035
Table of Contents3036
Abbreviation List3037
Hydraulic Circuit Diagram3043
Symbols Used in Hydraulic Circuit Diagram3043
Hydraulic Circuit Diagram3047
Electrical Circuit Diagram3049
Symbols Used in Electric Circuit Diagram3049
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/11)3053
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/11)3055
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/11)3057
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/11)3059
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/11)3061
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/11)3063
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/11)3065
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/11)3067
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/11)3069
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/11)3071
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/11)3073
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/13)3075
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/13)3077
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/13)3079
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/13)3081
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/13)3083
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/13)3085
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/13)3087
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/13)3089
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/13)3091
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/13)3093
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/13)3095
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/13)3097
Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/13)3099
INDEX3101
S.M 28/12/24
