Komatsu Bulldozer D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Shop Manual SEN06869-08 PDF

Description

Komatsu Bulldozer D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Shop Manual SEN06869-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Shop Manual SEN06869-08 – PDF DOWNLOAD

Language : English
Pages :3116
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Shop Manual SEN06869-08 – PDF DOWNLOAD

SERIAL NUMBERS
D37EXi- 90001
D37PXi- 90001
D39EXi-100001
D39PXi-100001
and up

TABLE OF CONTENTS:

Komatsu Bulldozer D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Shop Manual SEN06869-08 – PDF DOWNLOAD

SERIAL NUMBERS
D37EXi- 90001
D37PXi- 90001
D39EXi-100001
D39PXi-100001
and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 23
How to Read the Shop Manual 23
Safety Notice for Operation 25
Precautions to Prevent Fire 33
Procedures If Fire Occurs 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage 38
Precautions for Fire Hazard and Leakage 38
Other Precautions 38
Store DEF 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
Abbreviation List 89
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: D37EXI-24 95
Specification Drawing: D37PXI-24 97
Specification Drawing: D39EXI-24 98
Specification Drawing: D39PXI-24 99
Specifications 100
Specification: D37EXI-24 100
Specification: D37PXI-24 105
Specification: D39EXI-24 109
Specification: D39PXI-24 114
Weight Table 118
Weight Table: D37EXI-24 118
Weight Table: D37PXI-24 120
Weight Table: D39EXI-24 122
Weight Table: D39PXI-24 124
Table of Fuel, Coolant, and Lubricants 126
10 Structure and Function 127
Table of Contents 128
Urea SCR System 132
Layout Drawing of Urea SCR System 132
Urea SCR System Diagram 134
Function of Urea SCR System 135
Function of DEF System 135
Inducement Strategy 138
Component Parts of Urea SCR System 152
DEF Mixing Tube 152
SCR Assembly 153
DEF Tank 155
DEF Pump 157
DEF Injector 158
DEF Hose 159
DEF Tank Heating Valve 160
Boot-up System 161
Layout Drawing of Boot-up System 161
System Operating Lamp System 162
System Diagram of System Operating Lamp System 162
Function of Operation Lamp System 162
Battery Disconnect Switch 164
Function of Battery Disconnect Switch 164
Engine System 165
Layout Drawing of Engine System 165
Engine Control System 167
Layout Drawing of Engine Control System 167
System Diagram of Engine Control 169
Function of Engine Control System 171
Automatic Idle Stop System 173
System Diagram of Automatic Idle Stop System 173
Function of Automatic Idle Stop System 173
Component Parts of Engine System 176
Damper 176
Variable Flow Turbocharger 177
EGR System 181
EGR Valve 184
EGR Cooler 186
KCCV System 188
KCCV Ventilator 191
Exhaust Throttle Valve 193
KDOC 194
Cooling System 197
Layout Drawing of Cooling System 197
Specifications of Cooling System 198
Cooling Fan Control System 199
System Diagram of Cooling Fan Control System 199
Function of Cooling Fan Control System 200
Component Parts of Cooling System 202
Cooling Fan Motor 202
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 207
Hydraulic Oil Cooler Bypass Valve 209
HST Charge Safety Valve 210
Control System 212
Layout Drawing of Control System 212
Machine Monitor System 213
System Diagram of Machine Monitor System 213
Function of Machine Monitor System 214
KOMTRAX System 215
System Diagram of KOMTRAX System 215
Function of KOMTRAX System 216
Component Parts of Control System 217
Machine Monitor 217
Gateway Function Controller 232
Communication Terminal 235
HST Controller 237
Engine Controller 241
Fuel Control Dial 248
Decelerator and Brake Potentiometer 250
Hydraulic System 252
Layout Drawing of Hydraulic System 252
CLSS 253
Structure of CLSS 253
Function of CLSS 254
Component Parts of Hydraulic System 256
Hydraulic Tank 256
Work Equipment and Cooling Fan Pump 258
LS Valve 265
PC Valve 266
Control Valve 269
Power Train System 290
Layout Drawing of HST System 290
Operation of HST System 291
Steering and Brake Control System 293
Layout Drawing of Steering and Brake Control System 293
Function of Steering and Brake Control System 294
HST Control System 295
System Diagram of HST Control System 295
Gear Shift Control Function 296
Engine Low Speed Matching Control Function 300
HST Pump and Motor Sequence Control Function 301
Deceleration and Brake Control Function 302
Gear Shift Control Function by Load 304
Turn Control Function 305
Straight Travel Correction Control Function 306
Parking Brake Control System 307
System Diagram of Parking Brake Control System 307
Function of Parking Brake Control System 308
Operation of Parking Brake Control System 309
Component Parts of Power Train System 310
HST Pump 310
HST Charge Pump 327
HST Motor 328
Final Drive 340
Electric Steering Electric Lever 344
Work Equipment System 347
Work Equipment Control 347
Layout Drawing of Work Equipment Control 347
Function of Work Equipment Control 348
Layout Drawing of Front Work Equipment 350
Layout Drawing of Fixed Multi-Shank Ripper 351
Component Parts of Work Equipment System 352
Ripper PPC Valve 352
5-Spool EPC and Solenoid Valve 356
Pilot Circuit Accumulator 363
Angle Control EPC Valve 364
Piston Valve 367
Electric Blade Control Lever 368
ICT System 370
Layout Drawing of ICT System 370
System Diagram of ICT Control System 372
Blade Control System 374
Function of Blade Control System 374
Simple Grading Mode System Diagram 376
Function of Simple Grading Mode 377
Operation of Simple Grading Mode 377
Assist Control System 379
Assist Control System Diagram 379
Function of Assist Control System 379
Operation of Assist Control System 380
Back Grade Mode System 381
Back Grade Mode System Diagram 381
Function of Back Grade Mode System 382
Operation of Back Grade Mode System 382
Cut Control System 383
Cut Control System Diagram 383
Function of Cut Control System 384
Operation of Cut Control System 384
Smooth Start System 396
Smooth Start System Diagram 396
Function of Smooth Start System 397
Operation of Smooth Start System 397
Slip Control System 398
Slip Control System Diagram 398
Function of Slip Control System 399
Operation of Slip Control System 399
Speed Control System 400
Speed Control System Diagram 400
Function of Speed Control System 400
Operation of Speed Control System 400
Straight Travel Correction System 402
Straight Travel Correction System Diagram 402
Function of Straight Travel Correction System 403
Operation of Straight Travel Correction System 403
Quick Surface Control System 406
Quick Surface Control System Diagram 406
Function of Quick Surface Control System 406
Operation of Quick Surface Control System 407
System of Triangulated Surface from AS-BUILT 408
System Diagram of Triangulated Surface from AS-BUILT 408
Function of System of Triangulated Surface from AS-BUILT 408
Operation of System of Triangulated Surface from AS-BUILT 408
2 Surfaces Selection Control System 410
2 Surfaces Selection Control System Diagram 410
Function of 2 Surfaces Selection Control System 411
Operation of 2 Surfaces Selection Control System 411
Lift Layer Control System 412
Lift Layer Control System Diagram 412
Function of Lift Layer Control System 413
Operation of Lift Layer Control System 413
2D Laser Machine Control System 415
System Diagram of 2D Laser Machine Control System 415
Function of 2D Laser Machine Control System 416
Operation of 2D Laser Machine Control System 416
Component Parts of ICT System 417
ICT Sensor Controller 417
Control Box 421
GNSS Receiver 423
GNSS Antenna 425
IMU Sensor 426
GNSS External Radio Device 430
Navigation Controller 432
Stroke and Reset Sensor for Blade Lift Cylinder 437
Stroke Sensor for Blade Tilt Cylinder 440
Stroke Sensor for Blade Angle Cylinder 442
Undercarriage and Frame 444
Main Frame 444
Structure of Main Frame 444
Track Frame and Idler Cushion 445
Structure of Track Frame and Idler Cushion 445
Function of Track Frame and Idler Cushion 447
Work Equipment 448
Structure of Front Work Equipment 448
Structure of Fixed Multi-Shank Ripper 449
CAB Related Parts 450
ROPS CAB 450
Structure of ROPS CAB 450
Function of ROPS CAB 451
CAB Mount 452
Structure of CAB Mount 452
Function of CAB Mount 453
20 Standard Value Table 455
Table of Contents 456
Standard Value Table for Engine 457
Standard Value Table for Engine: D37EXI-24 457
Standard Value Table for Engine: D37PXI-24 460
Standard Value Table for Engine: D39EXI-24 463
Standard Value Table for Engine: D39PXI-24 466
Standard Value Table for Machine 469
Standard Value Table for Machine: D37EXI-24 469
Standard Value Table for Machine: D37PXI-24 486
Standard Value Table for Machine: D39EXI-24 501
Standard Value Table for Machine: D39PXI-24 518
Machine Posture and Procedures to Measure Performance 533
30 Testing and Adjusting 535
Table of Contents 536
Precautions Before Work 540
Related Information on Testing and Adjusting 541
Tools for Testing and Adjusting 541
Sketch of Tools for Testing and Adjusting 549
Engine and Cooling System 554
Examine Engine Speed 554
How to Examine Engine Speed 554
Examine Exhaust Gas Color 556
How to Examine Exhaust Gas Color with the Handy Smoke Checker 556
How to Examine Exhaust Gas Color with Smoke Meter 557
Examine the Clearance of Exhaust Throttle Valve 558
How to Measure Clearance of the Exhaust Throttle Valve 558
Examine and Adjust Valve Clearance 560
How to Examine Valve Clearance 560
How to Adjust Valve Clearance 561
Examine Compression Pressure 562
How to Examine Compression Pressure 562
Examine Blowby Pressure 565
How to Examine Blowby Pressure 565
Examine Engine Oil Pressure 567
How to Examine Engine Oil Pressure 567
Visual Check Inside of EGR Valve 569
How to do the Visual Check Inside of EGR Valve 569
Clean Inside of EGR Valve 571
How to Clean Inside of EGR Valve 571
Examine Fuel Pressure 574
How to Examine Fuel Pressure 574
Examine Fuel Return Rate and Leakage 576
How to Examine Fuel Return Rate and Leakage 577
Bleed Air from Fuel System 581
How to Bleed Air from Fuel System 581
Examine Fuel Circuit for Leakage 583
How to Examine Fuel System for Leakage 583
Handle Cylinder Cut-out Mode Operation 585
Handle No-Injection Cranking Operation 586
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 587
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage 587
Examine Installed Condition of Cylinder Heads and Manifolds 588
How to Examine Installed Condition of Cylinder Heads and Manifolds 588
Examine Engine Piping for Damage and Looseness 589
How to Examine Engine Piping for Damage and Looseness 589
Examine Alternator Belt 590
How to Examine Alternator Belt 590
Examine Automatic Tensioner 591
How to Examine Automatic Tensioner 591
Write Injector Compensation Value to Engine Controller 593
How to Write Injector Compensation Value 593
Examine SCR Related Functions 599
Examine DEF Pump Raised Pressure 603
Examine Injection Volume from DEF Injector 606
Examine DEF Line Heater Relay 1 611
Examine DEF Line Heater Relay 2 614
Examine DEF Pump Heater Relay 617
Examine DEF Tank Heater Valve 621
Examine SCR Denitration Efficiency 625
Clean DEF Tank 628
How to Clean DEF Tank 628
Clean DEF Tank Mounting Part 633
How to Clean DEF Tank Mounting Part 633
Clean DEF Pump 634
How to Clean DEF Pump 634
Power Train 640
Examine and Adjust HST Oil Pressure 640
How to Examine HST Oil Pressure 640
How to Adjust HST Oil Pressure 643
Bleed Air from HST Pump 645
How to Bleed Air from HST Pump 645
How to Bleed Air from Servo Valve of HST Pump 645
Examine Outlet Pressure of Solenoid Valve 647
How to Examine Outlet Pressure of Solenoid Valve 647
Examine Travel Deviation 652
How to Examine Travel Deviation 652
Examine Brake Performance Simply 654
How to Examine Brake Performance Simply 654
Examine and Adjust Deceleration/Brake Pedal 655
How to Examine Deceleration/Brake Pedal 655
How to Adjust Deceleration/Brake Pedal 657
How to Adjust Parking Brake Lever 659
Move Machine When It Cannot Travel 661
How to Move Machine with Hydraulic Type Parking Brake Release System 661
How to Move Machine After You Remove Final Drive Shaft 663
Undercarriage and Frame 665
Adjust Idler Clearance 665
How to Adjust Idler Clearance 665
Examine Sprocket Wear 666
How to Examine Sprocket Wear 666
Examine and Adjust Track Tension 667
How to Examine Track Tension 667
How to Adjust Track Tension 667
Hydraulic System 669
Release Remained Pressure in Hydraulic Circuit 669
How to Release Remained Pressure in Hydraulic System 669
Examine and Adjust Work Equipment Circuit Oil Pressure 670
How to Examine Work Equipment Circuit Oil Pressure 670
How to Adjust Work Equipment Circuit Oil Pressure 671
Examine and Adjust Oil Pressure in Control Circuit 673
How to Examine Oil Pressure in Control Circuit 673
How to Adjust Oil Pressure in Control Circuit 674
Examine Outlet Pressure of EPC Solenoid Valve 675
How to Examine Outlet Pressure of EPC Solenoid Valve 675
Bleed Air from Work Equipment and Cooling Fan Pump 677
How to Bleed Air from Work Equipment and Cooling Fan Pump 677
Examine Cooling Fan Speed 678
How to Examine Cooling Fan Speed 678
Examine Cooling Fan Circuit Oil Pressure 679
How to Examine Cooling Fan Circuit Oil Pressure 679
Examine Parts Which Cause Hydraulic Drift of Work Equipment 681
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 681
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 681
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 682
Examine Oil Leakage from Work Equipment Cylinder 683
How to Examine Internal Oil Leakage of Work Equipment Cylinder 683
Bleed Air from Work Equipment Cylinders 685
How to Bleed Air from Work Equipment Cylinder 685
Work Equipment 686
Adjust Work Equipment Lock Lever 686
How to Adjust Work Equipment Lock Lever 686
Examine and Adjust Play of Blade Electric Lever 688
How to Examine Play of Blade Electric Lever 690
How to Adjust Play of Blade Electric Lever 690
How to Replace Universal Joint 691
Electrical System 698
Set and Operate Machine Monitor 698
Operator Mode 702
Function to Show Technician Identification Status Screen 702
Function to Show Operator Identification Input Screen 702
Examine Function by LCD (Liquid Crystal Display) 703
Examine Function of Service Meter 703
How to Set Usage Limitation and Change Maintenance Password 703
Service Mode 706
How to Operate Service Mode 706
How to See Pre-defined Monitoring Information 707
How to Examine Self-Define Monitor Information 714
Abnormality Record Menu 726
How to See Maintenance Record 730
Maintenance Mode Setting 731
How to Set Phone Number Entry 735
Default Menu 737
Diagnostic Tests Menu 746
Adjustment Menu 754
No-Injection Cranking Operation 823
KOMTRAX Settings Menu 826
How to Show Service Message 828
How to Start Up KOMTRAX System 830
How to Stop Use of KOMTRAX System 836
Adjust After Replacement of HST Controller 838
How to Adjust After Replacement of HST Controller 838
Adjust After Replacement of Electric and Hydraulic Equipment 844
Adjust Rearview Camera Angle 846
How to Adjust Rearview Camera Angle 846
Set Region of Bluetooth(R) Compatible Radio 848
How to Set Region of Bluetooth(R) Compatible Radio 848
Handle Voltage Circuit of Engine Controller 850
Handle Battery Disconnect Switch 851
Examine Diodes 852
How to Examine Diodes by Digital Tester 852
How to Examine Diodes by Analog Tester 852
ICT System 853
Examine and Adjust ICT Related Devices 853
Set and Operate Control Box 855
Machine Calibration 856
Calibrate IMU Sensor 857
How to Operate Machine Calibration Step A 864
How to Operate Machine Calibration Step B 870
Calibrate GNSS Antenna (AUX) Location 876
How to Operate Pitch Rod Calibration 878
How to Input Wear Volume of Blade Edge and Track Shoes 880
Reset Cylinder Stroke End 882
Reset Lift Cylinder Stroke End 882
Reset Tilt Cylinder Stroke End 883
Reset Angle Cylinder Stroke End 883
How to Operate Manual Machine Calibration 884
Examine and Adjust Blade Elevation 886
Examine Stroke Sensor for Lift Cylinder 889
How to Examine Stroke Sensor for Lift Cylinder 889
Examine Stroke Sensor for Tilt Cylinder 891
How to Examine Stroke Sensor for Tilt Cylinder 891
Examine Stroke Sensor for Angle Cylinder 893
How to Examine Stroke Sensor for Angle Cylinder 893
Examine and Adjust Reset Sensor for Lift Cylinder 895
How to Examine Reset Sensor for Lift Cylinder 895
How to Adjust Reset Sensor for Lift Cylinder 895
Adjust When ICT Sensor Controller is Replaced 896
How to Adjust When ICT Sensor Controller is Replaced 896
Adjust After Replacement of IMU Sensor 899
How to Adjust After Replacement of IMU Sensor 899
How to Adjust When ICT Related Devices are Repaired or Replaced 900
Pm Clinic 903
Pm Clinic Service 903
Pm Clinic Check Sheet: D37EXI-24 905
Pm Clinic Check Sheet: D37PXI-24 913
Pm Clinic Check Sheet: D39EXI-24 921
Pm Clinic Check Sheet: D39PXI-24 928
Pm Clinic Check Sheet for Undercarriage: D37EXI-24 935
Pm Clinic Check Sheet for Undercarriage: D37PXI-24 942
Pm Clinic Check Sheet for Undercarriage: D39EXI-24 949
Pm Clinic Check Sheet for Undercarriage: D39PXI-24 956
40 Troubleshooting 965
Table of Contents 966
Precautions Before Work 978
Related Information to Troubleshooting 979
General Troubleshooting Points 979
Troubleshooting Points for Urea SCR System 980
Sequence of Events in Troubleshooting 992
Checks Before Troubleshooting 994
Inspection Procedure Before Troubleshooting 996
Walk-Around Check 996
Test in Accordance with Testing Procedure 998
Examine Fuel Level and Type 998
Examine for Impure Ingredient in Fuel 998
Examine DEF Level and Type 999
Examine Fuel Prefilter 999
Examine Fuel Main Filter1001
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1003
Examine Coolant Level (Reservoir Tank)1004
Examine Air Cleaner Clogging1005
Clean Outer Element1005
Replace Element1007
Examine Hydraulic Oil Level1007
Examine Hydraulic Oil Strainer1008
Examine Oil Level in Final Drive Case1012
Bleed Air from Fuel System1012
Bleed Air from Hydraulic System1013
How to Examine Electric Equipment1013
Preparation for Troubleshooting of Electrical System1020
Procedure for Troubleshooting1027
Symptom and Troubleshooting Numbers1030
Information Shown in Troubleshooting Table1035
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness1037
Connector List and Layout1040
Connector Contact Connection Table1062
T-Branch Box and T-Branch Adapter Table1102
Fuse Location Table1108
Precautions When You Replace KDOC1112
Failure Code Table1113
Troubleshooting by Failure Code (Display of Code)1135
Failure Code [6091NX]1135
Failure Code [989L00]1137
Failure Code [989M00]1138
Failure Code [989N00]1139
Failure Code [A1U0N3]1140
Failure Code [A1U0N4]1142
Failure Code [A900FR]1144
Failure Code [A900N6]1145
Failure Code [A900NY]1146
Failure Code [AA10NX]1147
Failure Code [AB00KE]1149
Failure Code [AQ10MB]1151
Failure Code [AQ10N3]1153
Failure Code [AS00R2]1154
Failure Code [AS00R3]1155
Failure Code [AS00R4]1156
Failure Code [AS00R5]1157
Failure Code [AS00R6]1158
Failure Code [AS00ZK]1159
Failure Code [AS10KM]1160
Failure Code [AS10NR]1161
Failure Code [AS10NT]1162
Failure Code [AU10QA]1163
Failure Code [B@BAZG]1164
Failure Code [B@BCNS]1165
Failure Code [B@BCQA]1166
Failure Code [B@BCZK]1168
Failure Code [B@CRNS]1170
Failure Code [B@CRZG]1171
Failure Code [CA115]1172
Failure Code [CA122]1173
Failure Code [CA123]1175
Failure Code [CA131]1177
Failure Code [CA132]1179
Failure Code [CA144]1181
Failure Code [CA145]1183
Failure Code [CA153]1185
Failure Code [CA154]1188
Failure Code [CA187]1191
Failure Code [CA221]1193
Failure Code [CA222]1195
Failure Code [CA227]1197
Failure Code [CA234]1198
Failure Code [CA238]1199
Failure Code [CA239]1201
Failure Code [CA249]1203
Failure Code [CA256]1205
Failure Code [CA271]1207
Failure Code [CA272]1209
Failure Code [CA322]1211
Failure Code [CA324]1213
Failure Code [CA331]1215
Failure Code [CA332]1217
Failure Code [CA343]1219
Failure Code [CA351]1220
Failure Code [CA352]1221
Failure Code [CA356]1224
Failure Code [CA357]1226
Failure Code [CA386]1228
Failure Code [CA435]1229
Failure Code [CA441]1231
Failure Code [CA442]1233
Failure Code [CA449]1234
Failure Code [CA451]1235
Failure Code [CA452]1237
Failure Code [CA515]1239
Failure Code [CA516]1241
Failure Code [CA553]1243
Failure Code [CA555]1244
Failure Code [CA556]1245
Failure Code [CA559]1246
Failure Code [CA689]1250
Failure Code [CA691]1252
Failure Code [CA692]1254
Failure Code [CA697]1256
Failure Code [CA698]1257
Failure Code [CA731]1258
Failure Code [CA778]1260
Failure Code [CA1117]1265
Failure Code [CA1664]1266
Failure Code [CA1669]1268
Failure Code [CA1673]1269
Failure Code [CA1677]1270
Failure Code [CA1678]1271
Failure Code [CA1682]1272
Failure Code [CA1683]1277
Failure Code [CA1684]1279
Failure Code [CA1686]1281
Failure Code [CA1691]1282
Failure Code [CA1694]1284
Failure Code [CA1695]1286
Failure Code [CA1696]1287
Failure Code [CA1712]1289
Failure Code [CA1713]1292
Failure Code [CA1714]1294
Failure Code [CA1715]1295
Failure Code [CA1776]1296
Failure Code [CA1777]1299
Failure Code [CA1843]1302
Failure Code [CA1844]1304
Failure Code [CA1885]1307
Failure Code [CA1887]1309
Failure Code [CA1896]1311
Failure Code [CA1938]1315
Failure Code [CA1942]1317
Failure Code [CA1961]1318
Failure Code [CA2185]1319
Failure Code [CA2186]1321
Failure Code [CA2249]1323
Failure Code [CA2272]1324
Failure Code [CA2311]1327
Failure Code [CA2349]1328
Failure Code [CA2353]1330
Failure Code [CA2357]1332
Failure Code [CA2555]1333
Failure Code [CA2556]1335
Failure Code [CA2636]1337
Failure Code [CA2637]1340
Failure Code [CA2765]1342
Failure Code [CA2771]1343
Failure Code [CA2976]1349
Failure Code [CA3142]1351
Failure Code [CA3143]1352
Failure Code [CA3144]1353
Failure Code [CA3146]1355
Failure Code [CA3147]1356
Failure Code [CA3148]1357
Failure Code [CA3151]1359
Failure Code [CA3165]1365
Failure Code [CA3229]1367
Failure Code [CA3231]1369
Failure Code [CA3232]1371
Failure Code [CA3235]1375
Failure Code [CA3239]1377
Failure Code [CA3241]1380
Failure Code [CA3242]1383
Failure Code [CA3251]1386
Failure Code [CA3313]1388
Failure Code [CA3314]1389
Failure Code [CA3315]1390
Failure Code [CA3419]1392
Failure Code [CA3421]1394
Failure Code [CA3497]1396
Failure Code [CA3498]1397
Failure Code [CA3543]1398
Failure Code [CA3545]1404
Failure Code [CA3547]1406
Failure Code [CA3558]1407
Failure Code [CA3559]1409
Failure Code [CA3562]1411
Failure Code [CA3563]1413
Failure Code [CA3567]1416
Failure Code [CA3568]1419
Failure Code [CA3571]1424
Failure Code [CA3572]1426
Failure Code [CA3574]1428
Failure Code [CA3575]1431
Failure Code [CA3577]1433
Failure Code [CA3578]1435
Failure Code [CA3582]1437
Failure Code [CA3583]1445
Failure Code [CA3596]1447
Failure Code [CA3649]1451
Failure Code [CA3681]1453
Failure Code [CA3682]1458
Failure Code [CA3713]1463
Failure Code [CA3717]1466
Failure Code [CA3718]1467
Failure Code [CA3724]1468
Failure Code [CA3725]1469
Failure Code [CA3748]1472
Failure Code [CA3755]1475
Failure Code [CA3866]1477
Failure Code [CA3867]1481
Failure Code [CA3868]1484
Failure Code [CA3899]1488
Failure Code [CA3911]1490
Failure Code [CA3912]1494
Failure Code [CA3918]1496
Failure Code [CA3921]1498
Failure Code [CA3928]1499
Failure Code [CA3932]1500
Failure Code [CA3933]1502
Failure Code [CA3934]1504
Failure Code [CA3935]1507
Failure Code [CA3936]1509
Failure Code [CA4152]1511
Failure Code [CA4155]1515
Failure Code [CA4156]1518
Failure Code [CA4157]1521
Failure Code [CA4159]1523
Failure Code [CA4164]1524
Failure Code [CA4165]1526
Failure Code [CA4166]1528
Failure Code [CA4168]1529
Failure Code [CA4169]1532
Failure Code [CA4171]1534
Failure Code [CA4249]1538
Failure Code [CA4251]1540
Failure Code [CA4261]1542
Failure Code [CA4277]1545
Failure Code [CA4281]1549
Failure Code [CA4459]1553
Failure Code [CA4461]1556
Failure Code [CA4533]1559
Failure Code [CA4534]1560
Failure Code [CA4731]1561
Failure Code [CA4732]1562
Failure Code [CA4739]1563
Failure Code [CA4768]1564
Failure Code [CA4769]1566
Failure Code [CA4842]1568
Failure Code [CA4952]1572
Failure Code [CA5115]1574
Failure Code [CA5179]1577
Failure Code [CA5181]1579
Failure Code [CA5271]1581
Failure Code [CA5272]1583
Failure Code [CA5273]1585
Failure Code [CA5274]1587
Failure Code [CA5275]1588
Failure Code [CA5276]1590
Failure Code [CA5387]1592
Failure Code [CA5388]1594
Failure Code [CA5389]1596
Failure Code [CA5391]1598
Failure Code [CA5392]1602
Failure Code [CA5393]1603
Failure Code [CA5394]1606
Failure Code [CA5395]1609
Failure Code [CA5396]1612
Failure Code [CA5631]1613
Failure Code [CA5938]1615
Failure Code [D130KA]1617
Failure Code [D130KB]1619
Failure Code [D130KY]1621
Failure Code [D19DKA]1623
Failure Code [D19DKB]1625
Failure Code [D19DKY]1627
Failure Code [D19JKZ]1630
Failure Code [D811MC]1633
Failure Code [D862KA]1634
Failure Code [D8ALKA]1635
Failure Code [D8ALKB]1638
Failure Code [D8AQKR]1640
Failure Code [D8G1KT]1643
Failure Code [D8G6KT]1644
Failure Code [DAF0MB]1645
Failure Code [DAF0MC]1646
Failure Code [DAF8KB]1647
Failure Code [DAF9KQ]1649
Failure Code [DAFGMC]1650
Failure Code [DAFLKA]1651
Failure Code [DAFLKB]1654
Failure Code [DAFQKR]1656
Failure Code [DAJ000]1660
Failure Code [DAJ0KQ]1661
Failure Code [DAJ0KT]1662
Failure Code [DAJ0MC]1663
Failure Code [DAJ1KK]1664
Failure Code [DAJ2KK]1666
Failure Code [DAJ5KK]1668
Failure Code [DAJ6KK]1671
Failure Code [DAJLKA]1673
Failure Code [DAJLKB]1675
Failure Code [DAJPMA]1677
Failure Code [DAJQKR]1678
Failure Code [DAJRKR]1679
Failure Code [DB2QKR]1683
Failure Code [DB2RKR]1690
Failure Code [DBR0KT]1695
Failure Code [DBR0MC]1696
Failure Code [DBR1KK]1697
Failure Code [DBR2KK]1700
Failure Code [DBR5KK]1703
Failure Code [DBRLKA]1705
Failure Code [DBRLKB]1707
Failure Code [DBRPMA]1709
Failure Code [DBRQKR]1710
Failure Code [DBRRKR]1712
Failure Code [DBU0KR]1716
Failure Code [DBUSKR]1717
Failure Code [DBUTKA]1722
Failure Code [DBUTKN]1724
Failure Code [DBUTMA]1726
Failure Code [DBUUKA]1727
Failure Code [DBUUKN]1729
Failure Code [DD12KA]1731
Failure Code [DD12KB]1733
Failure Code [DD13KA]1735
Failure Code [DD13KB]1737
Failure Code [DD14KA]1739
Failure Code [DD14KB]1741
Failure Code [DDKAKA]1743
Failure Code [DDKAKB]1745
Failure Code [DDKFL4]1747
Failure Code [DDKGL4]1749
Failure Code [DDKHKA]1751
Failure Code [DDKHKB]1753
Failure Code [DDKQKA]1755
Failure Code [DDKQKB]1757
Failure Code [DDKRKA]1759
Failure Code [DDKRKB]1761
Failure Code [DDKSKA]1763
Failure Code [DDKSKB]1765
Failure Code [DDNLKA]1767
Failure Code [DDNLKB]1769
Failure Code [DDP6KA]1771
Failure Code [DDP6KB]1773
Failure Code [DDP6MA]1775
Failure Code [DDU1FS]1777
Failure Code [DDU1KA]1779
Failure Code [DDU1KY]1781
Failure Code [DFA4KX]1783
Failure Code [DFA4KZ]1784
Failure Code [DFA4L8]1785
Failure Code [DFA5KA]1786
Failure Code [DFA5KB]1788
Failure Code [DFA6KA]1790
Failure Code [DFA6KB]1792
Failure Code [DFA7KX]1794
Failure Code [DFA7KZ]1795
Failure Code [DFA7L8]1796
Failure Code [DFA8KA]1797
Failure Code [DFA8KB]1799
Failure Code [DFA9KA]1801
Failure Code [DFA9KB]1803
Failure Code [DGS1KA]1805
Failure Code [DGS1KX]1807
Failure Code [DH21KA]1809
Failure Code [DH21KB]1811
Failure Code [DHA4KA]1812
Failure Code [DHH7KA]1814
Failure Code [DHH7KB]1816
Failure Code [DHH8KA]1818
Failure Code [DHH8KB]1820
Failure Code [DHH9KA]1822
Failure Code [DHH9KB]1824
Failure Code [DHHAKA]1826
Failure Code [DHHAKB]1828
Failure Code [DHRUKA]1830
Failure Code [DHRUKB]1832
Failure Code [DHRVKA]1834
Failure Code [DHRVKB]1836
Failure Code [DK30KA]1838
Failure Code [DK30KB]1840
Failure Code [DK30KX]1842
Failure Code [DK30KZ]1843
Failure Code [DK30L8]1844
Failure Code [DK31KA]1847
Failure Code [DK31KB]1849
Failure Code [DK40KA]1851
Failure Code [DK40KB]1853
Failure Code [DK55KX]1855
Failure Code [DK55KZ]1856
Failure Code [DK55L8]1857
Failure Code [DK56KA]1859
Failure Code [DK56KB]1861
Failure Code [DK57KA]1863
Failure Code [DK57KB]1865
Failure Code [DK80KA]1867
Failure Code [DK80KR]1870
Failure Code [DK80KT]1875
Failure Code [DKS0L8]1878
Failure Code [DKS1KA]1879
Failure Code [DKS1KB]1881
Failure Code [DKS2KA]1883
Failure Code [DKS2KB]1885
Failure Code [DKS3KA]1887
Failure Code [DKS3KB]1889
Failure Code [DKS3MB]1891
Failure Code [DKS4L8]1893
Failure Code [DKS5KA]1894
Failure Code [DKS5KB]1896
Failure Code [DKS6KA]1898
Failure Code [DKS6KB]1900
Failure Code [DKS7MB]1902
Failure Code [DKSCL8]1903
Failure Code [DKSDKA]1904
Failure Code [DKSDKB]1906
Failure Code [DKSEKA]1908
Failure Code [DKSEKB]1910
Failure Code [DKSFKA]1912
Failure Code [DKSFKB]1914
Failure Code [DKSFMB]1915
Failure Code [DLM0KX]1916
Failure Code [DLM0MA]1917
Failure Code [DLM1KA]1918
Failure Code [DLM1KB]1920
Failure Code [DLM1MA]1922
Failure Code [DLM2KA]1923
Failure Code [DLM2KB]1925
Failure Code [DLM2MA]1927
Failure Code [DLM3KA]1928
Failure Code [DLM3KB]1930
Failure Code [DLM3MB]1932
Failure Code [DN21FS]1933
Failure Code [DR21KX]1935
Failure Code [DR31KX]1936
Failure Code [DV20KB]1937
Failure Code [DW4BKA]1939
Failure Code [DW4BKB]1941
Failure Code [DW4BKY]1943
Failure Code [DW7BKA]1944
Failure Code [DW7BKB]1946
Failure Code [DW7EKA]1947
Failure Code [DW7EKB]1950
Failure Code [DW7EKY]1952
Failure Code [DWN5KA]1954
Failure Code [DWN5KB]1956
Failure Code [DWN5KY]1957
Failure Code [DXA4KA]1958
Failure Code [DXA4KB]1960
Failure Code [DXA4KY]1962
Failure Code [DXA5KA]1963
Failure Code [DXA5KB]1965
Failure Code [DXA5KY]1967
Failure Code [DXA6KA]1968
Failure Code [DXA6KB]1970
Failure Code [DXA6KY]1972
Failure Code [DXA7KA]1973
Failure Code [DXA7KB]1975
Failure Code [DXA7KY]1977
Failure Code [DXHRKA]1978
Failure Code [DXHRKB]1980
Failure Code [DXHRKY]1981
Failure Code [DXHSKA]1982
Failure Code [DXHSKB]1984
Failure Code [DXHSKY]1985
Failure Code [DXHTKA]1986
Failure Code [DXHTKB]1988
Failure Code [DXHTKY]1989
Failure Code [DXHUKA]1990
Failure Code [DXHUKB]1992
Failure Code [DXHUKY]1993
Failure Code [DXJ4KA]1994
Failure Code [DXJ4KB]1996
Failure Code [DXJCKA]1998
Failure Code [DXJCKB]2000
Failure Code [DXJCKY]2001
Failure Code [DXJDKA]2002
Failure Code [DXJDKB]2004
Failure Code [DXJDKY]2005
Failure Code [DXK1KA]2006
Failure Code [DXK1KB]2008
Failure Code [DXK1KY]2009
Failure Code [DXK2KA]2010
Failure Code [DXK2KB]2012
Failure Code [DXK2KY]2013
Failure Code [F311KA]2014
Failure Code [F311KB]2016
Failure Code [F312KA]2018
Failure Code [F312KB]2020
Failure Code [F313KA]2022
Failure Code [F313KB]2024
Failure Code [F314KA]2027
Failure Code [F314KB]2029
Failure Code [F315KB]2031
Failure Code [F315KY]2033
Failure Code [F316KB]2035
Failure Code [F316KY]2037
Failure Code [F318KB]2039
Failure Code [F318KY]2042
Failure Code [F31AKB]2044
Failure Code [F31AKY]2046
Failure Code [F31BKB]2048
Failure Code [F31BKY]2050
Failure Code [F31CKB]2052
Failure Code [F31CKY]2054
Failure Code [F31DKB]2056
Failure Code [F31DKY]2058
Failure Code [F31EKB]2060
Failure Code [F31EKY]2062
Failure Code [F7A0KQ]2064
Failure Code [F7A0KT]2065
Failure Code [F7A1KK]2066
Failure Code [F7ALKB]2069
Failure Code [F7AQKR]2071
Failure Code [F7ASKA]2072
Failure Code [FE0AKA]2074
Failure Code [FS10ZE]2076
Troubleshooting of Electrical System (E-Mode)2077
Engine Does Not Start (Engine Does Not Crank)2077
Manual Preheating System Does Not Operate2084
Automatic Preheating System Does Not Operate2087
While Preheating is in Operation, Preheating Monitor Does Not Come On2089
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing2091
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On2094
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation2095
Charge Level Monitor Comes On in Red While Engine is in Operation2096
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation2097
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation2098
HST Charge Pressure Monitor Comes On in Red While Engine Runs2099
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation2100
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs2101
Engine Coolant Temperature Gauge Does Not Show Correct Temperature2102
DEF Level is Not Shown Correctly2103
Fuel Gauge Does Not Show Normally2106
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature2109
Operation Mode Does Not Change2110
When You Operate Customize Switch Does Not Show Customize Screen2111
When You Change Setting on Customize Screen, Setting of Machine is Not Changed2112
Service Meter is Not Shown While Starting Switch is in OFF Position2113
Service Mode Cannot be Selected2114
Work Equipment Does Not Operate2115
Foot Heater Does Not Operate2117
Horn Does Not Sound2123
Horn Does Not Stop2125
Backup Alarm Does Not Sound2126
Backup Alarm Does Not Stop Operation2127
Headlamp Does Not Come On2128
Rear Lamp Does Not Come On2132
No Wiper Operates2135
Front Wiper Does Not Operate2137
Rear Wiper Does Not Operate2139
Left Door Wiper Does Not Operate2141
Right Door Wiper Does Not Operate2145
Front Washer Does Not Operate2149
Rear Washer Does Not Operate2151
Left Door Washer Does Not Operate2153
Right Door Washer Does Not Operate2155
KOMTRAX System Does Not Operate Correctly2157
Control Box Shows Message [Waiting for radio link]2158
Control Box Shows Message [Waiting for satellites]2160
Control Box Shows Message [GPS receiver not connected !] and [Komatsu Machine Trouble]2161
Control Box Shows Message [Komatsu Machine Trouble]2162
Control Box Shows Message [Waiting to initialize]2163
Control Box Shows Message [System initializing]2164
Control Box Shows Message [Initializing]2165
Control Box Shows Message [Connecting to GPS]2166
Elevation Control Key on Control Box Shows Message [Low precisions]2167
Control Box Shows Message [Heading Initializing]2168
Control Box Shows Message [Out of design area]2169
Control Box Shows Message [No GPS localization]2170
Control Box Shows Message [Loading Design Surface data]2171
Control Box Shows Message [Design Surface data invalid]2172
Control Box Shows Message [Starting switch is OFF]2173
Control Box Shows Message [Waiting for satellites] and [Komatsu Machine Trouble]2175
Control Box Can Not be Turned on2176
Control Box Does Not Display Intelligent Machine Control Screen2178
Control Box Does Not Display Bulldozer Image2179
Control Box Does Not Display Design Surface2180
Control Box Touch Panel Does Not Respond2181
Control Box Touch Panel is Inaccurate2182
Cylinder Stroke Reset Indication Does Not Go Out2183
AUTO or Strikethrough is Not Shown When AUTO/Manual Switch is Pushed (AUTO or Strikethrough Goes Out)2184
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine2186
Blade Automatic Lower Control Does Not Start While AUTO is Shown2187
Blade Automatic Raise Control Does Not Start While AUTO is Shown2188
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops)2189
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface)2190
Finished Surface is Inaccurate (The Finished Surface is Not Smooth)2191
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction)2192
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips)2194
Machine Speed Does Not Increase While Blade Automatic Control is Activated2195
Blade Tilt Angle Does Not Respond with Design Surface While Blade Automatic Control is Activated2196
Blade Tilts While Blade Automatic Control is Activated2198
Even After Lift Layer Control is Activated, Measured Lift Layer Terrain Shape Does Not Agree with Actual Terrain2200
The Surface Made with Quick Surface Creation Function is Different from the One in Machine Front Direction, Blade Edge Position2202
Machine Does Not Travel Straight While Tilt Steering Control is Activated2203
Control Box Continues to Show Progress Bar in Machine Manual Cal Screen2204
Engine Hunting Occurs When You Lower the Blade While Ground Line Assist is Activated2205
[Laser Receiver Error (Red)] Icon is Shown on Control Box (2D Laser Machine Control)2206
[System Error (Red)] Icon is Shown on Control Box (2D Laser Machine Control)2210
[AUTO (Green)] is Not Shown on Control Box (2D Laser Machine Control)2211
Finished Surface is Inaccurate (2D Laser Machine Control)2212
Ground Surface Becomes Rough in Leveling Work (2D Laser Machine Control)2213
Current Slope Value on Control Box is Different from Actual Value (2D Laser Machine Control)2214
Automatic Control Cannot be Done If You Change Application (2D Laser Machine Control)2215
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2216
Information Shown in Troubleshooting Table (H-Mode)2216
Failure Mode and Cause Table2217
RH and LH Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate)2223
RH or LH Track Cannot Travel FORWARD and REVERSE (One of RH or LH Travel Systems Cannot Operate)2225
RH or LH Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction)2227
Travel Speed or Power is Low2229
Speed Range Does Not Change2231
Shock is Large When Machine Moves Off or Stops2232
Travel Deviation is Large2233
Machine Drift on a Slope is Large2236
Engine Speed Drops Largely or Engine Stops2238
Unusual Noise is Heard from Around HST Pump or Motor2240
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High2242
All Work Equipment Do Not Operate2244
All Work Equipment Speed or Power is Low2246
Blade Lift Speed or Power is Low2247
Blade Tilt Speed or Power is Low2249
Blade Angle Speed or Power is Low2250
Time Lag of Blade Lift is Large2251
Hydraulic Drift of Blade Lift is Large2252
Hydraulic Drift of Tilted Blade is Large2253
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve2254
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2255
Unusual Noise is Heard from Around Fan2257
Troubleshooting of Engine (S-Mode)2258
Information Shown in Troubleshooting Table (S-Mode)2258
Engine Does Not Crank When Starting Switch is Turned to Start Position2259
Engine Cranks but No Exhaust Smoke Comes Out2260
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2261
Engine Startability is Unsatisfactory2262
Engine Does Not Pick Up Smoothly2264
Engine Stops During Operation2266
Engine Does Not Rotate Smoothly2268
Engine Lacks Output (or Lacks Power)2269
Exhaust Smoke is Black2271
Engine Oil Consumption is Excessive2273
Engine Oil Becomes Dirty Quickly2274
Fuel Consumption is Excessive2275
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2276
Engine Oil Pressure Drops2277
Fuel Mixes Into Engine Oil2278
Water Mixes Into Engine Oil (Milky)2279
Coolant Temperature Increases Too High (Overheat)2280
Unusual Noise is Heard2281
Vibration is Excessive2283
Air Cannot be Bled from Fuel Circuit2284
Active Regeneration is Done Frequently2285
Active Regeneration Continues Long2286
White Smoke is Exhausted During Active Regeneration2287
DEF Consumption is Excessive2288
There is an Unusual Smell (Irritating Odor)2290
Foreign Materials Enter DEF (DEF Increases)2291
50 Disassembly and Assembly2293
Table of Contents2294
Precautions Before Work2299
Related Information on Disassembly and Assembly2300
How to Read This Manual2300
Coating Materials List2301
Special Tool List2306
Sketches of Special Tools2324
Engine and Cooling System2340
Remove and Install Supply Pump Assembly2340
How to Remove Supply Pump Assembly2340
How to Install Supply Pump Assembly2344
Remove and Install Injector Assembly2348
How to Remove Injector Assembly2348
How to Install Injector Assembly2351
Remove and Install Cylinder Head Assembly2357
How to Remove Cylinder Head Assembly2357
How to Install Cylinder Head Assembly2371
Remove and Install EGR Valve Assembly2392
How to Remove EGR Valve Assembly2392
How to Install EGR Valve Assembly2393
Remove and Install EGR Cooler Assembly2395
How to Remove EGR Cooler Assembly2395
How to Install EGR Cooler Assembly2397
Remove and Install Starter Assembly2400
How to Remove Starting Motor Assembly2400
How to Install Starting Motor Assembly2401
Remove and Install Alternator Belt2403
How to Remove Alternator Belt2403
How to Install Alternator Belt2404
Remove and Install Automatic Tensioner2406
How to Remove Automatic Tensioner2406
How to Install Automatic Tensioner2406
Remove and Install Radiator Assembly2407
How to Remove Radiator Assembly2407
How to Install Radiator Assembly2410
Remove and Install Hydraulic Oil Cooler Assembly2414
How to Remove Hydraulic Oil Cooler Assembly2414
How to Install Hydraulic Oil Cooler Assembly2416
Remove and Install Aftercooler Assembly2420
How to Remove Aftercooler Assembly2420
How to Install Aftercooler Assembly2422
Remove and Install Cooling Fan Drive Assembly2426
How to Remove Cooling Fan Drive Assembly2426
How to Install Cooling Fan Drive Assembly2428
Remove and Install Cooling Fan Motor Assembly2430
How to Remove Cooling Fan Motor Assembly2430
How to Install Cooling Fan Motor Assembly2431
Remove and Install Engine and HST Pump Assembly2433
How to Remove Engine and HST Pump Assembly2433
How to Install Engine and HST Pump Assembly2439
Remove and Install Engine Front Oil Seal2447
How to Remove Engine Front Oil Seal2447
How to Install Engine Front Oil Seal2448
Remove and Install Engine Rear Oil Seal2450
How to Remove Engine Rear Oil Seal2450
How to Install Engine Rear Oil Seal2451
Remove and Install Engine Hood Assembly2454
How to Remove Engine Hood Assembly2454
How to Install Engine Hood Assembly2456
Remove and Install KDOC Assembly2460
How to Remove KDOC Assembly2460
How to Install KDOC Assembly2464
Remove and Install KDOC and SCR Assembly2471
How to Remove KDOC and SCR Assembly2472
How to Install KDOC and SCR Assembly2481
Remove and Install Bellows Pipe Assembly2491
How to Remove Bellows Pipe Assembly2491
How to Install Bellows Pipe Assembly2493
Remove and Install Fuel Tank Assembly2498
How to Remove Fuel Tank Assembly2498
How to Install Fuel Tank Assembly2501
Remove and Install DEF Tank Assembly2505
How to Remove DEF Tank Assembly2505
How to Install DEF Tank Assembly2511
Remove and Install DEF Tank Sensor Flange Assembly2517
How to Remove DEF Tank Sensor Flange Assembly2517
How to Install DEF Tank Sensor Flange Assembly2518
Remove and Install DEF Tank Sensor2522
How to Remove DEF Tank Sensor2522
How to Install DEF Tank Sensor2523
Remove and Install DEF Tank Strainer2530
How to Remove DEF Tank Strainer2530
How to Install DEF Tank Strainer2531
Remove and Install SCR Assembly2532
How to Remove SCR Assembly2532
How to Install SCR Assembly2536
Remove and Install KCCV Assembly2540
How to Remove KCCV Assembly2540
How to Install KCCV Assembly2541
Remove and Install Turbo Charger Assembly2542
How to Remove Turbo Charger Assembly2542
How to Install Turbo Charger Assembly2546
Remove and Install Exhaust Throttle Valve2552
How to Remove Exhaust Throttle Valve2552
How to Install Exhaust Throttle Valve2556
Remove and Install DEF Mixing Tube2562
How to Remove DEF Mixing Tube2563
How to Install DEF Mixing Tube2567
Remove and Install DEF Injector2575
How to Remove DEF Injector2575
How to Install DEF Injector2578
Remove and Install DEF Pump2582
How to Remove DEF Pump2582
How to Install DEF Pump2585
Remove and Install DEF Hose2588
How to Remove DEF Hose2588
How to Install DEF Hose2596
Remove and Install Air Cleaner Assembly2607
How to Remove Air Cleaner Assembly2607
How to Install Air Cleaner Assembly2608
Remove and Install Air Conditioner Compressor Assembly2610
How to Remove Air Conditioner Compressor Assembly2610
How to Install Air Conditioner Compressor Assembly2611
Power Train2613
Remove and Install Damper Assembly2613
How to Remove Damper Assembly2613
How to Install Damper Assembly2614
Remove and Install HST Pump Assembly2615
How to Remove HST Pump Assembly2615
How to Install HST Pump Assembly2618
Remove and Install HST Motor and Final Drive Assembly2621
How to Remove HST Motor and Final Drive Assembly2621
How to Install HST Motor and Final Drive Assembly2623
Disassemble and Assemble Final Drive Assembly2625
How to Disassemble Final Drive Assembly2625
How to Assemble Final Drive Assembly2631
Undercarriage and Frame2640
Remove and Install Idler and Recoil Spring Assembly2640
How to Remove Idler and Recoil Spring Assembly2640
How to Install Idler and Recoil Spring Assembly2640
Disassemble and Assemble Idler Assembly2642
How to Disassemble Idler Assembly2642
How to Assemble Idler Assembly2644
Disassemble and Assemble Recoil Spring Assembly2648
How to Disassemble Recoil Spring Assembly2649
How to Assemble Recoil Spring Assembly2650
Disassemble and Assemble Track Roller Assembly2652
How to Disassemble Track Roller Assembly2652
How to Assemble Track Roller Assembly2654
Disassemble and Assemble Carrier Roller Assembly2658
How to Disassemble Carrier Roller Assembly2658
How to Assemble Carrier Roller Assembly2659
Separate and Connect Track Assembly2662
How to Separate Track Assembly (Standard)2662
How to Install Track Assembly2663
Separate and Connect PLUS Type Track Assembly2666
Separate PLUS Type Track Assembly Generally2666
Install PLUS Type Track Assembly2666
Disassemble and Assemble Track Assembly Generally2668
How to Disassemble Full Track Shoes Assembly2669
How to Assemble Full Track Shoes Assembly2671
Disassemble and Assemble PLUS Type Track Assembly Generally2684
Disassemble PLUS Type Track Assembly Generally2685
How to Assemble PLUS Type Track Shoes Assembly Generally2686
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)2701
How to Disassemble One Track Link Assembly in Field (Track Assembly)2703
How to Assemble One Track Link Assembly in Field (Track Assembly)2704
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2712
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)2713
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2715
Hydraulic System2719
Remove and Install Hydraulic Tank Assembly2719
How to Remove Hydraulic Tank Assembly2719
How to Install Hydraulic Tank Assembly2724
Remove and Install Control Valve Assembly2729
How to Remove Control Valve Assembly2729
How to Install Control Valve Assembly2731
Work Equipment2734
Remove and Install Blade Assembly (Power Angle Power Tilt Dozer)2734
How to Remove Blade Assembly (Power Angle Power Tilt Dozer)2734
How to Install Blade Assembly2736
Remove and Install Work Equipment Assembly2739
How to Remove Work Equipment Assembly2739
How to Install Work Equipment Assembly2741
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly2744
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly2744
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly2745
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2748
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2748
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly2752
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly2761
How to Remove Stroke Sensing Blade Tilt Cylinder Assembly2761
How to Install Stroke Sensing Blade Tilt Cylinder Assembly2764
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly2768
How to Disassemble Stroke Sensing Blade Tilt Cylinder Assembly2768
How to Assemble Stroke Sensing Blade Tilt Cylinder Assembly2772
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly2777
How to Remove Stroke Sensing Blade Angle Cylinder Assembly2777
How to Install Stroke Sensing Blade Angle Cylinder Assembly2779
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly2783
How to Disassemble Stroke Sensing Blade Angle Cylinder Assembly2783
How to Assemble Stroke Sensing Blade Angle Cylinder Assembly2787
Remove and Install U-Frame Assembly2793
How to Remove U-Frame Assembly2793
How to Install U-Frame Assembly2795
CAB Related Parts2798
Remove and Install Operator Cab Assembly2798
How to Remove Operator Cab Assembly2798
How to Install Operator Cab Assembly2805
Remove and Install Wiper Arm2814
How to Remove Wiper Arm2814
How to Install Wiper Arm2815
Remove and Install Operator Cab Glass (Adhered Glass)2817
How to Remove Operator Cab Glass (Adhered Glass)2819
How to Install Operator Cab Glass (Adhered Glass)2819
Remove and Install Air Conditioner Unit Assembly2825
How to Remove Air Conditioner Unit Assembly2825
How to Install Air Conditioner Unit Assembly2831
Remove and Install Operator Seat2839
How to Remove Operator Seat2839
How to Install Operator Seat2840
How to Remove and Install Seat Belt2841
How to Remove Seat Belt2841
How to Install Seatbelt2841
Remove and Install Foot Heater Assembly2843
How to Remove Foot Heater Assembly2843
How to Install Foot Heater Assembly2845
Disassemble and Assemble Foot Heater Assembly2847
How to Disassemble Foot Heater Assembly2847
How to Assemble Foot Heater Assembly2848
Electrical System2849
Remove and Install Engine Controller Assembly2849
How to Remove Engine Controller Assembly2849
How to Install Engine Controller Assembly2852
Remove and Install HST Controller Assembly2855
How to Remove HST Controller Assembly2855
How to Install HST Controller Assembly2856
Remove and Install Machine Monitor Assembly2857
How to Remove Machine Monitor Assembly2857
How to Install Machine Monitor Assembly2858
Remove and Install Mass Air Flow and Temperature Sensor2860
How to Remove Mass Air Flow and Temperature Sensor2860
How to Install Mass Air Flow and Temperature Sensor2862
Remove and Install KCCV Crankcase Pressure Sensor2863
How to Remove KCCV Crankcase Pressure Sensor2863
How to Install KCCV Crankcase Pressure Sensor2864
Remove and Install SCR Temperature Sensor2866
How to Remove SCR Temperature Sensor2866
How to Install SCR Temperature Sensor2868
Remove and Install Gateway Function Controller Assembly2871
How to Remove Gateway Function Controller Assembly2871
How to Install Gateway Function Controller Assembly2872
Remove and Install Communication Antenna2873
How to Remove Communication Antenna2874
How to Install Communication Antenna2876
Remove and Install Navigation Controller2879
How to Remove Navigation Controller2880
How to Install Navigation Controller2884
Remove and Install ICT Sensor Controller Assembly2889
How to Remove ICT Sensor Controller Assembly2889
How to Install ICT Sensor Controller Assembly2889
Remove and Install Control Box2891
How to Remove Control Box2891
How to Install Control Box2892
Remove and Install GNSS Receiver2893
How to Remove GNSS Receiver2894
How to Install GNSS Receiver2894
Remove and Install GNSS Antenna2896
How to Remove GNSS Antenna2897
How to Install GNSS Antenna2901
Remove and Install GNSS External Radio Device2906
How to Remove GNSS External Radio Device2906
How to Install GNSS External Radio Device2908
Remove and Install IMU Sensor2910
How to Remove IMU Sensor2910
How to Install IMU Sensor2912
Remove and Install Communication Terminal2914
How to Remove Communication Terminal2914
How to Install Communication Terminal2917
60 Maintenance Standard2921
Table of Contents2922
Engine and Cooling System2923
Maintenance Standard for Engine Mount2923
Maintenance Standard for Damper2924
Maintenance Standard for Cooling System2925
Maintenance Standard for Cooling Fan Motor2927
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve2929
Power Train2930
Maintenance Standard for HST Pump2930
Maintenance Standard for EPC Valve of HST Pump2931
Maintenance Standard for Tow Receiving Valve of HST Pump2932
Maintenance Standard for HST Charge Pump2933
Maintenance Standard for HST Motor2935
Maintenance Standard for Final Drive2936
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D37EXI-24, D37PXI-242938
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D39EXI-24, D39PXI-242940
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D37EXI-24, D37PXI-242942
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D39EXI-24, D39PXI-242943
Undercarriage and Frame2944
Maintenance Standard for Track Frame and Idler Cushion2944
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D37EXI-24, D37PXI-242949
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D39EXI-24, D39PXI-242951
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)2953
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)2955
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes2957
Maintenance Standard for PLUS Type Track Shoes2959
Maintenance Standard for Single Shoes2963
Hydraulic System2964
Maintenance Standard for Hydraulic Tank2964
Maintenance Standard for Work Equipment and Cooling Fan Pump2965
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump2966
Maintenance Standard for Control Valve2968
Maintenance Standard for Ripper PPC Valve2975
Maintenance Standard for 5-Spool EPC and Solenoid Valve2977
Maintenance Standard for EPC Valve2978
Maintenance Standard for Angle Control EPC Valve2979
Work Equipment2980
Maintenance Standard for Front Work Equipment2980
Maintenance Standard for Cutting Edge and End Bit2983
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder2984
Maintenance Standard for Stroke Sensing Blade Tilt Cylinder2985
Maintenance Standard for Stroke Sensing Blade Angle Cylinder2986
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder2987
Maintenance Standard for Stroke Sensor for Blade Tilt Cylinder2988
Maintenance Standard for Stroke Sensor for Blade Angle Cylinder2989
Maintenance Standard for Fixed Multi-Shank Ripper2990
Maintenance Standard for Ripper Lift Cylinder2992
CAB Related Parts2993
Maintenance Standard for CAB Mount2993
Electrical System2994
Maintenance Standard for Steering Electric Lever2994
80 Appendix2995
Table of Contents2996
Precautions Before Work2997
Air Conditioner System2998
Precautions for Refrigerant2998
Air Conditioner Component2999
Specifications of Air Conditioner3002
Structure and Function of Refrigeration Cycle3003
Outline of Refrigeration Cycle3004
Component Parts of Air Conditioner System3006
Air Conditioner Unit3006
Configuration Diagram of Air Conditioner Unit3006
Function of Air Conditioner Unit3007
Component Parts of Air Conditioner Unit3008
Function of Evaporator as Air Conditioner Unit Component3008
Function of Heater Core as Air Conditioner Unit Component3008
Function of Thermostat as Air Conditioner Unit Component3008
Structure of Expansion Valve as Air Conditioner Unit Component3009
Function of Expansion Valve as Air Conditioner Unit Component3009
Operate Expansion Valve as Air Conditioner Unit Component3009
Function of Dual Pressure Switch3010
Function of Pressure Switch3010
Compressor3011
Structure of Compressor3011
Specifications of Compressor3011
Function of Compressor3011
Condenser3012
Structure of Condenser3012
Specifications of Condenser3012
Function of Condenser3013
Receiver Drier3014
Structure of Receiver Dryer3014
Specifications of Receiver Dryer3014
Function of Receiver Dryer3014
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner3016
Circuit Diagram of Air Conditioner3019
System Diagram of Air Conditioner3020
Control Function of Air Conditioner3021
Locations of Air Conditioner Parts and Layout of Connectors3022
Examine Relay3026
How to Examine Relay3026
Air Conditioner Troubleshooting Chart 13028
Air Conditioner Troubleshooting Chart 23029
Information Shown in Troubleshooting Table3032
Troubleshooting for Condenser Fan3033
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)3036
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)3040
Troubleshooting for Temperature Control Function3043
Troubleshooting by Gauge Pressure3047
Connect Service Tool3049
How to Connect Service Tool3049
Precautions for Disconnection and Connection of Air Conditioner Piping3050
Handle Compressor Oil3052
90 Circuit Diagrams3055
Table of Contents3056
Hydraulic Circuit Diagram3057
Symbols Used in Hydraulic Circuit Diagram3057
Hydraulic Circuit Diagram3061
Electrical Circuit Diagram3063
Symbols Used in Electric Circuit Diagram3063
Electrical Circuit Diagram (1/13)3067
Electrical Circuit Diagram (2/13)3069
Electrical Circuit Diagram (3/13)3071
Electrical Circuit Diagram (4/13)3073
Electrical Circuit Diagram (5/13)3075
Electrical Circuit Diagram (6/13)3077
Electrical Circuit Diagram (7/13)3079
Electrical Circuit Diagram (8/13)3081
Electrical Circuit Diagram (9/13)3083
Electrical Circuit Diagram (10/13)3085
Electrical Circuit Diagram (11/13)3087
Electrical Circuit Diagram (12/13)3089
Electrical Circuit Diagram (13/13)3091
Electrical Circuit Diagram (2D Laser Machine Control)3093
Index3095

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24