Komatsu BULLDOZER D51EX -24 D51PX-24 Shop Manual SEN06830-08 PDF
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Komatsu BULLDOZER D51EX -24 D51PX-24 Shop Manual SEN06830-08- PDF DOWNLOAD
SERIAL NUMBERS D51EX-15001
D51PX-15001 and up
Description
Komatsu BULLDOZER D51EX -24 D51PX-24 Shop Manual SEN06830-08- PDF DOWNLOAD
FILE DETAILS:
Komatsu BULLDOZER D51EX -24 D51PX-24 Shop Manual SEN06830-08- PDF DOWNLOAD
Language : English
Pages :2780
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu BULLDOZER D51EX -24 D51PX-24 Shop Manual SEN06830-08- PDF DOWNLOAD
SERIAL NUMBERS D51EX-15001
D51PX-15001 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 D51EX -24 D51PX-24 Shop Manual SEN06830-08- PDF DOWNLOAD
SERIAL NUMBERS D51EX-15001
D51PX-15001 and up
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 20
How to Read the Shop Manual 20
Safety Notice for Operation 22
Precautions to Prevent Fire 30
Procedures If Fire Occurs 32
Precautions for Disposing of Waste Materials 33
Procedures for Exhaust Gas Regulations 34
Precautions for DEF 35
General Character and Precautions for Handling 35
Precautions for Adding 35
Precautions for Storage 35
Precautions for Fire Hazard and Leakage 35
Other Precautions 35
Store DEF 36
Precautions When You Handle Hydraulic Equipment 37
Precautions When You Disconnect and Connect Pipings 40
Precautions When You Handle Electrical Equipment 47
Precautions When You Handle Fuel System Equipment 49
Precautions When You Handle Intake System Equipment 50
Practical Use of KOMTRAX 51
Disconnect and Connect Push-Pull Type Coupler 52
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 52
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 53
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 54
Precautions for Disconnection and Connection of Connectors 56
How to Disconnect and Connect Deutsch Connector 60
How to Disconnect and Connect Slide Lock Type Connector 61
How to Disconnect and Connect Connector with Lock to Pull 63
How to Disconnect and Connect Connector with Lock to Push 64
How to Disconnect and Connect Connector with Housing to Rotate 66
How to Read the Codes for Electric Cable 67
Explanation of Terms for Maintenance Standard 71
Standard Tightening Torque Table 74
Conversion Table 81
Abbreviation List 86
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: D51EX-24 91
Specification Drawing: D51PX-24 93
Specifications 95
Specification: D51EX-24 95
Specification: D51PX-24 100
Weight Table 105
Weight Table: D51EX-24 105
Weight Table: D51PX-24 107
Fuel, Coolant, Lubricant 109
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 109
10 Structure and Function 111
Table of Contents 112
Urea SCR System 115
Layout Drawing of Urea SCR System 115
Urea SCR System Diagram 117
Function of Urea SCR System 118
Function of DEF System 118
Inducement Strategy 121
Component Parts of Urea SCR System 135
DEF Mixing Tube 135
SCR Assembly 136
DEF Tank 138
DEF Pump 140
DEF Injector 141
DEF Hose 142
DEF Tank Heating Valve 143
Boot-up System 144
Layout Drawing of Boot-up System 144
System Operating Lamp System 145
System Diagram of System Operating Lamp System 145
Function of Operation Lamp System 145
Battery Disconnect Switch 147
Function of Battery Disconnect Switch 147
Engine System 148
Layout Drawing of Engine System 148
Engine Control System 150
Layout Drawing of Engine Control System 150
System Diagram of Engine Control 152
Function of Engine Control System 154
Automatic Idle Stop System 156
System Diagram of Automatic Idle Stop System 156
Function of Automatic Idle Stop System 156
Component Parts of Engine System 159
Damper 159
VGT 161
EGR System 164
EGR Valve 166
EGR Cooler 168
KCCV System 170
KCCV Ventilator 172
KDOC 174
Cooling System 177
Layout Drawing of Cooling System 177
Specifications of Cooling System 178
Cooling Fan Control System 179
System Diagram of Cooling Fan Control System 179
Function of Cooling Fan Control System 180
Component Parts of Cooling System 182
Cooling Fan Motor 182
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 187
Hydraulic Oil Cooler Bypass Valve 188
HST Charge Safety Valve 189
Control System 191
Layout Drawing of Control System 191
Machine Monitor System 192
System Diagram of Machine Monitor System 192
Function of Machine Monitor System 192
KOMTRAX System 193
System Diagram of KOMTRAX System 193
Function of KOMTRAX System 193
Component Parts of Control System 194
Machine Monitor 194
Gateway Function Controller 211
Communication Terminal 214
HST Controller 216
Engine Controller 220
Fuel Control Dial 227
Decelerator and Brake Potentiometer 229
Hydraulic System 231
Layout Drawing of Hydraulic System 231
CLSS 232
Structure of CLSS 232
Function of CLSS 233
Component Parts of Hydraulic System 235
Hydraulic Tank 235
Work Equipment and Cooling Fan Pump 237
LS Valve 245
PC Valve 246
Control Valve 249
Power Train System 267
Layout Drawing of HST System 267
Operation of HST System 268
Steering and Brake Control System 270
Layout Drawing of Steering and Brake Control System 270
Function of Steering and Brake Control System 270
HST Control System 272
System Diagram of HST Control System 272
Gear Shift Control Function 273
Engine Low Speed Matching Control Function 276
HST Pump and Motor Sequence Control Function 277
Deceleration and Brake Control Function 278
Gear Shift Control Function by Load 280
Turn Control Function 280
Straight Travel Correction Control Function 281
Parking Brake Control System 283
System Diagram of Parking Brake Control System 283
Function of Parking Brake Control System 284
Operation of Parking Brake Control System 285
Component Parts of Power Train System 286
HST Pump 286
HST Charge Pump 301
HST Motor 302
Final Drive 315
Electric Steering Electric Lever 319
Work Equipment System 322
Work Equipment Control 322
Layout Drawing of Work Equipment Control 322
Function of Work Equipment Control 323
Layout Drawing of Front Work Equipment 324
Layout Drawing of Fixed Multi-Shank Ripper 325
Component Parts of Work Equipment System 326
Ripper PPC Valve 326
5-Spool EPC and Solenoid Valve 330
Pilot Circuit Accumulator 336
Quick Drop Valve 337
Piston Valve 339
Electric Blade Control Lever 340
Undercarriage and Frame 342
Main Frame 342
Structure of Main Frame 342
Suspension 343
Structure of Suspension 343
Specifications of Suspension 344
Function of Suspension 345
Track Frame and Idler Cushion 346
Structure of Track Frame and Idler Cushion 346
Function of Track Frame and Idler Cushion 347
Work Equipment 348
Structure of Front Work Equipment (Serial No: 15001 to 15600) 348
Structure of Front Work Equipment (Serial No: 15601 and up) 349
Structure of Fixed Multi-Shank Ripper 350
CAB Related Parts 351
ROPS CAB 351
Structure of ROPS CAB 351
Function of ROPS CAB 352
CAB Mount 353
Structure of CAB Mount 353
Function of CAB Mount 353
20 Standard Value Table 355
Table of Contents 356
Standard Value Table for Engine 357
Standard Value Table for Engine: D51EX-24 357
Standard Value Table for Engine: D51PX-24 361
Standard Value Table for Machine 365
Standard Value Table for Machine: D51EX-24 365
Standard Value Table for Machine: D51PX-24 381
Machine Posture and Procedures to Measure Performance 395
30 Testing and Adjusting 397
Table of Contents 398
Precautions Before Work 401
Related Information on Testing and Adjusting 402
Differences In Machine Monitor Symbols 402
Tools for Testing and Adjusting 403
Sketch of Tools for Testing and Adjusting 410
Engine and Cooling System 413
Examine Engine Speed 413
How to Examine Engine Speed 413
Examine Boost Pressure 415
How to Examine Boost Pressure 415
Examine Exhaust Gas Color 416
How to Examine Exhaust Gas Color with the Handy Smoke Checker 416
How to Examine Exhaust Gas Color with Smoke Meter 417
Examine and Adjust Valve Clearance 418
How to Examine Valve Clearance 418
How to Adjust Valve Clearance 419
Examine Compression Pressure 420
How to Examine Compression Pressure 420
Examine Blowby Pressure 425
How to Examine Blowby Pressure 425
Examine Engine Oil Pressure 427
How to Examine Engine Oil Pressure 427
Visual Check Inside of EGR Valve 428
How to do the Visual Check Inside of EGR Valve 428
Clean Inside of EGR Valve 430
How to Clean Inside of EGR Valve 430
Examine Fuel Pressure 433
How to Examine Fuel Pressure 434
Examine Fuel Discharge, Return and Leakage 438
How to Examine Fuel Discharge, Return, and Leakage 439
Bleed Air from Fuel System 444
How to Bleed Air from Fuel System 444
Examine Fuel Circuit for Leakage 445
How to Examine Fuel System for Leakage 445
Handle Cylinder Cut-out Mode Operation 447
Handle No-Injection Cranking Operation 448
Examine and Adjust Air Conditioner Compressor Belt Tension 449
Examine and Adjust Air Conditioner Compressor Belt Tension 449
How to Adjust Air Conditioner Compressor Belt Tension 450
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 451
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage 451
Examine Installed Condition of Cylinder Heads and Manifolds 452
How to Examine Installed Condition of Cylinder Heads and Manifolds 452
Examine Engine Piping for Damage and Looseness 453
How to Examine Engine Piping for Damage and Looseness 453
Write Correction for Ash in Soot Accumulation to Engine Controller 454
How to Write Correction for Ash in Soot Accumulation to Engine Controller 455
Examine SCR Related Functions 456
Examine DEF Pump Raised Pressure 460
Examine Injection Volume from DEF Injector 463
Examine DEF Line Heater Relay 1 467
Examine DEF Line Heater Relay 2 470
Examine DEF Pump Heater Relay 473
Examine DEF Tank Heater Valve 477
Examine SCR Denitration Efficiency 481
Clean DEF Tank 484
How to Clean DEF Tank 484
Clean DEF Pump 488
How to Clean DEF Pump 488
Clean DEF Tank Mounting Part 494
How to Clean DEF Tank Mounting Part 494
Power Train 495
Examine and Adjust HST Oil Pressure 495
How to Examine HST Oil Pressure 495
How to Adjust HST Oil Pressure 497
Bleed Air from HST Pump 500
How to Bleed Air from HST Pump 500
How to Bleed Air from Servo Valve of HST Pump 500
Examine Outlet Pressure of Solenoid Valve 502
How to Examine Outlet Pressure of Solenoid Valve 502
Examine Travel Deviation 506
How to Examine Travel Deviation 506
Examine Brake Performance Simply 508
How to Examine Brake Performance Simply 508
Examine and Adjust Deceleration/Brake Pedal 509
How to Examine Deceleration/Brake Pedal 509
How to Adjust Deceleration/Brake Pedal 511
Adjust Parking Brake Lever 513
How to Adjust Parking Brake Lever 513
Move Machine When It Cannot Travel 515
How to Move Machine with Hydraulic Type Parking Brake Release System 515
How to Move Machine After You Remove Final Drive Shaft 517
Undercarriage and Frame 518
Examine and Adjust Idler Clearance 518
How to Adjust Idler Clearance Horizontally 518
How to Adjust Idler Clearance Vertically 518
Examine Sprocket Wear 520
How to Examine Sprocket Wear 520
Examine and Adjust Track Tension 521
How to Examine Track Tension 521
How to Adjust Track Tension 521
Hydraulic System 523
Release Remained Pressure in Hydraulic Circuit 523
How to Release Remained Pressure in Hydraulic System 523
Examine and Adjust Work Equipment Circuit Oil Pressure 524
How to Examine Work Equipment Circuit Oil Pressure 524
How to Adjust Work Equipment Circuit Oil Pressure 525
Examine and Adjust Oil Pressure in Control Circuit 527
How to Examine Oil Pressure in Control Circuit 527
How to Adjust Oil Pressure in Control Circuit 528
Examine Outlet Pressure of EPC Solenoid Valve 529
How to Examine Outlet Pressure of EPC Solenoid Valve 529
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 531
How to Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 531
Examine Cooling Fan Speed 532
How to Examine Cooling Fan Speed 532
Examine Cooling Fan Circuit Oil Pressure 533
How to Examine Cooling Fan Circuit Oil Pressure 533
Examine Parts Which Cause Hydraulic Drift of Work Equipment 535
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 535
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 535
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 536
Examine Oil Leakage from Work Equipment Cylinder 537
How to Examine Internal Oil Leakage of Work Equipment Cylinder 537
Bleed Air from Work Equipment Cylinders 540
How to Bleed Air from Work Equipment Cylinder 540
Work Equipment 541
Adjust Work Equipment Lock Lever 541
How to Adjust Work Equipment Lock Lever 541
Examine and Adjust Play of Blade Electric Lever 543
How to Examine Play of Blade Electric Lever 545
How to Adjust Play of Blade Electric Lever 545
How to Replace Universal Joint 547
Electrical System 553
Set and Operate Machine Monitor 553
Operator Mode 557
Function to Show Technician Identification Status Screen 557
Function to Show Operator Identification Input Screen 557
Examine Function by LCD (Liquid Crystal Display) 558
Examine Function of Service Meter 558
How to Set Usage Limitation and Change Maintenance Password 558
Service Mode 561
How to Operate Service Mode 561
How to See Pre-defined Monitoring Information 562
How to Examine Self-Define Monitor Information 569
Abnormality Record Menu 579
How to See Maintenance Record 583
Maintenance Mode Setting 584
How to Set Phone Number Entry 588
Default Menu 590
Diagnostic Tests Menu 598
Adjustment Menu 605
No-Injection Cranking Operation 662
KOMTRAX Settings Menu 664
How to Show Service Message 666
How to Start Up KOMTRAX System 668
How to Stop Use of KOMTRAX System 674
Adjust After Replacement of HST Controller 676
How to Adjust After Replacement of HST Controller 676
Adjust After Replacement of Electric and Hydraulic Equipment 682
Adjust Rearview Camera Angle 684
How to Adjust Rearview Camera Angle 684
Set Region of Bluetooth(R) Compatible Radio 685
How to Set Region of Bluetooth(R) Compatible Radio 685
Handle Voltage Circuit of Engine Controller 687
Handle Battery Disconnect Switch 688
Examine Diodes 689
How to Examine Diodes by Digital Tester 689
How to Examine Diodes by Analog Tester 689
Pm Clinic 690
Pm Clinic Service 690
Pm Clinic Check Sheet: D51EX-24 692
Pm Clinic Check Sheet: D51PX-24 700
Pm Clinic Check Sheet for Undercarriage: D51EX-24 707
Pm Clinic Check Sheet for Undercarriage: D51PX-24 711
40 Troubleshooting 715
Table of Contents 716
Precautions Before Work 726
Related Information to Troubleshooting 727
General Troubleshooting Points 727
Troubleshooting Points for Urea SCR System 728
Sequence of Events in Troubleshooting 740
Checks Before Troubleshooting 742
Inspection Procedure Before Troubleshooting 744
Walk-Around Check 744
Test in Accordance with Testing Procedure 746
Examine Fuel Level and Type 746
Examine for Impure Ingredient in Fuel 746
Examine DEF Level and Type 747
Examine Fuel Prefilter 747
Examine Fuel Main Filter 749
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 750
Examine Coolant Level (Reservoir Tank) 752
Examine Air Cleaner Clogging 752
Clean Outer Element 753
Replace Element 755
Examine Hydraulic Oil Level 756
Examine Hydraulic Oil Strainer 757
Examine Oil Level in Final Drive Case 760
Bleed Air from Fuel System 761
Bleed Air from Hydraulic System 761
How to Examine Electric Equipment 761
Preparation for Troubleshooting of Electrical System 768
Procedure for Troubleshooting 775
Symptom and Troubleshooting Numbers 778
Information Shown in Troubleshooting Table 781
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 783
Connector List and Layout 786
Connector Contact Connection Table 804
T-Branch Box and T-Branch Adapter Table 844
Fuse Location Table 850
Precautions When You Replace KDOC 854
Failure Code Table 855
Troubleshooting by Failure Code (Display of Code) 874
Failure Code [6091NX] 874
Failure Code [989L00] 876
Failure Code [989M00] 877
Failure Code [989N00] 878
Failure Code [A1U0N3] 879
Failure Code [A1U0N4] 881
Failure Code [A900FR] 883
Failure Code [A900N6] 884
Failure Code [A900NY] 885
Failure Code [AA10NX] 886
Failure Code [AB00KE] 888
Failure Code [AQ10MB] 890
Failure Code [AQ10N3] 892
Failure Code [AS00R2] 894
Failure Code [AS00R3] 895
Failure Code [AS00R4] 896
Failure Code [AS00R5] 897
Failure Code [AS00R6] 898
Failure Code [AS00ZK] 899
Failure Code [AS10KM] 900
Failure Code [AS10NR] 901
Failure Code [AS10NT] 902
Failure Code [B@BAZG] 903
Failure Code [B@BCNS] 904
Failure Code [B@BCQA] 905
Failure Code [B@BCZK] 907
Failure Code [B@CRNS] 909
Failure Code [B@CRZG] 910
Failure Code [CA115] 911
Failure Code [CA122] 912
Failure Code [CA123] 914
Failure Code [CA131] 916
Failure Code [CA132] 918
Failure Code [CA144] 920
Failure Code [CA145] 922
Failure Code [CA153] 924
Failure Code [CA154] 926
Failure Code [CA187] 928
Failure Code [CA221] 930
Failure Code [CA222] 932
Failure Code [CA227] 934
Failure Code [CA234] 936
Failure Code [CA238] 937
Failure Code [CA239] 938
Failure Code [CA249] 939
Failure Code [CA256] 941
Failure Code [CA271] 943
Failure Code [CA272] 945
Failure Code [CA295] 947
Failure Code [CA322] 948
Failure Code [CA324] 950
Failure Code [CA331] 952
Failure Code [CA332] 954
Failure Code [CA343] 956
Failure Code [CA351] 957
Failure Code [CA352] 958
Failure Code [CA356] 960
Failure Code [CA357] 962
Failure Code [CA386] 964
Failure Code [CA428] 965
Failure Code [CA429] 967
Failure Code [CA435] 969
Failure Code [CA441] 971
Failure Code [CA442] 973
Failure Code [CA451] 974
Failure Code [CA452] 976
Failure Code [CA488] 978
Failure Code [CA515] 979
Failure Code [CA516] 981
Failure Code [CA553] 983
Failure Code [CA555] 984
Failure Code [CA556] 985
Failure Code [CA559] 986
Failure Code [CA595] 989
Failure Code [CA687] 991
Failure Code [CA689] 993
Failure Code [CA691] 996
Failure Code [CA692] 998
Failure Code [CA697]1000
Failure Code [CA698]1001
Failure Code [CA731]1002
Failure Code [CA778]1004
Failure Code [CA1117]1009
Failure Code [CA1664]1011
Failure Code [CA1669]1013
Failure Code [CA1673]1014
Failure Code [CA1677]1015
Failure Code [CA1678]1016
Failure Code [CA1682]1017
Failure Code [CA1683]1019
Failure Code [CA1684]1021
Failure Code [CA1686]1023
Failure Code [CA1691]1024
Failure Code [CA1694]1026
Failure Code [CA1695]1028
Failure Code [CA1696]1029
Failure Code [CA1712]1031
Failure Code [CA1713]1034
Failure Code [CA1714]1036
Failure Code [CA1715]1037
Failure Code [CA1776]1038
Failure Code [CA1777]1041
Failure Code [CA1843]1044
Failure Code [CA1844]1046
Failure Code [CA1885]1049
Failure Code [CA1887]1051
Failure Code [CA1896]1053
Failure Code [CA1898]1057
Failure Code [CA1938]1059
Failure Code [CA1942]1061
Failure Code [CA1961]1062
Failure Code [CA1962]1063
Failure Code [CA2185]1064
Failure Code [CA2186]1066
Failure Code [CA2198]1068
Failure Code [CA2272]1070
Failure Code [CA2288]1072
Failure Code [CA2311]1073
Failure Code [CA2349]1074
Failure Code [CA2353]1076
Failure Code [CA2357]1078
Failure Code [CA2373]1079
Failure Code [CA2374]1081
Failure Code [CA2375]1083
Failure Code [CA2376]1085
Failure Code [CA2387]1088
Failure Code [CA2554]1089
Failure Code [CA2555]1091
Failure Code [CA2556]1094
Failure Code [CA2634]1097
Failure Code [CA2635]1099
Failure Code [CA2636]1100
Failure Code [CA2637]1102
Failure Code [CA2771]1104
Failure Code [CA2961]1108
Failure Code [CA2973]1109
Failure Code [CA2976]1110
Failure Code [CA3142]1112
Failure Code [CA3143]1113
Failure Code [CA3144]1114
Failure Code [CA3146]1116
Failure Code [CA3147]1117
Failure Code [CA3148]1118
Failure Code [CA3151]1120
Failure Code [CA3165]1125
Failure Code [CA3228]1127
Failure Code [CA3229]1129
Failure Code [CA3231]1131
Failure Code [CA3232]1133
Failure Code [CA3235]1137
Failure Code [CA3239]1139
Failure Code [CA3241]1142
Failure Code [CA3242]1145
Failure Code [CA3251]1148
Failure Code [CA3313]1150
Failure Code [CA3314]1151
Failure Code [CA3315]1152
Failure Code [CA3419]1154
Failure Code [CA3421]1156
Failure Code [CA3497]1158
Failure Code [CA3498]1159
Failure Code [CA3545]1160
Failure Code [CA3547]1162
Failure Code [CA3558]1163
Failure Code [CA3559]1165
Failure Code [CA3562]1167
Failure Code [CA3563]1169
Failure Code [CA3567]1172
Failure Code [CA3568]1176
Failure Code [CA3571]1180
Failure Code [CA3572]1182
Failure Code [CA3574]1184
Failure Code [CA3575]1186
Failure Code [CA3577]1188
Failure Code [CA3578]1190
Failure Code [CA3582]1192
Failure Code [CA3583]1197
Failure Code [CA3596]1199
Failure Code [CA3649]1203
Failure Code [CA3681]1205
Failure Code [CA3682]1210
Failure Code [CA3713]1215
Failure Code [CA3717]1218
Failure Code [CA3718]1219
Failure Code [CA3724]1220
Failure Code [CA3725]1221
Failure Code [CA3741]1224
Failure Code [CA3748]1225
Failure Code [CA3755]1227
Failure Code [CA3866]1229
Failure Code [CA3868]1232
Failure Code [CA4152]1236
Failure Code [CA4155]1240
Failure Code [CA4156]1243
Failure Code [CA4157]1246
Failure Code [CA4159]1248
Failure Code [CA4164]1249
Failure Code [CA4165]1251
Failure Code [CA4166]1253
Failure Code [CA4168]1254
Failure Code [CA4169]1257
Failure Code [CA4171]1259
Failure Code [CA4249]1261
Failure Code [CA4251]1263
Failure Code [CA4261]1265
Failure Code [CA4277]1268
Failure Code [CA4459]1272
Failure Code [CA4461]1274
Failure Code [CA4533]1277
Failure Code [CA4534]1278
Failure Code [CA4731]1279
Failure Code [CA4732]1280
Failure Code [CA4739]1281
Failure Code [CA4768]1282
Failure Code [CA4769]1284
Failure Code [CA4842]1286
Failure Code [CA4952]1289
Failure Code [CA5115]1291
Failure Code [CA5179]1294
Failure Code [CA5181]1296
Failure Code [CA5387]1298
Failure Code [CA5388]1300
Failure Code [CA5389]1303
Failure Code [CA5391]1305
Failure Code [CA5392]1309
Failure Code [CA5393]1311
Failure Code [CA5394]1314
Failure Code [CA5395]1317
Failure Code [CA5396]1320
Failure Code [CA5631]1321
Failure Code [CA5632]1323
Failure Code [CA5938]1324
Failure Code [D130KA]1326
Failure Code [D130KB]1329
Failure Code [D130KY]1331
Failure Code [D19JKZ]1333
Failure Code [D811MC]1336
Failure Code [D862KA]1337
Failure Code [D8ALKA]1338
Failure Code [D8ALKB]1340
Failure Code [D8AQKR]1342
Failure Code [D8G1KT]1344
Failure Code [D8G6KT]1345
Failure Code [DAF0MB]1346
Failure Code [DAF0MC]1347
Failure Code [DAF8KB]1348
Failure Code [DAF9KQ]1350
Failure Code [DAFGMC]1351
Failure Code [DAFLKA]1352
Failure Code [DAFLKB]1354
Failure Code [DAFQKR]1356
Failure Code [DAJ000]1357
Failure Code [DAJ0KQ]1358
Failure Code [DAJ0KT]1359
Failure Code [DAJ0MC]1360
Failure Code [DAJ1KK]1361
Failure Code [DAJ2KK]1363
Failure Code [DAJ5KK]1365
Failure Code [DAJ6KK]1368
Failure Code [DAJLKA]1370
Failure Code [DAJLKB]1372
Failure Code [DAJPMA]1374
Failure Code [DAJQKR]1375
Failure Code [DAJRKR]1376
Failure Code [DB2QKR]1377
Failure Code [DB2RKR]1382
Failure Code [DD12KA]1387
Failure Code [DD12KB]1389
Failure Code [DD13KA]1391
Failure Code [DD13KB]1393
Failure Code [DD14KA]1395
Failure Code [DD14KB]1397
Failure Code [DDKAKA]1399
Failure Code [DDKAKB]1401
Failure Code [DDKFL4]1403
Failure Code [DDKGL4]1405
Failure Code [DDKHKA]1407
Failure Code [DDKHKB]1409
Failure Code [DDNLKA]1411
Failure Code [DDNLKB]1413
Failure Code [DDP6KA]1415
Failure Code [DDP6KB]1418
Failure Code [DDP6MA]1420
Failure Code [DDU1FS]1422
Failure Code [DDU1KA]1424
Failure Code [DDU1KY]1427
Failure Code [DFA4KX]1429
Failure Code [DFA4KZ]1430
Failure Code [DFA4L8]1431
Failure Code [DFA5KA]1432
Failure Code [DFA5KB]1435
Failure Code [DFA6KA]1438
Failure Code [DFA6KB]1441
Failure Code [DFA7KX]1444
Failure Code [DFA7KZ]1445
Failure Code [DFA7L8]1446
Failure Code [DFA8KA]1447
Failure Code [DFA8KB]1450
Failure Code [DFA9KA]1453
Failure Code [DFA9KB]1456
Failure Code [DGS1KA]1459
Failure Code [DGS1KX]1462
Failure Code [DH21KA]1463
Failure Code [DH21KB]1465
Failure Code [DHA4KA]1467
Failure Code [DHH7KA]1469
Failure Code [DHH7KB]1472
Failure Code [DHH8KA]1474
Failure Code [DHH8KB]1477
Failure Code [DHH9KA]1479
Failure Code [DHH9KB]1482
Failure Code [DHHAKA]1484
Failure Code [DHHAKB]1487
Failure Code [DHRUKA]1489
Failure Code [DHRUKB]1491
Failure Code [DHRVKA]1493
Failure Code [DHRVKB]1495
Failure Code [DK30KA]1497
Failure Code [DK30KB]1500
Failure Code [DK30KX]1502
Failure Code [DK30KZ]1503
Failure Code [DK30L8]1504
Failure Code [DK31KA]1505
Failure Code [DK31KB]1508
Failure Code [DK40KA]1510
Failure Code [DK40KB]1513
Failure Code [DK55KX]1515
Failure Code [DK55KZ]1516
Failure Code [DK55L8]1517
Failure Code [DK56KA]1518
Failure Code [DK56KB]1521
Failure Code [DK57KA]1523
Failure Code [DK57KB]1526
Failure Code [DLM0KX]1528
Failure Code [DLM1KA]1529
Failure Code [DLM1KB]1531
Failure Code [DLM1MA]1533
Failure Code [DLM2KA]1534
Failure Code [DLM2KB]1536
Failure Code [DLM2MA]1538
Failure Code [DLM3KA]1539
Failure Code [DLM3KB]1541
Failure Code [DLM3MB]1543
Failure Code [DN21FS]1544
Failure Code [DR21KX]1546
Failure Code [DR31KX]1547
Failure Code [DV20KB]1548
Failure Code [DW4BKA]1550
Failure Code [DW4BKB]1552
Failure Code [DW4BKY]1554
Failure Code [DW7BKA]1556
Failure Code [DW7BKB]1558
Failure Code [DW7EKA]1560
Failure Code [DW7EKB]1562
Failure Code [DW7EKY]1564
Failure Code [DWN5KA]1566
Failure Code [DWN5KB]1568
Failure Code [DWN5KY]1570
Failure code [DXA4KA]1572
Failure code [DXA4KB]1574
Failure code [DXA4KY]1576
Failure code [DXA5KA]1578
Failure code [DXA5KB]1580
Failure code [DXA5KY]1582
Failure code [DXA6KA]1584
Failure code [DXA6KB]1586
Failure code [DXA6KY]1588
Failure code [DXA7KA]1590
Failure code [DXA7KB]1592
Failure code [DXA7KY]1594
Failure Code [DXHRKA]1596
Failure Code [DXHRKB]1598
Failure Code [DXHRKY]1600
Failure Code [DXHSKA]1602
Failure Code [DXHSKB]1604
Failure Code [DXHSKY]1606
Failure Code [DXHTKA]1608
Failure Code [DXHTKB]1610
Failure Code [DXHTKY]1612
Failure Code [DXHUKA]1614
Failure Code [DXHUKB]1616
Failure Code [DXHUKY]1618
Failure Code [DXJ4KA]1620
Failure Code [DXJ4KB]1622
Failure Code [DXJCKA]1624
Failure Code [DXJCKB]1626
Failure Code [DXJCKY]1628
Failure Code [DXJDKA]1630
Failure Code [DXJDKB]1632
Failure Code [DXJDKY]1634
Failure Code [DXK1KA]1636
Failure Code [DXK1KB]1638
Failure Code [DXK1KY]1640
Failure Code [DXK2KA]1642
Failure Code [DXK2KB]1644
Failure Code [DXK2KY]1646
Failure Code [F311KA]1648
Failure Code [F311KB]1650
Failure Code [F312KA]1652
Failure Code [F312KB]1654
Failure Code [F313KA]1656
Failure Code [F313KB]1658
Failure Code [F314KA]1661
Failure Code [F314KB]1663
Failure Code [F315KB]1665
Failure Code [F315KY]1667
Failure Code [F316KB]1669
Failure Code [F316KY]1671
Failure Code [F318KB]1673
Failure Code [F318KY]1676
Failure Code [F31AKB]1678
Failure Code [F31AKY]1680
Failure Code [F31BKB]1682
Failure Code [F31BKY]1684
Failure Code [F31CKB]1686
Failure Code [F31CKY]1688
Failure Code [F31DKB]1690
Failure Code [F31DKY]1692
Failure Code [F31EKB]1694
Failure Code [F31EKY]1696
Failure Code [FS10ZE]1698
Troubleshooting of Electrical System (E-Mode)1699
Engine Does Not Start (Engine Does Not Crank)1699
Manual Preheating System Does Not Operate1706
Automatic Preheating System Does Not Operate1709
While Preheating is in Operation, Preheating Monitor Does Not Come On1711
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1713
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On1717
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation1718
Charge Level Monitor Comes On in Red While Engine is in Operation1719
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1720
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation1721
HST Charge Pressure Monitor Comes On in Red While Engine Runs1722
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1723
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs1724
Engine Coolant Temperature Gauge Does Not Show Correct Temperature1725
DEF Level is Not Shown Correctly1726
Fuel Gauge Does Not Show Normally1729
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature1732
Operation Mode Does Not Change1733
When You Operate Customize Switch Does Not Show Customize Screen1734
When You Change Setting on Customize Screen, Setting of Machine is Not Changed1735
Service Meter is Not Shown While Starting Switch is in OFF Position1736
Service Mode Cannot be Selected1737
Work Equipment Does Not Operate1738
Foot Heater Does Not Operate1740
Horn Does Not Sound1746
Horn Does Not Stop1748
Backup Alarm Does Not Sound1749
Backup Alarm Does Not Stop Operation1750
Headlamp Does Not Come On1751
Rear Lamp Does Not Come On1755
No Wiper Operates1758
Front Wiper Does Not Operate1760
Rear Wiper Does Not Operate1762
Left Door Wiper Does Not Operate1764
Right Door Wiper Does Not Operate1768
Front Washer Does Not Operate1772
Rear Washer Does Not Operate1774
Left Door Washer Does Not Operate1776
Right Door Washer Does Not Operate1778
KOMTRAX System Does Not Operate Correctly1780
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1781
Information Shown in Troubleshooting Table (H-Mode)1781
Failure Mode and Cause Table1782
RH and LH Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate)1788
RH or LH Track Cannot Travel FORWARD and REVERSE (One of RH or LH Travel Systems Cannot Operate)1790
RH or LH Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction)1792
Travel Speed or Power is Low1794
Speed Range Does Not Change1796
Shock is Large When Machine Moves Off or Stops1797
Travel Deviation is Large1798
Machine Drift on a Slope is Large1801
Engine Speed Drops Largely or Engine Stops1803
Unusual Noise is Heard from Around HST Pump or Motor1805
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High1807
All Work Equipment Do Not Operate1809
All Work Equipment Speed or Power is Low1811
Blade Lift Speed or Power is Low1812
Blade Tilt Speed or Power is Low1814
Blade Angle Speed or Power is Low1815
Time Lag of Blade Lift is Large1816
Hydraulic Drift of Blade Lift is Large1817
Hydraulic Drift of Tilted Blade is Large1818
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve1819
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)1820
Unusual Noise is Heard from Around Fan1822
Troubleshooting of Engine (S-Mode)1823
Information Shown in Troubleshooting Table (S-Mode)1823
Engine Does Not Crank When Starting Switch is Turned to Start Position1824
Engine Cranks but No Exhaust Smoke Comes Out1825
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1826
Engine Startability is Unsatisfactory1828
Engine Does Not Pick Up Smoothly1830
Engine Stops During Operation1832
Engine Does Not Rotate Smoothly1834
Engine Lacks Output (or Lacks Power)1835
Exhaust Smoke is Black1837
Engine Oil Consumption is Excessive1839
Engine Oil Becomes Dirty Quickly1840
Fuel Consumption is Excessive1841
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)1842
Engine Oil Pressure Drops1843
Fuel Mixes Into Engine Oil1845
Water Mixes Into Engine Oil (Milky)1846
Coolant Temperature Increases Too High (Overheat)1847
Unusual Noise is Heard1848
Vibration is Excessive1849
Air Cannot be Bled from Fuel Circuit1850
Active Regeneration is Done Frequently1851
Active Regeneration Continues Long1852
White Smoke is Exhausted During Active Regeneration1853
DEF Consumption is Excessive1854
There is an Unusual Smell (Irritating Odor)1856
Foreign Materials Enter DEF (DEF Increases)1857
50 Disassembly and Assembly1859
Table of Contents1860
Precautions Before Work1865
Related Information on Disassembly and Assembly1866
How to Read This Manual1866
Coating Materials List1867
Special Tool List1872
Sketches of Special Tools1893
Engine and Cooling System1906
Remove and Install Supply Pump Assembly1906
How to Remove Supply Pump Assembly1906
How to Install Supply Pump Assembly1916
Remove and Install Injector Assembly1926
How to Remove Injector Assembly1926
How to Install Injector Assembly1937
Remove and Install Cylinder Head Assembly1951
How to Remove Cylinder Head Assembly1951
How to Install Cylinder Head Assembly1970
Remove and Install EGR Valve Assembly1994
How to Remove EGR Valve Assembly1994
How to Install EGR Valve Assembly1997
Remove and Install EGR Cooler Assembly2001
How to Remove EGR Cooler Assembly2001
How to Install EGR Cooler Assembly2005
Remove and Install Starter Assembly2009
How to Remove Starting Motor Assembly2009
How to Install Starting Motor Assembly2011
Remove and Install Air Conditioner Compressor Belt2014
How to Remove Air Conditioner Compressor Belt2014
How to Install Air Conditioner Compressor Belt2018
Remove and Install Alternator Belt2023
How to Remove Alternator Belt2023
How to Install Alternator Belt2026
Remove and Install Automatic Tensioner2028
How to Remove Automatic Tensioner2028
How to Install Automatic Tensioner2029
Remove and Install Radiator Assembly2031
How to Remove Radiator Assembly2032
How to Install Radiator Assembly2040
Remove and Install Hydraulic Oil Cooler Assembly2048
How to Remove Hydraulic Oil Cooler Assembly2049
How to Install Hydraulic Oil Cooler Assembly2054
Remove and Install Aftercooler Assembly2059
How to Remove Aftercooler Assembly2060
How to Install Aftercooler Assembly2066
Remove and Install Cooling Fan Drive Assembly2073
How to Remove Cooling Fan Drive Assembly2073
How to Install Cooling Fan Drive Assembly2078
Remove and Install Cooling Fan Motor Assembly2082
How to Remove Cooling Fan Motor Assembly2082
How to Install Cooling Fan Motor Assembly2085
Remove and Install Engine and HST Pump Assembly2088
How to Remove Engine and HST Pump Assembly2088
Install Engine and HST Pump Assembly2099
Remove and Install Engine Front Oil Seal2111
How to Remove Engine Front Oil Seal2111
How to Install Engine Front Oil Seal2113
Remove and Install Engine Rear Oil Seal2115
How to Remove Engine Rear Oil Seal2115
How to Install Engine Rear Oil Seal2116
Remove and Install Engine Hood Assembly2119
How to Remove Engine Hood Assembly2119
How to Install Engine Hood Assembly2123
Remove and Install KDOC Assembly2127
How to Remove KDOC Assembly2127
How to Install KDOC Assembly2133
Remove and Install KDOC and SCR Assembly2140
How to Remove KDOC and SCR Assembly2141
How to Install KDOC and SCR Assembly2147
Remove and Install Bellows Pipe Assembly2155
How to Remove Bellows Pipe Assembly2155
How to Install Bellows Pipe Assembly2158
Remove and Install Fuel Tank Assembly2162
How to Remove Fuel Tank Assembly2163
Install Fuel Tank Assembly2170
Remove and Install DEF Tank Assembly2177
How to Remove DEF Tank Assembly2178
How to Install DEF Tank Assembly2188
Remove and Install DEF Tank Sensor Flange Assembly2197
How to Remove DEF Tank Sensor Flange Assembly2197
How to Install DEF Tank Sensor Flange Assembly2199
Remove and Install DEF Tank Sensor2203
How to Remove DEF Tank Sensor2203
How to Install DEF Tank Sensor2204
Remove and Install DEF Tank Strainer2211
How to Remove DEF Tank Strainer2211
How to Install DEF Tank Strainer2212
Remove and Install SCR Assembly2213
How to Remove SCR Assembly2213
How to Install SCR Assembly2216
Remove and Install KCCV Assembly2219
How to Remove KCCV Assembly2219
How to Install KCCV Assembly2220
Remove and Install DEF Mixing Tube2223
How to Remove DEF Mixing Tube2223
How to Install DEF Mixing Tube2227
Remove and Install DEF Injector2232
How to Remove DEF Injector2232
How to Install DEF Injector2237
Remove and Install DEF Pump2242
How to Remove DEF Pump2242
How to Install DEF Pump2246
Remove and Install DEF Hose2250
How to Remove DEF Hose2252
How to Install DEF Hose2271
Remove and Install Air Cleaner Assembly2292
How to Remove Air Cleaner Assembly2292
How to Install Air Cleaner Assembly2294
Remove and Install Air Conditioner Compressor Assembly2297
How to Remove Air Conditioner Compressor Assembly2297
How to Install Air Conditioner Compressor Assembly2301
Remove and Install Air Conditioner Condenser Assembly2306
How to Remove Air Conditioner Condenser Assembly2306
How to Install Air Conditioner Condenser Assembly2310
Power Train2314
Disassemble and Assemble Final Drive Assembly2314
How to Disassemble Final Drive Assembly2315
How to Assemble Final Drive Assembly2319
Undercarriage and Frame2328
Remove and Install Track Frame Assembly2328
How to Remove Track Frame Assembly2328
How to Install Track Frame Assembly2333
Remove and Install Idler Assembly2338
How to Remove Idler Assembly2338
How to Install Idler Assembly2340
Disassemble and Assemble Idler Assembly2343
How to Disassemble Idler Assembly2343
How to Assemble Idler Assembly2345
Remove and Install Recoil Spring Assembly2350
How to Remove Recoil Spring Assembly2350
How to Install Recoil Spring Assembly2350
Disassemble and Assemble Recoil Spring Assembly2351
How to Disassemble Recoil Spring Assembly2351
How to Assemble Recoil Spring Assembly2354
Remove and Install Track Roller Assembly2357
How to Remove Track Roller Assembly2357
How to Install Track Roller Assembly2359
Disassemble and Assemble Track Roller Assembly2363
How to Disassemble Track Roller Assembly2363
How to Assemble Track Roller Assembly2364
Remove and Install Carrier Roller Assembly2368
How to Remove Carrier Roller Assembly2368
How to Install Carrier Roller Assembly2369
Disassemble and Assemble Carrier Roller Assembly2371
How to Disassemble Carrier Roller Assembly2371
How to Assemble Carrier Roller Assembly2372
Remove and Install Pivot Shaft Assembly2375
How to Remove Pivot Shaft Assembly2375
How to Install Pivot Shaft Assembly2376
Separate and Connect Track Assembly2378
How to Examine Before Separation of Track Assembly2378
How to Separate Track Assembly (Standard)2379
How to Separate Track Assembly (When Track Frame Has Internal Defect)2380
How to Install Track Assembly2381
Separate and Connect PLUS Type Track Assembly2383
Separate PLUS Type Track Assembly Generally2383
Install PLUS Type Track Assembly2383
Disassemble and Assemble Track Assembly Generally2385
How to Disassemble Full Track Shoes Assembly2385
How to Assemble Full Track Shoes Assembly2390
Disassemble and Assemble PLUS Type Track Assembly Generally2403
Disassemble PLUS Type Track Assembly Generally2404
How to Assemble PLUS Type Track Shoes Assembly Generally2405
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)2414
How to Disassemble One Track Link Assembly in Field (Track Assembly)2415
How to Assemble One Track Link Assembly in Field (Track Assembly)2416
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2423
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)2424
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2426
Remove and Install Equalizer Bar Assembly2430
How to Remove Equalizer Bar Assembly2430
How to Install Equalizer Bar Assembly2432
Remove and Install Equalizer Bar Side Bushing2435
How to Remove Equalizer Bar Side Bushings2435
How to Install Equalizer Bar Side Bushings2436
Remove and Install Segment Teeth2437
How to Remove Segment Teeth2437
How to Install Segment Teeth2439
Hydraulic System2441
Remove and Install Hydraulic Tank Assembly2441
How to Remove Hydraulic Tank Assembly2442
How to Install Hydraulic Tank Assembly2448
Remove and Install Control Valve Assembly2457
How to Remove Control Valve Assembly2457
How to Install Control Valve Assembly2461
Work Equipment2465
Remove and Install Blade Assembly (Serial No: 15001 to 15600)2465
How to Remove Blade Assembly (Serial No: 15001 to 15600)2465
How to Install Blade Assembly (Serial No: 15001 to 15600)2468
Remove and Install Blade Assembly (Serial No: 15601 and up)2473
How to Remove Blade Assembly (Serial No: 15601 and up)2474
How to Install Blade Assembly (Serial No: 15601 and up)2477
Remove and Install Blade Lift Cylinder Assembly2482
How to Remove Blade Lift Cylinder Assembly2482
How to Install Blade Lift Cylinder Assembly2484
Remove and Install Blade Tilt Cylinder Assembly (Serial No: 15001 to 15600)2486
How to Remove Blade Tilt Cylinder Assembly (Serial No: 15001 to 15600)2486
How to Install Blade Tilt Cylinder Assembly (Serial No: 15001 to 15600)2487
Remove and Install Blade Tilt Cylinder Assembly (Serial No: 15601 and up)2489
How to Remove Blade Tilt Cylinder Assembly (Serial No: 15601 and up)2489
How to Install Blade Tilt Cylinder Assembly (Serial No: 15601 and up)2490
Remove and Install Blade Angle Cylinder Assembly2492
How to Remove Blade Angle Cylinder Assembly2492
How to Install Blade Angle Cylinder Assembly2494
Remove and Install U-Frame Assembly (Serial No: 15001 to 15600)2496
How to Remove U-frame Assembly (serial No: 15001 to 15600)2496
How to Install U-frame Assembly (serial No: 15001 to 15600)2500
Remove and Install U-Frame Assembly (Serial No: 15601 and up)2503
How to Remove U-Frame Assembly (Serial No: 15601 and up)2503
How to Install U-Frame Assembly (Serial No: 15601 and up)2506
CAB Related Parts2509
Remove and Install Operator Cab Assembly2509
How to Remove Operator Cab Assembly2510
How to Install Operator Cab Assembly2517
Remove and Install Operator Cab Glass (Adhered Glass)2525
How to Remove Operator Cab Glass (Adhered Glass)2527
How to Install Operator Cab Glass (Adhered Glass)2527
Remove and Install Air Conditioner Unit Assembly2533
How to Remove Air Conditioner Unit Assembly2533
How to Install Air Conditioner Unit Assembly2539
Remove and Install Receiver Drier2546
How to Remove Receiver Drier2546
How to Install Receiver Drier2547
Remove and Install Operator Seat2550
How to Remove Operator Seat2550
How to Install Operator Seat2551
How to Remove and Install Seat Belt2552
How to Remove Seat Belt2552
How to Install Seatbelt2552
Remove and Install Foot Heater Assembly2554
How to Remove Foot Heater Assembly2554
How to Install Foot Heater Assembly2556
Disassemble and Assemble Foot Heater Assembly2559
How to Disassemble Foot Heater Assembly2559
How to Assemble Foot Heater Assembly2560
Electrical System2561
Remove and Install Engine Controller Assembly2561
How to Remove Engine Controller Assembly2561
How to Install Engine Controller Assembly2564
Remove and Install HST Controller Assembly2568
How to Remove HST Controller Assembly2568
How to Install HST Controller Assembly2569
Remove and Install Machine Monitor Assembly2570
How to Remove Machine Monitor Assembly2570
How to Install Machine Monitor Assembly2571
Remove and Install Mass Air Flow and Temperature Sensor2573
How to Remove Mass Air Flow and Temperature Sensor2573
How to Install Mass Air Flow and Temperature Sensor2575
Remove and Install KCCV Crankcase Pressure Sensor2577
How to Remove KCCV Crankcase Pressure Sensor2577
How to Install KCCV Crankcase Pressure Sensor2579
Remove and Install Gateway Function Controller Assembly2581
How to Remove Gateway Function Controller Assembly2581
How to Install Gateway Function Controller Assembly2582
Remove and Install Communication Terminal2583
How to Remove Communication Terminal2583
How to Install Communication Terminal2586
60 Maintenance Standard2589
Table of Contents2590
Engine and Cooling System2591
Maintenance Standard for Engine Mount2591
Maintenance Standard for Damper (Serial No: 15001 to 15600)2592
Maintenance Standard for Damper (Serial No: 15601 and up)2593
Maintenance Standard for Cooling System2594
Maintenance Standard for Cooling Fan Motor2596
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve2598
Power Train2599
Maintenance Standard for HST Pump2599
Maintenance Standard for EPC Valve of HST Pump2601
Maintenance Standard for Tow Receiving Valve of HST Pump2602
Maintenance Standard for HST Charge Pump2603
Maintenance Standard for HST Motor2605
Maintenance Standard for Final Drive2607
Maintenance Standard for Sprocket for PLUS Type Track Shoes2609
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes2610
Undercarriage and Frame2611
Maintenance Standard for Suspension2611
Maintenance Standard for Track Frame and Idler Cushion2614
Maintenance Standard for Idler2617
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)2619
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)2620
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes2622
Maintenance Standard for PLUS Type Track Shoes2623
Maintenance Standard for Single Shoes2625
Hydraulic System2626
Maintenance Standard for Hydraulic Tank2626
Maintenance Standard for Work Equipment and Cooling Fan Pump2627
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump2628
Maintenance Standard for Control Valve2630
Maintenance Standard for Ripper PPC Valve2636
Maintenance Standard for 5-Spool EPC and Solenoid Valve2638
Maintenance Standard for EPC Valve2639
Maintenance Standard for Quick Drop Valve2640
Work Equipment2642
Maintenance Standard for Front Work Equipment (Serial No: 15001 to 15600)2642
Maintenance Standard for Front Work Equipment (Serial No: 15601 and up)2645
Maintenance Standard for Cutting Edge and End Bit2648
Maintenance Standard for Blade Lift Cylinder2649
Maintenance Standard for Blade Tilt Cylinder2650
Maintenance Standard for Blade Angle Cylinder2651
Maintenance Standard for Fixed Multi-Shank Ripper2652
Maintenance Standard for Ripper Lift Cylinder2654
CAB Related Parts2655
Maintenance Standard for CAB Mount2655
Electrical System2657
Maintenance Standard for Steering Electric Lever2657
80 Appendix2659
Table of Contents2660
Precautions Before Work2661
Air Conditioner System2662
Precautions for Refrigerant2662
Air Conditioner Component2663
Specifications of Air Conditioner2666
Structure and Function of Refrigeration Cycle2667
Outline of Refrigeration Cycle2668
Component Parts of Air Conditioner System2670
Air Conditioner Unit2670
Configuration Diagram of Air Conditioner Unit2670
Function of Air Conditioner Unit2671
Component Parts of Air Conditioner Unit2672
Function of Evaporator as Air Conditioner Unit Component2672
Function of Heater Core as Air Conditioner Unit Component2672
Function of Thermistor as Air Conditioner Unit Component2672
Structure of Expansion Valve as Air Conditioner Unit Component2673
Function of Expansion Valve as Air Conditioner Unit Component2673
Operate Expansion Valve as Air Conditioner Unit Component2673
Function of Dual Pressure Switch2674
Function of Pressure Switch2674
Compressor2675
Structure of Compressor2675
Specifications of Compressor2675
Function of Compressor2675
Condenser2676
Structure of Condenser2676
Specifications of Condenser2676
Function of Condenser2677
Receiver Drier2678
Structure of Receiver Dryer2678
Specifications of Receiver Dryer2678
Function of Receiver Dryer2678
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2680
Circuit Diagram of Air Conditioner2683
System Diagram of Air Conditioner2684
Control Function of Air Conditioner2685
Locations of Air Conditioner Parts and Layout of Connectors2686
Examine Relay2690
How to Examine Relay2690
Air Conditioner Troubleshooting Chart 12692
Air Conditioner Troubleshooting Chart 22693
Information Shown in Troubleshooting Table2696
Troubleshooting for Condenser Fan2697
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2700
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2704
Troubleshooting for Temperature Control Function2707
Troubleshooting by Gauge Pressure2711
Connect Service Tool2713
How to Connect Service Tool2714
Precautions for Disconnection and Connection of Air Conditioner Piping2715
Handle Compressor Oil2717
90 Circuit Diagrams2719
Table of Contents2720
Hydraulic Circuit Diagram2721
Symbols Used in Hydraulic Circuit Diagram2721
Hydraulic Circuit Diagram2725
Electrical Circuit Diagram2727
Symbols Used in Electric Circuit Diagram2727
Electrical Circuit Diagram (1/16)2731
Electrical Circuit Diagram (2/16)2733
Electrical Circuit Diagram (3/16)2735
Electrical Circuit Diagram (4/16)2737
Electrical Circuit Diagram (5/16)2739
Electrical Circuit Diagram (6/16)2741
Electrical Circuit Diagram (7/16)2743
Electrical Circuit Diagram (8/16)2745
Electrical Circuit Diagram (9/16)2747
Electrical Circuit Diagram (10/16)2749
Electrical Circuit Diagram (11/16)2751
Electrical Circuit Diagram (12/16)2753
Electrical Circuit Diagram (13/16)2755
Electrical Circuit Diagram (14/16)2757
Electrical Circuit Diagram (15/16)2759
Electrical Circuit Diagram (16/16)2761
Index2763
IMAGES PREVIEW OF THE MANUAL:
S.M 28/12/24
