Komatsu BULLDOZER D61EXi -24E0 D61PXi-24E0 Shop Manual – PDF DOWNLOAD

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Komatsu BULLDOZER D61EXi -24E0 D61PXi-24E0 Shop Manual SEN06798-01 – PDF DOWNLOAD

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Komatsu BULLDOZER D61EXi -24E0 D61PXi-24E0 Shop Manual SEN06798-01 – PDF DOWNLOAD

Language : English
Pages :3048
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D61EXi -24E0 D61PXi-24E0 Shop Manual SEN06798-01 – PDF DOWNLOAD

SERIAL NUMBERS D61EXi-41275
D61PXi-41275 and up

TABLE OF CONTENTS:

Komatsu BULLDOZER D61EXi -24E0 D61PXi-24E0 Shop Manual SEN06798-01 – PDF DOWNLOAD

SERIAL NUMBERS D61EXi-41275
D61PXi-41275 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D61EXI-24E0 103
SPECIFICATION DRAWING: D61PXI-24E0 104
SPECIFICATIONS 106
SPECIFICATIONS: D61EXI-24E0 106
SPECIFICATIONS: D61PXI-24E0 112
WEIGHT TABLE 117
WEIGHT TABLE: D61EXI-24E0 117
WEIGHT TABLE: D61PXI-24E0 119
TABLE OF FUEL, COOLANT, AND LUBRICANTS 121
10 STRUCTURE AND FUNCTION 123
CONTENTS 124
ABBREVIATION LIST 128
UREA SCR SYSTEM 134
LAYOUT DRAWING OF UREA SCR SYSTEM 134
UREA SCR SYSTEM DIAGRAM 137
FUNCTION OF UREA SCR SYSTEM 138
FUNCTION OF AdBlue/DEF SYSTEM 138
INDUCEMENT STRATEGY 140
COMPONENT PARTS OF UREA SCR SYSTEM 154
AdBlue/DEF MIXING TUBE 154
SCR ASSEMBLY 155
AdBlue/DEF TANK 157
AdBlue/DEF PUMP 159
AdBlue/DEF INJECTOR 160
AdBlue/DEF HOSE 161
AdBlue/DEF TANK HEATING VALVE 162
BOOT-UP SYSTEM 163
LAYOUT DRAWING OF BOOT-UP SYSTEM 163
SYSTEM OPERATING LAMP SYSTEM 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 164
BATTERY DISCONNECT SWITCH 166
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 166
FUNCTION OF BATTERY DISCONNECT SWITCH 166
ENGINE SYSTEM 168
LAYOUT DRAWING OF ENGINE SYSTEM 168
ENGINE CONTROL SYSTEM 170
LAYOUT OF ENGINE CONTROL SYSTEM 170
ENGINE CONTROL SYSTEM DIAGRAM 172
FUNCTION OF ENGINE CONTROL SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM 176
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 176
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 176
COMPONENT PARTS OF ENGINE SYSTEM 179
DAMPER 179
VGT 180
EGR SYSTEM 184
EGR VALVE 186
EGR COOLER 188
KCCV SYSTEM 190
KCCV VENTILATOR 192
KDPF 194
COOLING SYSTEM 198
LAYOUT DRAWING OF COOLING SYSTEM 198
SPECIFICATIONS OF COOLING SYSTEM 199
COOLING FAN CONTROL SYSTEM 200
COOLING FAN CONTROL SYSTEM DIAGRAM 200
FUNCTION OF COOLING FAN CONTROL SYSTEM 201
COMPONENT PARTS OF COOLING SYSTEM 203
COOLING FAN MOTOR 203
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 208
HYDRAULIC OIL COOLER BYPASS VALVE 210
HST CHARGE SAFETY VALVE 211
CONTROL SYSTEM 213
LAYOUT DRAWING OF CONTROL SYSTEM 213
MACHINE MONITOR SYSTEM 214
MACHINE MONITOR SYSTEM DIAGRAM 214
FUNCTION OF MACHINE MONITOR SYSTEM 214
KOMTRAX SYSTEM 215
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 215
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
GATEWAY FUNCTION CONTROLLER 231
COMMUNICATION TERMINAL 234
HST CONTROLLER 236
ENGINE CONTROLLER 240
FUEL CONTROL DIAL 246
DECELERATOR AND BRAKE POTENTIOMETER 248
HYDRAULIC SYSTEM 250
LAYOUT DRAWING OF HYDRAULIC SYSTEM 250
CLSS 251
STRUCTURE OF CLSS 251
FUNCTION OF CLSS 252
COMPONENT PARTS OF HYDRAULIC SYSTEM 254
HYDRAULIC TANK 254
WORK EQUIPMENT AND COOLING FAN PUMP 256
LS VALVE 264
PC VALVE 265
CONTROL VALVE 268
POWER TRAIN SYSTEM 289
LAYOUT DRAWING OF HST SYSTEM 289
OPERATION OF HST SYSTEM 290
STEERING AND BRAKE CONTROL SYSTEM 292
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 292
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 292
HST CONTROL SYSTEM 294
HST CONTROL SYSTEM DIAGRAM 294
GEAR SHIFT CONTROL FUNCTION 295
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 299
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 299
DECELERATION AND BRAKE CONTROL FUNCTION 301
GEAR SHIFT CONTROL FUNCTION BY LOAD 302
TURN CONTROL FUNCTION 302
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 303
PARKING BRAKE CONTROL SYSTEM 305
PARKING BRAKE CONTROL SYSTEM DIAGRAM 305
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 306
OPERATION OF PARKING BRAKE CONTROL SYSTEM 307
COMPONENT PARTS OF POWER TRAIN SYSTEM 308
HST PUMP 308
HST CHARGE PUMP 324
HST MOTOR 325
FINAL DRIVE 337
ELECTRIC STEERING CONTROL LEVER 341
WORK EQUIPMENT SYSTEM 344
WORK EQUIPMENT CONTROL 344
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 344
FUNCTION OF WORK EQUIPMENT CONTROL 345
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 347
LAYOUT OF FIXED MULTI-SHANK RIPPER 348
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 349
RIPPER PPC VALVE 349
5-PORT VALVE OF EPC AND SOLENOID 353
PILOT CIRCUIT ACCUMULATOR 359
ANGLE CONTROL EPC VALVE 360
QUICK DROP VALVE 363
PISTON VALVE 365
ELECTRIC BLADE CONTROL LEVER 366
ICT SYSTEM 368
LAYOUT DRAWING OF ICT SYSTEM 368
ICT CONTROL SYSTEM DIAGRAM 370
BLADE CONTROL SYSTEM 372
FUNCTION OF BLADE CONTROL SYSTEM 372
LEVELING MODE SYSTEM DIAGRAM 374
FUNCTION OF LEVELING MODE 375
OPERATION OF LEVELING MODE 375
DOZING MODE SYSTEM DIAGRAM 376
FUNCTION OF DOZING MODE 376
OPERATION OF DOZING MODE 376
SMOOTH START SYSTEM 378
SMOOTH START SYSTEM DIAGRAM 378
FUNCTION OF SMOOTH START SYSTEM 378
OPERATION OF SMOOTH START SYSTEM 378
SLIP CONTROL SYSTEM 380
SLIP CONTROL SYSTEM DIAGRAM 380
FUNCTION OF SLIP CONTROL SYSTEM 380
OPERATION OF SLIP CONTROL SYSTEM 380
ASSIST CONTROL SYSTEM 381
ASSIST CONTROL SYSTEM DIAGRAM 381
FUNCTION OF ASSIST CONTROL SYSTEM 381
OPERATION OF ASSIST CONTROL SYSTEM 382
HST SPEED RANGE CONTROL SYSTEM 383
HST SPEED RANGE CONTROL SYSTEM DIAGRAM 383
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM 383
OPERATION OF HST SPEED RANGE CONTROL SYSTEM 383
COMPONENT PARTS OF ICT SYSTEM 385
ICT SENSOR CONTROLLER 385
CONTROL BOX 389
GNSS RECEIVER 392
GNSS ANTENNA 396
IMU SENSOR 397
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 401
STROKE SENSOR FOR BLADE TILT CYLINDER 404
STROKE SENSOR FOR BLADE ANGLE CYLINDER 406
UNDERCARRIAGE AND FRAME 408
MAIN FRAME 408
STRUCTURE OF MAIN FRAME 408
SUSPENSION 409
STRUCTURE OF SUSPENSION 409
SPECIFICATIONS OF SUSPENSION 410
FUNCTION OF SUSPENSION 411
TRACK FRAME AND IDLER CUSHION 412
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 412
FUNCTION OF TRACK FRAME AND IDLER CUSHION 413
WORK EQUIPMENT 415
STRUCTURE OF FRONT WORK EQUIPMENT 415
STRUCTURE OF FIXED MULTI-SHANK RIPPER 416
CAB AND ITS ATTACHMENTS 417
ROPS CAB 417
STRUCTURE OF ROPS CAB 417
FUNCTION OF ROPS CAB 418
CAB MOUNT 419
STRUCTURE OF CAB MOUNT 419
FUNCTION OF CAB MOUNT 419
20 STANDARD VALUE TABLE 421
CONTENTS 422
ABBREVIATION LIST 423
STANDARD VALUE TABLE FOR ENGINE 429
STANDARD VALUE TABLE FOR ENGINE: D61EXI-24E0 429
STANDARD VALUE TABLE FOR ENGINE: D61PXI-24E0 433
STANDARD VALUE TABLE FOR MACHINE 437
STANDARD VALUE TABLE FOR MACHINE: D61EXI-24E0 437
STANDARD VALUE TABLE FOR MACHINE: D61PXI-24E0 454
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 471
30 TESTING AND ADJUSTING 473
CONTENTS 474
ABBREVIATION LIST 478
RELATED INFORMATION ON TESTING AND ADJUSTING 484
TOOLS FOR TESTING AND ADJUSTING 484
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 491
ENGINE AND COOLING SYSTEM 495
TEST ENGINE SPEED 495
METHOD FOR TESTING ENGINE SPEED 495
TEST BOOST PRESSURE 498
METHOD FOR TESTING BOOST PRESSURE 498
TEST EXHAUST GAS COLOR 500
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 500
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 502
TEST AND ADJUST VALVE CLEARANCE 504
METHOD FOR TESTING VALVE CLEARANCE 504
METHOD FOR ADJUSTING VALVE CLEARANCE 505
TEST COMPRESSION PRESSURE 506
METHOD FOR TESTING COMPRESSION PRESSURE 506
TEST BLOWBY PRESSURE 511
METHOD FOR TESTING BLOWBY PRESSURE 511
TEST ENGINE OIL PRESSURE 514
METHOD FOR TESTING ENGINE OIL PRESSURE 514
TEST EGR VALVE AND VGT OIL PRESSURE 515
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 515
TEST FUEL PRESSURE 517
METHOD FOR TESTING FUEL PRESSURE 518
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 523
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 524
BLEEDING AIR FROM FUEL SYSTEM 530
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 530
TEST FUEL CIRCUIT FOR LEAKAGE 531
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 531
HANDLE CYLINDER CUT-OUT MODE OPERATION 533
HANDLE NO-INJECTION CRANKING OPERATION 534
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 535
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 535
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 536
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 536
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 537
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 537
TEST ALTERNATOR BELT 538
METHOD FOR REMOVING ALTERNATOR BELT 538
TEST AUTOMATIC TENSIONER 540
METHOD FOR TESTING AUTOMATIC TENSIONER 540
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 542
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 542
TEST SCR RELATED FUNCTIONS 543
TEST AdBlue/DEF PUMP RAISED PRESSURE 547
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 550
TEST AdBlue/DEF LINE HEATER RELAY 1 555
TEST AdBlue/DEF LINE HEATER RELAY 2 558
TEST AdBlue/DEF PUMP HEATER RELAY 561
TEST AdBlue/DEF TANK HEATER VALVE 565
TEST DENITRATION EFFICIENCY OF SCR 569
CLEAN AdBlue/DEF TANK 572
METHOD FOR CLEANING AdBlue/DEF TANK 572
CLEAN AdBlue/DEF PUMP 576
CLEAN AdBlue/DEF PUMP 576
CLEAN AdBlue/DEF TANK MOUNTING PORTION 582
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 582
POWER TRAIN 583
TEST AND ADJUST HST OIL PRESSURE 583
METHOD FOR TESTING HST OIL PRESSURE 583
METHOD FOR ADJUSTING HST OIL PRESSURE 586
BLEED AIR FROM HST PUMP 588
METHOD FOR BLEEDING AIR FROM HST PUMP 588
TEST OUTLET PRESSURE OF SOLENOID VALVE 589
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 589
TEST TRAVEL DEVIATION 594
METHOD FOR TESTING TRAVEL DEVIATION 594
TEST BRAKE PERFORMANCE SIMPLY 596
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 596
TEST AND ADJUST DECELERATION/BRAKE PEDAL 597
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 597
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 599
ADJUST PARKING BRAKE LEVER 601
METHOD FOR ADJUSTING PARKING BRAKE LEVER 601
MOVE MACHINE WHEN IT CANNOT TRAVEL 603
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 603
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 605
UNDERCARRIAGE AND FRAME 607
CHECK AND ADJUST IDLER CLEARANCE 607
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE 607
TESTING SPROCKET WEAR 608
METHOD FOR TESTING SPROCKET WEAR 608
TEST AND ADJUST TRACK TENSION 609
METHOD FOR TESTING TRACK TENSION 609
METHOD FOR ADJUSTING TRACK TENSION 609
HYDRAULIC SYSTEM 611
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 611
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 611
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 612
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 612
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 613
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 615
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 615
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 616
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 617
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 617
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 619
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 619
TEST COOLING FAN SPEED 620
METHOD FOR TESTING COOLING FAN SPEED 620
TEST COOLING FAN CIRCUIT OIL PRESSURE 621
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 621
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 623
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 623
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 623
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 624
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 625
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 625
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 628
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 628
WORK EQUIPMENT 629
ADJUST WORK EQUIPMENT LOCK LEVER 629
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 629
ELECTRICAL SYSTEM 631
SET AND OPERATE MACHINE MONITOR 631
OPERATOR MODE 635
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 635
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 635
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 636
CHECKING FUNCTION OF SERVICE METER 636
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 636
SERVICE MODE 639
SERVICE MODE 639
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 640
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 647
ABNORMALITY RECORD MENU 659
METHOD FOR CONFIRMING MAINTENANCE RECORD 663
METHOD FOR OPERATING MAINTENANCE MODE SETTING 664
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 668
DEFAULT MENU 670
DIAGNOSTIC TESTS MENU 678
ADJUSTMENT MENU 687
METHOD FOR PERFORMING NO-INJECTION CRANKING 755
KOMTRAX SETTINGS MENU 758
METHOD FOR DISPLAYING SERVICE MESSAGE 760
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 762
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 768
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 768
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 774
ADJUST REARVIEW CAMERA ANGLE 776
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 776
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 777
HANDLE BATTERY DISCONNECT SWITCH 778
TEST DIODES 779
METHOD FOR TESTING DIODE USING DIGITAL TESTER 779
METHOD FOR TESTING DIODE USING ANALOG TESTER 779
ICT SYSTEM 780
SET AND OPERATE CONTROL BOX 780
TEST AND ADJUST ICT RELATED DEVICES 781
CALIBRATE BLADE EDGE POSITION 784
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION) 785
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) 788
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) 793
CALIBRATE IMU SENSOR 807
METHOD FOR CALIBRATING IMU SENSOR 807
RESET CYLINDER STROKE END 814
RESET LIFT CYLINDER STROKE END 814
RESET TILT CYLINDER STROKE END 815
RESET ANGLE CYLINDER STROKE END 815
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 817
CHECK BLADE ELEVATION, ADJUST 818
CHECK BLADE ELEVATION (FOR OLD CONTROL BOX) 818
CHECK BLADE ELEVATION (FOR NEW CONTROL BOX) 820
ADJUST BLADE ELEVATION (FOR OLD CONTROL BOX) 823
ADJUST BLADE ELEVATION (FOR NEW CONTROL BOX) 824
TEST STROKE SENSOR FOR LIFT CYLINDER 826
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 826
TEST STROKE SENSOR FOR TILT CYLINDER 828
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER 828
TEST STROKE SENSOR FOR ANGLE CYLINDER 830
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER 830
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 832
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER 832
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER 833
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED 834
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED 834
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 837
Pm CLINIC 840
Pm CLINIC SERVICE 840
Pm CLINIC CHECK SHEET: D61EXI-24E0 842
Pm CLINIC CHECK SHEET: D61PXI-24E0 849
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EXI-24E0 856
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PXI-24E0 859
40 TROUBLESHOOTING 863
CONTENTS 864
ABBREVIATION LIST 876
RELATED INFORMATION ON TROUBLESHOOTING 882
GENERAL TROUBLESHOOTING POINTS 882
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 883
SEQUENCE OF EVENTS IN TROUBLESHOOTING 895
CHECKS BEFORE TROUBLESHOOTING 897
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 899
WALK-AROUND CHECK 899
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 901
CHECK FUEL LEVEL AND TYPE 901
CHECK IMPURE INGREDIENT IN FUEL 901
CHECK AdBule/DEF LEVEL AND TYPE 902
CHECK FUEL PREFILTER 902
CHECK MAIN FILTER 904
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 905
CHECK COOLANT LEVEL (RESERVOIR TANK) 906
CHECK CLOGGING OF AIR CLEANER 907
CLEAN OUTER ELEMENT 907
REPLACE ELEMENT 910
CHECK HYDRAULIC OIL LEVEL 910
CHECK HYDRAULIC OIL STRAINER 911
CHECK HYDRAULIC FILTER 914
CHECK OIL LEVEL IN FINAL DRIVE CASE 915
BLEED AIR FROM FUEL SYSTEM 916
BLEED AIR FROM HYDRAULIC SYSTEM 916
METHOD FOR CHECKING ELECTRIC EQUIPMENT 916
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 923
PROCEDURE FOR TROUBLESHOOTING 930
SYMPTOM AND TROUBLESHOOTING NUMBERS 933
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 938
CONNECTORS LIST AND LAYOUT 940
CONNECTOR CONTACT IDENTIFICATION 956
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 996
FUSE LOCATION TABLE1002
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1006
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1010
FAILURE CODES TABLE1012
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1032
FAILURE CODE [6091NX]1032
FAILURE CODE [989L00]1034
FAILURE CODE [989M00]1035
FAILURE CODE [989N00]1036
FAILURE CODE [A1U0N3]1037
FAILURE CODE [A1U0N4]1039
FAILURE CODE [A900FR]1041
FAILURE CODE [A900N6]1042
FAILURE CODE [A900NY]1043
FAILURE CODE [AA10NX]1044
FAILURE CODE [AB00KE]1046
FAILURE CODE [AQ10N3]1048
FAILURE CODE [AS00N3]1050
FAILURE CODE [AS00R2]1052
FAILURE CODE [AS00R3]1053
FAILURE CODE [AS00R4]1054
FAILURE CODE [AS00R5]1055
FAILURE CODE [AS00R6]1056
FAILURE CODE [AS00ZK]1057
FAILURE CODE [AS10KM]1058
FAILURE CODE [AS10NR]1059
FAILURE CODE [AS10NT]1060
FAILURE CODE [B@BAZG]1061
FAILURE CODE [B@BCNS]1062
FAILURE CODE [B@CRNS]1063
FAILURE CODE [B@CRZG]1064
FAILURE CODE [CA115]1065
FAILURE CODE [CA122]1066
FAILURE CODE [CA123]1068
FAILURE CODE [CA131]1070
FAILURE CODE [CA132]1072
FAILURE CODE [CA144]1074
FAILURE CODE [CA145]1076
FAILURE CODE [CA153]1078
FAILURE CODE [CA154]1081
FAILURE CODE [CA187]1083
FAILURE CODE [CA221]1085
FAILURE CODE [CA222]1087
FAILURE CODE [CA227]1089
FAILURE CODE [CA234]1090
FAILURE CODE [CA238]1091
FAILURE CODE [CA239]1093
FAILURE CODE [CA249]1095
FAILURE CODE [CA256]1097
FAILURE CODE [CA271]1099
FAILURE CODE [CA272]1101
FAILURE CODE [CA322]1103
FAILURE CODE [CA323]1105
FAILURE CODE [CA324]1107
FAILURE CODE [CA325]1109
FAILURE CODE [CA331]1111
FAILURE CODE [CA332]1113
FAILURE CODE [CA343]1115
FAILURE CODE [CA351]1116
FAILURE CODE [CA352]1117
FAILURE CODE [CA356]1120
FAILURE CODE [CA357]1122
FAILURE CODE [CA386]1125
FAILURE CODE [CA428]1126
FAILURE CODE [CA429]1128
FAILURE CODE [CA435]1130
FAILURE CODE [CA441]1132
FAILURE CODE [CA442]1134
FAILURE CODE [CA449]1135
FAILURE CODE [CA451]1136
FAILURE CODE [CA452]1138
FAILURE CODE [CA488]1140
FAILURE CODE [CA515]1141
FAILURE CODE [CA516]1143
FAILURE CODE [CA553]1145
FAILURE CODE [CA555]1146
FAILURE CODE [CA556]1147
FAILURE CODE [CA559]1148
FAILURE CODE [CA595]1151
FAILURE CODE [CA687]1152
FAILURE CODE [CA689]1154
FAILURE CODE [CA691]1157
FAILURE CODE [CA692]1159
FAILURE CODE [CA697]1161
FAILURE CODE [CA698]1162
FAILURE CODE [CA731]1163
FAILURE CODE [CA778]1165
FAILURE CODE [CA1117]1170
FAILURE CODE [CA1664]1171
FAILURE CODE [CA1669]1174
FAILURE CODE [CA1673]1175
FAILURE CODE [CA1677]1176
FAILURE CODE [CA1678]1177
FAILURE CODE [CA1682]1178
FAILURE CODE [CA1683]1182
FAILURE CODE [CA1684]1184
FAILURE CODE [CA1686]1186
FAILURE CODE [CA1691]1187
FAILURE CODE [CA1694]1190
FAILURE CODE [CA1695]1193
FAILURE CODE [CA1696]1194
FAILURE CODE [CA1712]1196
FAILURE CODE [CA1713]1199
FAILURE CODE [CA1714]1201
FAILURE CODE [CA1715]1202
FAILURE CODE [CA1776]1203
FAILURE CODE [CA1777]1206
FAILURE CODE [CA1843]1209
FAILURE CODE [CA1844]1211
FAILURE CODE [CA1879]1214
FAILURE CODE [CA1881]1217
FAILURE CODE [CA1883]1219
FAILURE CODE [CA1885]1223
FAILURE CODE [CA1887]1225
FAILURE CODE [CA1921]1227
FAILURE CODE [CA1922]1230
FAILURE CODE [CA1942]1235
FAILURE CODE [CA1993]1236
FAILURE CODE [CA2185]1239
FAILURE CODE [CA2186]1241
FAILURE CODE [CA2249]1243
FAILURE CODE [CA2271]1244
FAILURE CODE [CA2272]1247
FAILURE CODE [CA2288]1250
FAILURE CODE [CA2311]1251
FAILURE CODE [CA2349]1252
FAILURE CODE [CA2353]1255
FAILURE CODE [CA2357]1257
FAILURE CODE [CA2381]1258
FAILURE CODE [CA2382]1261
FAILURE CODE [CA2383]1264
FAILURE CODE [CA2386]1267
FAILURE CODE [CA2387]1269
FAILURE CODE [CA2555]1270
FAILURE CODE [CA2556]1273
FAILURE CODE [CA2637]1276
FAILURE CODE [CA2639]1278
FAILURE CODE [CA2771]1281
FAILURE CODE [CA2777]1287
FAILURE CODE [CA2976]1290
FAILURE CODE [CA3133]1292
FAILURE CODE [CA3134]1294
FAILURE CODE [CA3135]1296
FAILURE CODE [CA3142]1300
FAILURE CODE [CA3143]1301
FAILURE CODE [CA3144]1302
FAILURE CODE [CA3146]1304
FAILURE CODE [CA3147]1305
FAILURE CODE [CA3148]1306
FAILURE CODE [CA3151]1308
FAILURE CODE [CA3165]1314
FAILURE CODE [CA3229]1316
FAILURE CODE [CA3231]1318
FAILURE CODE [CA3232]1320
FAILURE CODE [CA3235]1324
FAILURE CODE [CA3239]1326
FAILURE CODE [CA3241]1329
FAILURE CODE [CA3242]1332
FAILURE CODE [CA3251]1335
FAILURE CODE [CA3253]1337
FAILURE CODE [CA3254]1340
FAILURE CODE [CA3255]1343
FAILURE CODE [CA3256]1346
FAILURE CODE [CA3311]1348
FAILURE CODE [CA3312]1350
FAILURE CODE [CA3313]1353
FAILURE CODE [CA3314]1354
FAILURE CODE [CA3315]1355
FAILURE CODE [CA3316]1358
FAILURE CODE [CA3317]1359
FAILURE CODE [CA3318]1360
FAILURE CODE [CA3319]1363
FAILURE CODE [CA3321]1364
FAILURE CODE [CA3322]1366
FAILURE CODE [CA3419]1369
FAILURE CODE [CA3421]1371
FAILURE CODE [CA3497]1373
FAILURE CODE [CA3498]1374
FAILURE CODE [CA3543]1375
FAILURE CODE [CA3545]1382
FAILURE CODE [CA3547]1384
FAILURE CODE [CA3558]1385
FAILURE CODE [CA3559]1387
FAILURE CODE [CA3562]1389
FAILURE CODE [CA3563]1391
FAILURE CODE [CA3567]1394
FAILURE CODE [CA3568]1397
FAILURE CODE [CA3571]1403
FAILURE CODE [CA3572]1405
FAILURE CODE [CA3574]1407
FAILURE CODE [CA3575]1410
FAILURE CODE [CA3577]1412
FAILURE CODE [CA3578]1414
FAILURE CODE [CA3582]1416
FAILURE CODE [CA3583]1424
FAILURE CODE [CA3596]1426
FAILURE CODE [CA3649]1429
FAILURE CODE [CA3681]1431
FAILURE CODE [CA3682]1436
FAILURE CODE [CA3713]1442
FAILURE CODE [CA3717]1445
FAILURE CODE [CA3718]1446
FAILURE CODE [CA3725]1447
FAILURE CODE [CA3741]1450
FAILURE CODE [CA3748]1451
FAILURE CODE [CA3751]1453
FAILURE CODE [CA3755]1455
FAILURE CODE [CA3866]1457
FAILURE CODE [CA3867]1461
FAILURE CODE [CA3868]1464
FAILURE CODE [CA3899]1468
FAILURE CODE [CA3911]1470
FAILURE CODE [CA3912]1474
FAILURE CODE [CA3932]1476
FAILURE CODE [CA3933]1478
FAILURE CODE [CA3934]1480
FAILURE CODE [CA3935]1483
FAILURE CODE [CA3936]1485
FAILURE CODE [CA4151]1487
FAILURE CODE [CA4152]1491
FAILURE CODE [CA4155]1495
FAILURE CODE [CA4156]1497
FAILURE CODE [CA4157]1500
FAILURE CODE [CA4158]1502
FAILURE CODE [CA4159]1503
FAILURE CODE [CA4161]1504
FAILURE CODE [CA4162]1507
FAILURE CODE [CA4163]1510
FAILURE CODE [CA4164]1512
FAILURE CODE [CA4165]1514
FAILURE CODE [CA4166]1516
FAILURE CODE [CA4168]1518
FAILURE CODE [CA4169]1521
FAILURE CODE [CA4171]1523
FAILURE CODE [CA4249]1526
FAILURE CODE [CA4251]1528
FAILURE CODE [CA4259]1530
FAILURE CODE [CA4261]1533
FAILURE CODE [CA4277]1536
FAILURE CODE [CA4281]1540
FAILURE CODE [CA4459]1543
FAILURE CODE [CA4461]1546
FAILURE CODE [CA4658]1549
FAILURE CODE [CA4731]1553
FAILURE CODE [CA4732]1554
FAILURE CODE [CA4739]1555
FAILURE CODE [CA4768]1556
FAILURE CODE [CA4769]1558
FAILURE CODE [CA4842]1561
FAILURE CODE [CA4952]1565
FAILURE CODE [CA5115]1567
FAILURE CODE [CA5383]1570
FAILURE CODE [D130KA]1572
FAILURE CODE [D130KB]1575
FAILURE CODE [D130KY]1577
FAILURE CODE [D19JKZ]1579
FAILURE CODE [D811MC]1582
FAILURE CODE [D862KA]1583
FAILURE CODE [D8ALKA]1584
FAILURE CODE [D8ALKB]1586
FAILURE CODE [D8AQKR]1588
FAILURE CODE [D8G1KT]1590
FAILURE CODE [D8G6KT]1591
FAILURE CODE [DAF0MB]1592
FAILURE CODE [DAF8KB]1593
FAILURE CODE [DAF9KQ]1595
FAILURE CODE [DAFGMC]1596
FAILURE CODE [DAFLKA]1597
FAILURE CODE [DAFLKB]1599
FAILURE CODE [DAFQKR]1601
FAILURE CODE [DAJ000]1602
FAILURE CODE [DAJ0KQ]1603
FAILURE CODE [DAJ0KT]1604
FAILURE CODE [DAJ0MC]1605
FAILURE CODE [DAJ1KK]1606
FAILURE CODE [DAJ2KK]1608
FAILURE CODE [DAJ5KK]1610
FAILURE CODE [DAJ6KK]1613
FAILURE CODE [DAJLKA]1615
FAILURE CODE [DAJLKB]1617
FAILURE CODE [DAJPMA]1619
FAILURE CODE [DAJQKR]1620
FAILURE CODE [DAJRKR]1621
FAILURE CODE [DB2QKR]1622
FAILURE CODE [DB2RKR]1627
FAILURE CODE [DBR0KT]1633
FAILURE CODE [DBR0MC]1634
FAILURE CODE [DBR1KK]1635
FAILURE CODE [DBR2KK]1638
FAILURE CODE [DBR5KK]1641
FAILURE CODE [DBRLKA]1643
FAILURE CODE [DBRLKB]1645
FAILURE CODE [DBRPMA]1647
FAILURE CODE [DBRQKR]1648
FAILURE CODE [DBRRKR]1650
FAILURE CODE [DBTSKR]1651
FAILURE CODE [DBUTKA]1654
FAILURE CODE [DD12KA]1655
FAILURE CODE [DD12KB]1657
FAILURE CODE [DD13KA]1659
FAILURE CODE [DD13KB]1661
FAILURE CODE [DD14KA]1663
FAILURE CODE [DD14KB]1665
FAILURE CODE [DDKAKA]1667
FAILURE CODE [DDKAKB]1669
FAILURE CODE [DDKFL4]1671
FAILURE CODE [DDKGL4]1673
FAILURE CODE [DDKHKA]1675
FAILURE CODE [DDKHKB]1677
FAILURE CODE [DDKQKA]1679
FAILURE CODE [DDKQKB]1681
FAILURE CODE [DDKRKA]1683
FAILURE CODE [DDKRKB]1685
FAILURE CODE [DDKSKA]1687
FAILURE CODE [DDKSKB]1689
FAILURE CODE [DDNLKA]1691
FAILURE CODE [DDNLKB]1693
FAILURE CODE [DDP6KA]1695
FAILURE CODE [DDP6KB]1698
FAILURE CODE [DDP6MA]1700
FAILURE CODE [DDU1FS]1702
FAILURE CODE [DDU1KA]1704
FAILURE CODE [DDU1KY]1707
FAILURE CODE [DFA4KX]1709
FAILURE CODE [DFA4KZ]1710
FAILURE CODE [DFA4L8]1711
FAILURE CODE [DFA5KA]1712
FAILURE CODE [DFA5KB]1715
FAILURE CODE [DFA6KA]1718
FAILURE CODE [DFA6KB]1721
FAILURE CODE [DFA7KX]1724
FAILURE CODE [DFA7KZ]1725
FAILURE CODE [DFA7L8]1726
FAILURE CODE [DFA8KA]1727
FAILURE CODE [DFA8KB]1730
FAILURE CODE [DFA9KA]1733
FAILURE CODE [DFA9KB]1736
FAILURE CODE [DGS1KA]1739
FAILURE CODE [DGS1KX]1742
FAILURE CODE [DH21KA]1743
FAILURE CODE [DH21KB]1745
FAILURE CODE [DHA4KA]1747
FAILURE CODE [DHAAMA]1749
FAILURE CODE [DHACMA]1751
FAILURE CODE [DHH7KA]1753
FAILURE CODE [DHH7KB]1756
FAILURE CODE [DHH8KA]1758
FAILURE CODE [DHH8KB]1761
FAILURE CODE [DHH9KA]1763
FAILURE CODE [DHH9KB]1766
FAILURE CODE [DHHAKA]1768
FAILURE CODE [DHHAKB]1771
FAILURE CODE [DK30KA]1773
FAILURE CODE [DK30KB]1776
FAILURE CODE [DK30KX]1778
FAILURE CODE [DK30KZ]1779
FAILURE CODE [DK30L8]1780
FAILURE CODE [DK31KA]1781
FAILURE CODE [DK31KB]1784
FAILURE CODE [DK40KA]1786
FAILURE CODE [DK40KB]1789
FAILURE CODE [DK55KX]1791
FAILURE CODE [DK55KZ]1792
FAILURE CODE [DK55L8]1793
FAILURE CODE [DK56KA]1794
FAILURE CODE [DK56KB]1797
FAILURE CODE [DK57KA]1799
FAILURE CODE [DK57KB]1802
FAILURE CODE [DK80KA]1804
FAILURE CODE [DKS0L8]1807
FAILURE CODE [DKS1KA]1808
FAILURE CODE [DKS1KB]1810
FAILURE CODE [DKS2KA]1812
FAILURE CODE [DKS2KB]1814
FAILURE CODE [DKS3KA]1816
FAILURE CODE [DKS3KB]1818
FAILURE CODE [DKS3MB]1820
FAILURE CODE [DKS4L8]1822
FAILURE CODE [DKS5KA]1823
FAILURE CODE [DKS5KB]1825
FAILURE CODE [DKS6KA]1827
FAILURE CODE [DKS6KB]1829
FAILURE CODE [DKS7MB]1831
FAILURE CODE [DKSCL8]1832
FAILURE CODE [DKSDKA]1833
FAILURE CODE [DKSDKB]1835
FAILURE CODE [DKSEKA]1837
FAILURE CODE [DKSEKB]1839
FAILURE CODE [DKSFMB]1841
FAILURE CODE [DLM0KX]1842
FAILURE CODE [DLM0MA]1843
FAILURE CODE [DLM1KA]1844
FAILURE CODE [DLM1KB]1846
FAILURE CODE [DLM1MA]1848
FAILURE CODE [DLM2KA]1849
FAILURE CODE [DLM2KB]1851
FAILURE CODE [DLM2MA]1853
FAILURE CODE [DLM3KA]1854
FAILURE CODE [DLM3KB]1856
FAILURE CODE [DLM3MB]1858
FAILURE CODE [DN21FS]1859
FAILURE CODE [DR21KX]1861
FAILURE CODE [DR31KX]1862
FAILURE CODE [DV20KB]1863
FAILURE CODE [DW4BKA]1865
FAILURE CODE [DW4BKB]1867
FAILURE CODE [DW4BKY]1869
FAILURE CODE [DW7BKA]1871
FAILURE CODE [DW7BKB]1873
FAILURE CODE [DW7EKA]1875
FAILURE CODE [DW7EKB]1877
FAILURE CODE [DW7EKY]1879
FAILURE CODE [DWN5KA]1881
FAILURE CODE [DWN5KB]1883
FAILURE CODE [DWN5KY]1885
FAILURE CODE [DXA4KA]1887
FAILURE CODE [DXA4KB]1889
FAILURE CODE [DXA4KY]1891
FAILURE CODE [DXA5KA]1893
FAILURE CODE [DXA5KB]1895
FAILURE CODE [DXA5KY]1897
FAILURE CODE [DXA6KA]1899
FAILURE CODE [DXA6KB]1901
FAILURE CODE [DXA6KY]1903
FAILURE CODE [DXA7KA]1905
FAILURE CODE [DXA7KB]1907
FAILURE CODE [DXA7KY]1909
FAILURE CODE [DXHRKA]1911
FAILURE CODE [DXHRKB]1913
FAILURE CODE [DXHRKY]1915
FAILURE CODE [DXHSKA]1917
FAILURE CODE [DXHSKB]1919
FAILURE CODE [DXHSKY]1921
FAILURE CODE [DXHTKA]1923
FAILURE CODE [DXHTKB]1925
FAILURE CODE [DXHTKY]1927
FAILURE CODE [DXHUKA]1929
FAILURE CODE [DXHUKB]1931
FAILURE CODE [DXHUKY]1933
FAILURE CODE [DXJ4KA]1935
FAILURE CODE [DXJ4KB]1937
FAILURE CODE [DXJCKA]1939
FAILURE CODE [DXJCKB]1941
FAILURE CODE [DXJCKY]1943
FAILURE CODE [DXJDKA]1945
FAILURE CODE [DXJDKB]1947
FAILURE CODE [DXJDKY]1949
FAILURE CODE [DXK1KA]1951
FAILURE CODE [DXK1KB]1953
FAILURE CODE [DXK1KY]1955
FAILURE CODE [DXK2KA]1957
FAILURE CODE [DXK2KB]1959
FAILURE CODE [DXK2KY]1961
FAILURE CODE [F313KA]1963
FAILURE CODE [F313KB]1964
FAILURE CODE [F318KB]1965
FAILURE CODE [F318KY]1966
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1967
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1967
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1974
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1977
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1979
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1981
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP1985
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1986
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1987
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1988
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1989
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1990
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1991
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1992
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE1993
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1994
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE1997
E-17 OPERATION MODE DOES NOT CHANGE1998
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN1999
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE2000
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION2001
E-21 SERVICE MODE CANNOT BE SELECTED2002
E-22 WORK EQUIPMENT DOES NOT OPERATE2003
E-23 FOOT HEATER DOES NOT OPERATE2005
E-24 HORN DOES NOT SOUND2011
E-25 HORN DOES NOT STOP SOUNDING2013
E-26 BACKUP ALARM DOES NOT SOUND2014
E-27 BACKUP ALARM DOES NOT STOP SOUNDING2015
E-28 HEADLAMP DOES NOT LIGHT UP2016
E-29 REAR LAMP DOES NOT LIGHT UP2020
E-30 ALL WIPERS DO NOT OPERATE2023
E-31 FRONT WIPER DOES NOT OPERATE2025
E-32 REAR WIPER DOES NOT OPERATE2027
E-33 LEFT DOOR WIPER DOES NOT OPERATE2029
E-34 RIGHT DOOR WIPER DOES NOT OPERATE2033
E-35 FRONT WASHER DOES NOT OPERATE2037
E-36 REAR WASHER DOES NOT OPERATE2039
E-37 LEFT DOOR WASHER DOES NOT OPERATE2041
E-38 RIGHT DOOR WASHER DOES NOT OPERATE2043
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2045
E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]2046
E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]2050
E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link]2055
E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]2056
E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites]2057
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]2058
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]2060
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal]2061
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble]2062
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize]2063
E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]2064
E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing]2065
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]2066
E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization]2067
E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions]2068
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing]2069
E-56 CONTROL BOX DISPLAYS [Out of design area]2070
E-57 CONTROL BOX CAN NOT BE TURNED ON2071
E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN2072
E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE2073
E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE2074
E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND2075
E-62 CONTROL BOX TOUCH PANEL IS INACCURATE2076
E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT2077
E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)2078
E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED2080
E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED2081
E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)2082
E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE2083
E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)2084
E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH)2085
E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)2086
E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)2088
E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED2089
E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE2090
E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED2092
E-76 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT2094
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2096
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2096
FAILURE MODE AND CAUSE TABLE2097
H-1 NEITHER RH NOR LH OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)2103
H-2 EITHER RH OR LH OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF RH OR LH TRAVEL SYSTEMS CANNOT OPERATE)2105
H-3 EITHER RH OR LH OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)2107
H-4 TRAVEL SPEED OR POWER IS LOW2109
H-5 SPEED RANGE DOES NOT CHANGE2111
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS2112
H-7 MACHINE DEVIATES LARGELY2113
H-8 MACHINE DRIFT ON A SLOPE IS LARGE2116
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2118
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR2120
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH2122
H-12 ALL WORK EQUIPMENT DO NOT OPERATE2124
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW2126
H-14 BLADE LIFT SPEED OR POWER IS LOW2127
H-15 BLADE TILT SPEED OR POWER IS LOW2129
H-16 BLADE ANGLE SPEED OR POWER IS LOW2130
H-17 TIME LAG OF BLADE LIFT IS LARGE2131
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE2132
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE2133
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE2134
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2135
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN2137
TROUBLESHOOTING OF ENGINE (S-MODE)2138
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2138
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2139
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2140
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2141
S-4 ENGINE STARTABILITY IS POOR2143
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2145
S-6 ENGINE STOPS DURING OPERATION2147
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2149
S-8 ENGINE LACKS POWER2150
S-9 KDPF GETS CLOGGED IN A SHORT TIME2152
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2154
S-11 OIL BECOMES CONTAMINATED QUICKLY2155
S-12 FUEL CONSUMPTION IS EXCESSIVE2156
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2157
S-14 OIL PRESSURE DROPS2158
S-15 FUEL MIXES INTO ENGINE OIL2160
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2161
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2162
S-18 UNUSUAL NOISE IS HEARD2163
S-19 VIBRATION IS EXCESSIVE2164
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2165
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2166
S-22 ACTIVE REGENERATION TAKES TIME2168
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2169
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2170
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2172
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2173
50 DISASSEMBLY AND ASSEMBLY2175
CONTENTS2176
ABBREVIATION LIST2181
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2187
HOW TO READ THIS MANUAL2187
COATING MATERIALS LIST2189
SPECIAL TOOLS LIST2193
SKETCHES OF SPECIAL TOOLS2214
ENGINE AND COOLING SYSTEM2227
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2227
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2228
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2233
REMOVE AND INSTALL INJECTOR ASSEMBLY2240
METHOD FOR REMOVING INJECTOR ASSEMBLY2240
METHOD FOR INSTALLING INJECTOR ASSEMBLY2247
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2257
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2257
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2269
REMOVE AND INSTALL EGR VALVE ASSEMBLY2287
METHOD FOR REMOVING EGR VALVE ASSEMBLY2287
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2288
REMOVE AND INSTALL EGR COOLER ASSEMBLY2290
METHOD FOR REMOVING EGR COOLER ASSEMBLY2290
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2292
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2295
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2295
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2297
REMOVE AND INSTALL ALTERNATOR BELT2299
METHOD FOR REMOVING ALTERNATOR BELT2299
METHOD FOR INSTALLING ALTERNATOR BELT2300
REMOVE AND INSTALL AUTOMATIC TENSIONER2302
METHOD FOR REMOVING AUTOMATIC TENSIONER2302
METHOD FOR INSTALLING AUTOMATIC TENSIONER2302
REMOVE AND INSTALL RADIATOR ASSEMBLY2303
METHOD FOR REMOVING RADIATOR ASSEMBLY2303
METHOD FOR INSTALLING RADIATOR ASSEMBLY2306
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2310
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2310
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2313
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2316
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2316
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2319
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY2323
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY2323
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY2326
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY2330
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY2330
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY2333
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY2337
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY2337
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY2346
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2357
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2357
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2358
REMOVE AND INSTALL ENGINE REAR OIL SEAL2360
METHOD FOR REMOVING ENGINE REAR OIL SEAL2360
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2362
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2365
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2365
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2368
REMOVE AND INSTALL FUEL TANK ASSEMBLY2372
METHOD FOR REMOVING FUEL TANK ASSEMBLY2372
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2378
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2384
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2384
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2390
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2396
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2396
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2397
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2400
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2400
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2401
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2408
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2408
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2409
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2410
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2410
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2411
REMOVE AND INSTALL KDPF ASSEMBLY2414
METHOD FOR REMOVING KDPF ASSEMBLY2415
METHOD FOR INSTALLING KDPF ASSEMBLY2418
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2421
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2421
METHOD FOR ASSEMBLING KDPF ASSEMBLY2424
REMOVE AND INSTALL SCR ASSEMBLY2431
METHOD FOR REMOVING SCR ASSEMBLY2431
METHOD FOR INSTALLING SCR ASSEMBLY2433
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2437
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2438
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2444
REMOVE AND INSTALL KCCV ASSEMBLY2451
METHOD FOR REMOVING KCCV ASSEMBLY2451
METHOD FOR INSTALLING KCCV ASSEMBLY2453
REMOVE AND INSTALL VGT ASSEMBLY2455
METHOD FOR REMOVING VGT ASSEMBLY2455
METHOD FOR INSTALLING VGT ASSEMBLY2457
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2460
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2461
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2463
REMOVE AND INSTALL AdBlue/DEF INJECTOR2467
METHOD FOR REMOVING AdBlue/DEF INJECTOR2467
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2470
REMOVE AND INSTALL AdBlue/DEF PUMP2474
METHOD FOR REMOVING AdBlue/DEF PUMP2474
METHOD FOR INSTALLING AdBlue/DEF PUMP2477
REMOVE AND INSTALL AdBlue/DEF HOSE2480
METHOD FOR REMOVING AdBlue/DEF HOSE2480
METHOD FOR INSTALLING AdBlue/DEF HOSE2484
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2490
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2490
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2492
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2495
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2495
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2496
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2498
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2498
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2502
POWER TRAIN2506
REMOVE AND INSTALL DAMPER ASSEMBLY2506
METHOD FOR REMOVING DAMPER ASSEMBLY2506
METHOD FOR INSTALLING DAMPER ASSEMBLY2507
REMOVE AND INSTALL HST PUMP ASSEMBLY2509
METHOD FOR REMOVING HST PUMP ASSEMBLY2509
METHOD FOR INSTALLING HST PUMP ASSEMBLY2511
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY2513
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY2513
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY2516
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2519
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2520
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2525
UNDERCARRIAGE AND FRAME2534
REMOVE AND INSTALL TRACK FRAME ASSEMBLY2534
METHOD FOR REMOVING TRACK FRAME ASSEMBLY2534
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY2538
REMOVE AND INSTALL IDLER ASSEMBLY2543
METHOD FOR REMOVING IDLER ASSEMBLY2543
METHOD FOR INSTALLING IDLER ASSEMBLY2545
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2547
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2547
METHOD FOR ASSEMBLING IDLER ASSEMBLY2549
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY2554
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY2554
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY2555
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY2556
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY2556
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY2559
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY2562
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY2562
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY2563
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2566
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2566
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2568
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY2572
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY2572
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY2573
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2575
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2575
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2576
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY2579
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY2579
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY2580
SEPARATE AND CONNECT TRACK ASSEMBLY2582
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY2582
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)2583
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)2584
METHOD FOR CONNECTING TRACK ASSEMBLY2585
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY2587
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY2587
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY2587
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY2589
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY2589
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY2594
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY2607
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY2608
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY2609
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2624
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2625
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2626
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2633
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2634
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2636
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY2640
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY2640
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY2642
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS2645
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS2645
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS2645
REMOVE AND INSTALL SEGMENT TEETH2647
METHOD FOR REMOVING SEGMENT TEETH2647
METHOD FOR INSTALLING SEGMENT TEETH2648
HYDRAULIC SYSTEM2649
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2649
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2650
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2654
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2659
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2659
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2664
WORK EQUIPMENT2669
REMOVE AND INSTALL BLADE ASSEMBLY2669
METHOD FOR REMOVING BLADE ASSEMBLY2669
METHOD FOR INSTALLING BLADE ASSEMBLY2671
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2675
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2675
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2679
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2682
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2682
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2684
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2687
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2688
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2692
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2700
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2700
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2703
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2708
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2709
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2712
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2717
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2717
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2720
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2723
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2724
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2727
REMOVE AND INSTALL U-FRAME ASSEMBLY2733
METHOD FOR REMOVING U-FRAME ASSEMBLY2733
METHOD FOR INSTALLING U-FRAME ASSEMBLY2736
CAB AND ITS ATTACHMENTS2739
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2739
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2739
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2747
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2755
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)2757
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)2757
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2763
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2763
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2769
REMOVE AND INSTALL OPERATOR’S SEAT2776
METHOD FOR REMOVING OPERATOR’S SEAT2776
METHOD FOR INSTALLING OPERATOR’S SEAT2777
REMOVE AND INSTALL SEAT BELT2778
METHOD FOR REMOVING SEAT BELT2778
METHOD FOR INSTALLING SEAT BELT2778
REMOVE AND INSTALL FOOT HEATER ASSEMBLY2780
METHOD FOR REMOVING FOOT HEATER ASSEMBLY2780
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY2782
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY2785
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY2785
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY2786
ELECTRICAL SYSTEM2787
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2787
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2787
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2789
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY2792
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2792
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2793
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2794
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2794
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2795
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2797
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2797
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2799
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2800
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2800
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2802
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2804
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2804
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2805
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2807
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2807
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2808
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY2809
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY2809
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY2809
REMOVE AND INSTALL CONTROL BOX2811
METHOD FOR REMOVING CONTROL BOX (FOR OLD CONTROL BOX)2811
METHOD FOR REMOVING CONTROL BOX (FOR NEW CONTROL BOX)2812
METHOD FOR INSTALLING CONTROL BOX (FOR OLD CONTROL BOX)2812
METHOD FOR INSTALLING CONTROL BOX (FOR NEW CONTROL BOX)2813
REMOVE AND INSTALL GNSS RECEIVER2815
METHOD FOR REMOVING GNSS RECEIVER2815
METHOD FOR INSTALLING GNSS RECEIVER2815
REMOVE AND INSTALL GNSS ANTENNA2817
METHOD FOR REMOVING GNSS ANTENNA2817
METHOD FOR INSTALLING GNSS ANTENNA2818
REMOVE AND INSTALL IMU SENSOR2823
METHOD FOR REMOVING IMU SENSOR2823
METHOD FOR INSTALLING IMU SENSOR2825
60 MAINTENANCE STANDARD2829
CONTENTS2830
ABBREVIATION LIST2832
ENGINE AND COOLING SYSTEM2838
MAINTENANCE STANDARD OF ENGINE MOUNT2838
MAINTENANCE STANDARD OF DAMPER2839
MAINTENANCE STANDARD OF COOLING SYSTEM2840
MAINTENANCE STANDARD OF COOLING FAN MOTOR2842
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP2844
POWER TRAIN2845
MAINTENANCE STANDARD OF HST PUMP2845
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP2846
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP2847
MAINTENANCE STANDARD OF HST CHARGE PUMP2848
MAINTENANCE STANDARD OF HST MOTOR2850
MAINTENANCE STANDARD OF FINAL DRIVE2851
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE2853
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE2854
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE2856
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE2857
UNDERCARRIAGE AND FRAME2859
MAINTENANCE STANDARD OF SUSPENSION2859
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2861
MAINTENANCE STANDARD OF IDLER2863
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE)2865
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE)2866
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)2867
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)2868
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE2869
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE2870
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE2871
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE2873
MAINTENANCE STANDARD OF SINGLE SHOE2875
MAINTENANCE STANDARD OF SWAMP SHOE2876
HYDRAULIC SYSTEM2877
MAINTENANCE STANDARD OF HYDRAULIC TANK2877
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP2878
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP2879
MAINTENANCE STANDARD OF CONTROL VALVE2881
MAINTENANCE STANDARD OF RIPPER PPC VALVE2888
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID2890
MAINTENANCE STANDARD OF EPC VALVE2891
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE2892
MAINTENANCE STANDARD OF QUICK DROP VALVE2893
WORK EQUIPMENT2895
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT2895
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT2898
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER2899
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER2900
MAINTENANCE STANDARD OF BLADE TILT CYLINDER2901
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER2902
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER2903
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER2904
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER2905
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER2906
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER2907
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER2908
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER2910
CAB AND ITS ATTACHMENTS2911
MAINTENANCE STANDARD OF CAB MOUNT2911
ELECTRICAL SYSTEM2912
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER2912
80 APPENDIX2913
CONTENTS2914
ABBREVIATION LIST2915
AIR CONDITIONER SYSTEM2921
PRECAUTIONS FOR REFRIGERANT2921
AIR CONDITIONER COMPONENT2922
SPECIFICATIONS OF AIR CONDITIONER2925
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2926
OUTLINE OF REFRIGERATION CYCLE2927
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2929
AIR CONDITIONER UNIT2929
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2929
FUNCTION OF AIR CONDITIONER UNIT2930
COMPONENT PARTS OF AIR CONDITIONER UNIT2931
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2931
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2931
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT2931
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2932
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2932
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2932
FUNCTION OF DUAL PRESSURE SWITCH2933
FUNCTION OF PRESSURE SWITCH2933
COMPRESSOR2934
STRUCTURE OF COMPRESSOR2934
SPECIFICATIONS OF COMPRESSOR2934
FUNCTION OF COMPRESSOR2934
CONDENSER2935
STRUCTURE OF CONDENSER2935
SPECIFICATIONS OF CONDENSER2935
FUNCTION OF CONDENSER2936
RECEIVER DRIER2937
STRUCTURE OF RECEIVER DRIER2937
SPECIFICATIONS OF RECEIVER DRIER2937
FUNCTION OF RECEIVER DRIER2937
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2939
CIRCUIT DIAGRAM OF AIR CONDITIONER2942
AIR CONDITIONER SYSTEM DIAGRAM2943
CONTROL FUNCTION OF AIR CONDITIONER2944
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2945
TEST RELAYS2949
METHOD FOR TESTING RELAYS2949
AIR CONDITIONER TROUBLESHOOTING CHART 12951
AIR CONDITIONER TROUBLESHOOTING CHART 22952
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2955
A-1 TROUBLESHOOTING FOR CONDENSER FAN2957
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2960
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2964
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION2967
TROUBLESHOOTING USING GAUGE PRESSURE2971
CONNECTION OF SERVICE TOOL2973
METHOD FOR CONNECTING SERVICE TOOL2973
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2974
HANDLE COMPRESSOR OIL2976
90 CIRCUIT DIAGRAMS2979
CONTENTS2980
ABBREVIATION LIST2981
HYDRAULIC CIRCUIT DIAGRAM2987
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2987
HYDRAULIC CIRCUIT DIAGRAM2991
ELECTRICAL CIRCUIT DIAGRAM2993
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2993
ELECTRICAL CIRCUIT DIAGRAM (1/16)2997
ELECTRICAL CIRCUIT DIAGRAM (2/16)2999
ELECTRICAL CIRCUIT DIAGRAM (3/16)3001
ELECTRICAL CIRCUIT DIAGRAM (4/16)3003
ELECTRICAL CIRCUIT DIAGRAM (5/16)3005
ELECTRICAL CIRCUIT DIAGRAM (6/16)3007
ELECTRICAL CIRCUIT DIAGRAM (7/16)3009
ELECTRICAL CIRCUIT DIAGRAM (8/16)3011
ELECTRICAL CIRCUIT DIAGRAM (9/16)3013
ELECTRICAL CIRCUIT DIAGRAM (10/16)3015
ELECTRICAL CIRCUIT DIAGRAM (11/16)3017
ELECTRICAL CIRCUIT DIAGRAM (12/16)3019
ELECTRICAL CIRCUIT DIAGRAM (13/16)3021
ELECTRICAL CIRCUIT DIAGRAM (14/16)3023
ELECTRICAL CIRCUIT DIAGRAM (15/16)3025
ELECTRICAL CIRCUIT DIAGRAM (16/16)3027
INDEX3029

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24