Komatsu D275A-6 Bulldozer Shop Manual SEN06879-04 PDF

Description

Komatsu D275A-6 Bulldozer Shop Manual SEN06879-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D275A-6 Bulldozer Shop Manual SEN06879-04 – PDF DOWNLOAD 

Language : English
Pages : 1928
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D275A-6 Bulldozer Shop Manual SEN06879-04 – PDF DOWNLOAD 

Foreword, Safety, Basic Information
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.

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.

TABLE OF CONTENTS:

Komatsu D275A-6 Bulldozer Shop Manual SEN06879-04 – PDF DOWNLOAD 

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 16
Foreword, Safety, Basic Information 22
How to Read the Shop Manual 22
Safety Notice for Operation 24
Precautions to Prevent Fire 32
Procedures If Fire Occurs 34
Precautions When You Discard Waste Materials 35
Precautions When You Handle Hydraulic Equipment 36
Precautions When You Disconnect and Connect Pipings 39
Precautions When You Handle Electrical Equipment 45
Precautions When You Handle Fuel System Equipment 47
Precautions When You Handle Intake System Equipment 48
Practical Use of KOMTRAX 49
Disconnect and Connect Push-Pull Type Coupler 50
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 50
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 51
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 52
Precautions for Disconnection and Connection of Connectors 54
How to Disconnect and Connect Deutsch Connector 58
How to Disconnect and Connect Slide Lock Type Connector 59
How to Disconnect and Connect Connector with Lock to Pull 61
How to Disconnect and Connect Connector with Lock to Push 62
How to Disconnect and Connect Connector with Housing to Rotate 64
How to Read the Codes for Electric Cable 65
Explanation of Terms for Maintenance Standard 69
Standard Tightening Torque Table 72
Conversion Table 79
01 Specifications 85
Table of Contents 86
Specifications 87
Specification Drawing 87
Specification Drawing: D275A-6 87
Specifications 89
Specification: D275A-6 89
Weight Table 95
Weight Table: D275A-6 95
Fuel, Coolant, Lubricant 97
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 97
10 Structure and Function 99
Table of Contents 100
Boot-up System 102
Battery Disconnect Switch 102
Layout Drawing of Battery Disconnect Switch 102
Function of Battery Disconnect Switch 102
Engine System 104
Layout Drawing of Engine System 104
Engine Control System 106
Layout Drawing of Engine Control System 106
System Diagram of Engine Control 107
Function of Engine Control System 107
Component Parts of Engine System 108
Damper 108
Turbocharger 110
EGR System 111
EGR Valve 114
EGR Cooler 116
CRI System 117
Cooling System 121
Layout Drawing of Cooling System 121
Specifications of Cooling System 122
Component Parts of Cooling System 123
Cooling Fan Pump 123
Cooling Fan Motor 131
Control System 138
Layout Drawing of Control System 138
Machine Monitor System 139
System Diagram of Machine Monitor System 139
Function of Machine Monitor System 139
Component Parts of Control System 142
Machine Monitor 142
KOMTRAX Terminal 155
Electric Heater Control 157
Preheating System 157
External Power Supply Engine Preheater 158
Combustion-Type Preheater 164
Power Train Controller 167
Engine Controller 171
Hydraulic System 176
Layout Drawing of Hydraulic System 176
CLSS 177
Structure of CLSS 177
Function of CLSS 178
Component Parts of Hydraulic System 180
Hydraulic Tank 180
Work Equipment Pump 181
LS Valve 189
Variable Throttle Valve 193
Transmission Lubrication Pump and Power Train Pump 196
Control Valve 197
Power Train System 213
Layout Drawing of Power Train System 213
Operation of Power Train System 215
Transmission, Steering, and Brake Control 216
Layout Drawing of Transmission, Steering, and Brake Control System 216
Function of Transmission, Steering, and Brake Control System 217
Palm Command Control System 219
Palm Command Control System Diagram 219
Centralized Pressure Pickup Port 222
Layout Drawing of Centralized Pressure Pickup Port 222
Function of Centralized Pressure Pickup Port 222
Component Parts of Power Train System 223
Universal Joint 223
Power Train Mount 224
Torque Converter and PTO 224
Transmission 228
Transmission ECMV 239
Main Relief Valve and Torque Converter Relief Valve 245
Transmission Lubrication Relief Valve 247
Bevel Gear, Steering Clutch, and Brake 248
Steering Control Valve 255
Steering Clutch ECMV 256
Brake 257
Final Drive 266
Scavenging Pump 269
PCCS Lever 269
PPC Lock Valve 273
Work Equipment System 274
Work Equipment Control 274
Layout Drawing of Work Equipment Control 274
Layout Drawing of Front Work Equipment 275
Layout Drawing of Variable Giant Ripper 276
Layout Drawing of Variable Multi-Shank Ripper 277
Shoe Slip Control System 278
Function of Shoes Slip Control System 278
Component Parts of Work Equipment System 279
Self-Pressure Reducing Valve 279
Pilot Circuit Accumulator 284
Quick Drop Valve 285
Piston Valve 286
PPC Valve 287
Pin Puller Switch 296
Undercarriage and Frame 297
Main Frame 297
Structure of Main Frame 297
Suspension 299
Structure of Suspension 299
Function of Suspension 301
Track Frame and Idler Cushion 302
Structure of Track Frame and Idler Cushion 302
Specifications of Track Frame and Idler Cushion 303
Function of Track Frame and Idler Cushion 303
Work Equipment 304
Structure of Front Work Equipment 304
Structure of Cylinder Stay 306
Structure of Variable Giant Ripper 307
Structure of Variable Multi-Shank Ripper 308
CAB Related Parts 309
ROPS 309
Structure of ROPS 309
Function of ROPS 309
CAB 310
Structure of CAB 310
CAB Mount 311
Structure of CAB Mount 311
20 Standard Value Table 313
Table of Contents 314
Standard Value Table for Engine 315
Standard Value Table for Engine: D275A-6 315
Standard Value Table for Machine 321
Standard Value Table for Machine: D275A-6 321
Machine Posture and Procedures to Measure Performance 343
30 Testing and Adjusting 347
Table of Contents 348
Related Information on Testing and Adjusting 351
Tools for Testing and Adjusting 351
Sketch of Tools for Testing and Adjusting 356
Engine and Cooling System 358
Examine Engine Speed 358
How to Examine Engine Speed 358
Examine Boost Pressure 363
How to Examine Boost Pressure on Machine Monitor 363
How to Examine Boost Pressure by Testing Tool 364
Examine Exhaust Gas Temperature 366
How to Examine Exhaust Temperature by Testing Tools 366
Examine Exhaust Gas Color 370
How to Examine Exhaust Gas Color with the Handy Smoke Checker 370
How to Examine Exhaust Gas Color with Smoke Meter 370
Examine and Adjust Valve Clearance 372
How to Examine and Adjust Valve Clearance 372
Examine Compression Pressure 374
How to Examine Compression Pressure 374
Examine Blowby Pressure 378
How to Examine Blowby Pressure 378
Examine Engine Oil Pressure 380
How to Examine Engine Oil Pressure on Machine Monitor 380
How to Examine Engine Oil Pressure by Testing Tool 381
Examine EGR Valve and VGT Oil Pressure 382
How to Examine EGR Valve and VGT Oil Pressure 382
Examine Fuel Pressure 384
How to Examine Fuel Pressure 384
Examine Fuel Return Rate and Leakage 386
How to Examine Fuel Return Rate and Leakage 387
Bleed Air from Fuel System 391
How to Bleed Air from Fuel System 391
Examine Fuel Circuit for Leakage 393
How to Examine Fuel System for Leakage 393
Handle Cylinder Cut-out Mode Operation 395
Handle No-Injection Cranking Operation 396
Examine and Adjust Alternator Belt Tension 397
How to Examine Alternator Belt Tension 397
How to Adjust Alternator Belt Tension 397
Examine and Adjust Air Conditioner Compressor Belt Tension 399
How to Examine Air Conditioner Compressor Belt Tension 399
How to Adjust Air Conditioner Compressor Belt Tension 399
Adjust Decelerator Pedal 400
How to Adjust Decelerator Pedal 400
Power Train 402
Examine Power Train Oil Pressure 402
How to Examine Power Train Oil Pressure 403
Adjust Transmission Output Shaft Speed Sensor 419
How to Adjust Transmission Output Shaft Speed Sensor 419
Examine Brake Performance Simply 421
How to Examine Brake Performance Simply 421
Examine and Adjust Brake Pedal 422
How to Examine Brake Pedal 422
How to Adjust Brake Pedal 422
Adjust Parking Brake Lever 425
How to Adjust Parking Brake Lever 425
Release Parking Brake and Move Machine 427
Release Parking Brake and Move Machine (Hydraulic Type) 427
Release Parking Brake and Move Machine (Electric Type) 428
Adjust PCCS Lever Console Position 430
How to Adjust PCCS Lever Console Position 430
Undercarriage and Frame 432
Examine and Adjust Track Tension 432
How to Examine Track Tension 432
How to Adjust Track Tension 432
Hydraulic System 434
Release Remained Pressure in Hydraulic Circuit 434
How to Release Remained Pressure in Hydraulic System 434
Examine and Adjust Work Equipment Oil Pressure 435
How to Examine Work Equipment Oil Pressure 435
How to Adjust Work Equipment Oil Pressure 437
Examine Oil Pressure of Control Circuit 438
How to Examine Oil Pressure in Control Circuit 438
Examine PPC Valve Outlet Pressure 440
How to Examine PPC Valve Outlet Pressure 440
Adjust Play of PPC Valve 443
How to Adjust Play of PPC Valve 443
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 446
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 446
Examine Cooling Fan Speed 448
How to Examine Cooling Fan Speed 448
Examine Cooling Fan Circuit Oil Pressure 449
How to Examine Cooling Fan Circuit Oil Pressure 449
Bleed Air in Cooling Fan Pump 451
How to Bleed Air in Cooling Fan Pump 451
Examine Parts Which Cause Hydraulic Drift of Work Equipment 452
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 452
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 452
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 453
Examine Oil Leakage from Work Equipment Cylinder 454
How to Examine Internal Oil Leakage of Work Equipment Cylinder 454
Bleed Air from Work Equipment Cylinders 456
How to Bleed Air from Work Equipment Cylinder 456
Adjust Ripper Control Lever Position 457
How to Adjust Ripper Control Lever Position 457
Work Equipment 458
Adjust Work Equipment Lock Lever 458
How to Adjust Work Equipment Lock Lever 458
Adjust Blade 459
How to Adjust Blade 459
CAB Related Parts 461
Examine and Adjust Operator Cab 461
How to Examine Operator Cab 461
How to Adjust Operator Cab 465
Adjust Play of Operator Seat 468
How to Adjust Play of Operator Seat 468
Electrical System 469
Set and Operate Machine Monitor 469
Operator Mode 472
Function to Show Technician Identification Status Screen 472
Function to Show Operator Identification Input Screen 472
Examine Function by LCD (Liquid Crystal Display) 473
Examine Function of Service Meter 473
How to Set Usage Limitation and Change Maintenance Password 473
Service Mode 476
How to Operate Service Mode 476
How to See Pre-defined Monitoring Information 477
How to Examine Self-Define Monitor Information 480
Abnormality Record Menu 487
How to See Maintenance Record 492
Maintenance Mode Setting 494
How to Set Phone Number Entry 497
Default Menu 498
Diagnostic Tests Menu 501
Adjustment Menu 504
KOMTRAX Settings Menu 535
How to Show Service Message 538
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 540
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 545
Handle Voltage Circuit of Engine Controller 547
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 548
Examine Diodes 549
How to Examine Diodes by Digital Tester 549
How to Examine Diodes by Analog Tester 549
Pm Clinic 550
Pm Clinic Service 550
Pm Clinic Check Sheet: D275A-6 551
Pm Clinic Check Sheet for Undercarriage: D275A-6 571
40 Troubleshooting 577
Table of Contents 578
Related Information to Troubleshooting 584
General Troubleshooting Points 584
Sequence of Events in Troubleshooting 585
Checks Before Troubleshooting 587
Inspection Procedure Before Troubleshooting 589
Walk-Around Check 589
Test in Accordance with Testing Procedure 591
How to Drain Water and Sediment from Fuel Tank 591
How to Examine Water Separator, Drain Water and Sediment 591
How to Examine Additional Water Separator and Drain Water and Sediment 592
Examine Fuel Main Filter 593
How to Examine Oil Level in Hydraulic Tank, Add Oil 595
How to Examine Coolant Level, Add Coolant 596
How to Examine Oil Level in Engine Oil Pan, Add Oil 597
How to Examine Oil Level in Power Train Case, Add Oil 598
How to Examine Dust Indicator 600
How to Examine Brake Operation 600
How to Examine Electric Wiring 600
How to Examine Fuel Level, Add Fuel 601
How to Examine Operation of Lamps 601
How to Examine Machine Monitor 602
How to Remove Sediment in Engine Room 602
How to Examine Operation State of Horn 603
How to Examine Operation State of Backup Alarm 603
How to Examine Electric Equipment 604
Preparation for Troubleshooting of Electrical System 609
Preparation for Troubleshooting of Machine Monitor 609
Preparation for Troubleshooting of Engine Controller 609
Preparation for Troubleshooting of Power Train Controller 609
Preparation for Troubleshooting of KOMTRAX Terminal 610
How to Disconnect and Connect Connector with a Special Lock 610
Procedure for Troubleshooting 614
Symptom and Troubleshooting Numbers 617
Information Shown in Troubleshooting Table 620
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 622
Connector List and Layout 625
Connector Contact Connection Table 640
T-Branch Box and T-Branch Adapter Table 680
Fuse Location Table 686
Failure Code Table 690
Troubleshooting by Failure Code (Display of Code) 700
Failure Code [1500L0] 700
Failure Code [15SAL1] 701
Failure Code [15SALH] 703
Failure Code [15SBL1] 705
Failure Code [15SBLH] 707
Failure Code [15SEL1] 709
Failure Code [15SELH] 711
Failure Code [15SFL1] 713
Failure Code [15SFLH] 715
Failure Code [15SGL1] 717
Failure Code [15SGLH] 719
Failure Code [1800MW] 721
Failure Code [2201L1] 722
Failure Code [2201LH] 723
Failure Code [2202L1] 725
Failure Code [2202LH] 727
Failure Code [2300NR] 729
Failure Code [2301L1] 730
Failure Code [2301LH] 732
Failure Code [2301NR] 734
Failure Code [2301NT] 735
Failure Code [2302L1] 736
Failure Code [2302LH] 738
Failure Code [2302NR] 740
Failure Code [2302NT] 741
Failure Code [989L00] 742
Failure Code [989M00] 743
Failure Code [989N00] 744
Failure Code [AA10NX] 745
Failure Code [AB00KE] 747
Failure Code [B@BAZG] 749
Failure Code [B@BCNS] 750
Failure Code [B@BCQA] 751
Failure Code [B@BCZK] 753
Failure Code [B@CENS] 755
Failure Code [B@HANS] 757
Failure Code [CA111] 759
Failure Code [CA115] 760
Failure Code [CA122] 762
Failure Code [CA123] 764
Failure Code [CA131] 765
Failure Code [CA132] 767
Failure Code [CA135] 768
Failure Code [CA141] 770
Failure Code [CA144] 771
Failure Code [CA145] 773
Failure Code [CA153] 774
Failure Code [CA154] 776
Failure Code [CA187] 777
Failure Code [CA221] 778
Failure Code [CA222] 780
Failure Code [CA227] 781
Failure Code [CA234] 783
Failure Code [CA238] 784
Failure Code [CA263] 786
Failure Code [CA265] 788
Failure Code [CA271] 789
Failure Code [CA272] 790
Failure Code [CA273] 791
Failure Code [CA274] 793
Failure Code [CA322] 794
Failure Code [CA323] 796
Failure Code [CA324] 798
Failure Code [CA325] 800
Failure Code [CA331] 802
Failure Code [CA332] 804
Failure Code [CA342] 806
Failure Code [CA351] 807
Failure Code [CA352] 809
Failure Code [CA386] 810
Failure Code [CA441] 812
Failure Code [CA442] 813
Failure Code [CA449] 814
Failure Code [CA451] 815
Failure Code [CA452] 817
Failure Code [CA553] 818
Failure Code [CA554] 819
Failure Code [CA559] 820
Failure Code [CA689] 825
Failure Code [CA731] 827
Failure Code [CA757] 828
Failure Code [CA778] 829
Failure Code [CA1228] 831
Failure Code [CA1625] 832
Failure Code [CA1626] 833
Failure Code [CA1627] 835
Failure Code [CA1628] 836
Failure Code [CA1629] 837
Failure Code [CA1631] 838
Failure Code [CA1632] 840
Failure Code [CA1633] 841
Failure Code [CA1642] 843
Failure Code [CA1653] 844
Failure Code [CA2185] 846
Failure Code [CA2186] 848
Failure Code [CA2249] 849
Failure Code [CA2271] 850
Failure Code [CA2272] 852
Failure Code [CA2351] 853
Failure Code [CA2352] 855
Failure Code [CA2555] 856
Failure Code [CA2556] 857
Failure Code [D130KA] 859
Failure Code [D130KB] 861
Failure Code [D190KA] 863
Failure Code [D190KB] 865
Failure Code [D19JKZ] 867
Failure Code [D811MC] 869
Failure Code [D862KA] 870
Failure Code [D8AQKR] 871
Failure Code [DAF0MB] 872
Failure Code [DAF0MC] 873
Failure Code [DAF9KQ] 874
Failure Code [DAFGMC] 875
Failure Code [DAFQKR] 876
Failure Code [DB2QKR] 880
Failure Code [DBE0KT] 884
Failure Code [DBE0MC] 885
Failure Code [DBE1KK] 886
Failure Code [DBE2KK] 889
Failure Code [DBE5KK] 892
Failure Code [DBE6KK] 894
Failure Code [DBE7KK] 896
Failure Code [DBE9KQ] 898
Failure Code [DBEQKR] 899
Failure Code [DBERKR] 903
Failure Code [DD12KA] 907
Failure Code [DD12KB] 909
Failure Code [DD13KA] 911
Failure Code [DD13KB] 913
Failure Code [DD14KA] 915
Failure Code [DD14KB] 917
Failure Code [DDNLKA] 919
Failure Code [DDNLKB] 921
Failure Code [DGS1KA] 923
Failure Code [DGS1KX] 925
Failure Code [DGT1KA] 927
Failure Code [DGT1KX] 929
Failure Code [DH21KA] 931
Failure Code [DH21KY] 933
Failure Code [DHA4KA] 934
Failure Code [DK10KA] 936
Failure Code [DK10KB] 938
Failure Code [DK30KA] 939
Failure Code [DK30KX] 941
Failure Code [DK30KY] 942
Failure Code [DK30KZ] 944
Failure Code [DK30L8] 945
Failure Code [DK31KA] 947
Failure Code [DK31KY] 949
Failure Code [DK40KA] 951
Failure Code [DK40KY] 953
Failure Code [DK55KX] 955
Failure Code [DK55KZ] 956
Failure Code [DK55L8] 957
Failure Code [DK56KA] 958
Failure Code [DK56KY] 960
Failure Code [DK57KA] 962
Failure Code [DK57KY] 964
Failure Code [DK60KA] 966
Failure Code [DK60KY] 968
Failure Code [DKH1KA] 970
Failure Code [DKH1KB] 972
Failure Code [DLM3KA] 973
Failure Code [DLM3MB] 974
Failure Code [DLT3KA] 975
Failure Code [DLT3KB] 977
Failure Code [DV20KB] 979
Failure Code [DW7BKA] 981
Failure Code [DW7BKB] 983
Failure Code [DWN3KA] 984
Failure Code [DWN3KB] 985
Failure Code [DWN3KY] 986
Failure Code [DWN5KA] 987
Failure Code [DWN5KB] 988
Failure Code [DWN5KY] 989
Failure Code [DXH4KA] 990
Failure Code [DXH4KB] 992
Failure Code [DXH4KY] 994
Failure Code [DXH5KA] 995
Failure Code [DXH5KB] 997
Failure Code [DXH5KY] 999
Failure Code [DXH6KA] 1000
Failure Code [DXH6KB] 1002
Failure Code [DXH6KY] 1004
Failure Code [DXH7KA] 1005
Failure Code [DXH7KB] 1007
Failure Code [DXH7KY] 1009
Failure Code [DXH8KA] 1010
Failure Code [DXH8KB] 1011
Failure Code [DXH8KY] 1012
Failure Code [DXH9KA] 1013
Failure Code [DXH9KB] 1014
Failure Code [DXH9KY] 1015
Failure Code [DXHAKA] 1016
Failure Code [DXHAKB] 1018
Failure Code [DXHAKY] 1020
Failure Code [DXHBKA] 1021
Failure Code [DXHBKB] 1023
Failure Code [DXHBKY] 1025
Failure Code [DXHCKA] 1026
Failure Code [DXHCKB] 1028
Failure Code [DXHCKY] 1030
Troubleshooting of Electrical System (E-Mode) 1031
E-1 Engine Does Not Start (Engine Does Not Crank) 1031
E-2 Manual Preheating System Does Not Operate 1034
E-3 Automatic Preheating System Does Not Operate 1037
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1039
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1041
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1044
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1046
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 1047
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1049
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1050
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 1051
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1052
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1053
E-14 Fuel Gauge Does Not Show Normally 1054
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 1056
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1058
E-17 Operation Mode Does Not Change 1059
E-18 Gear Shift Mode Does Not Change 1060
E-19 Operating Customize Switch Does Not Display Customize Screen 1061
E-20 Modifying Setting on Customize Screen Does Not Change Setting of Machine 1062
E-21 Some Areas of Machine Monitor Screen are Not Shown 1063
E-22 Alarm Buzzer Does Not Sound or Cannot be Stopped 1064
E-23 Service Meter is Not Shown, While Starting Switch is in OFF Position 1065
E-24 Machine Does Not Change to Service Mode 1066
E-25 Horn Does Not Sound 1067
E-26 Horn Does Not Stop 1069
E-27 Backup Alarm Does Not Sound 1070
E-28 Backup Alarm Does Not Stop 1071
E-29 Headlamp Does Not Come On 1072
E-30 Rear Lamp and Ripper Point Lamp Do Not Come On 1076
E-31 No Wiper Operates 1080
E-32 Front Wiper Does Not Operate 1082
E-33 Rear Wiper Does Not Operate 1085
E-34 Left Door Wiper Does Not Operate 1088
E-35 Right Door Wiper Does Not Operate 1091
E-36 Fan Does Not Rotate in Reverse 1094
E-37 Gear Cannot be Shifted 1095
E-38 Front Washer Does Not Operate 1096
E-39 Rear Washer Does Not Operate 1099
E-40 Left Door Washer Does Not Operate 1102
E-41 Right Door Washer Does Not Operate 1105
E-42 Ripper Pin Puller Does Not Work 1108
E-43 KOMTRAX System Does Not Operate Correctly 1110
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1111
Information Shown in Troubleshooting Table (H-Mode) 1111
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 1112
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 1114
H-3 Machine Does Not Move Off at All Gear Speeds 1115
H-4 Machine Travels Only in One Direction, Forward or in Reverse 1117
H-5 Large Time Lag is in Gear Shifting or Directional Change 1119
H-6 Brake Does Not Work 1121
H-7 Power Train Oil Overheats 1122
H-8 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 1123
H-9 Machine Can Turn (Steering) Only in One Direction 1124
H-10 Machine Overturns (Steering) 1125
H-11 All Work Equipment Operate Slowly 1126
H-12 All Work Equipment Do Not Operate 1127
H-13 Blade Lift Speed or Power is Low 1128
H-14 Blade Tilt Speed or Power is Low 1129
H-15 Ripper Lift Speed or Power is Low 1130
H-16 Ripper Tilt Speed is Low or Power is Low 1131
H-17 Hydraulic Drift of Blade Lift is Large 1132
H-18 Hydraulic Drift of Tilted Blade is Large 1133
H-19 Hydraulic Drift of Lifted Ripper is Large 1134
H-20 Ripper Pin Puller Cylinder Does Not Operate (Machine with Giant Ripper) 1135
H-21 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 1136
H-22 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1137
Troubleshooting of Engine (S-Mode) 1138
Information Shown in Troubleshooting Table (S-Mode) 1138
S-1 Engine Does Not Rotate 1142
S-2 Engine Rotates but No Exhaust Gas Comes Out 1144
S-3 Exhaust Gas Comes but Engine Does Not Start 1145
S-4 Engine Startability is Unsatisfactory 1146
S-5 Engine Does Not Pick Up Smoothly 1148
S-6 Engine Stops During Operation 1150
S-7 Engine Runs Rough or is Not Stable 1151
S-8 Engine Lacks Power 1152
S-9 Oil Consumption is Excessive (or Exhaust Gas is Blue) 1154
S-10 Oil Becomes Dirty Quickly 1155
S-11 Fuel Consumption is Excessive 1156
S-12 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1157
S-13 Oil Pressure Drops 1158
S-14 Oil Level Increases (Entry of Coolant or Fuel) 1159
S-15 Coolant Temperature Becomes Too High (Overheating) 1161
S-16 Abnormal Noise is Made 1162
S-17 Vibration is Excessive 1163
S-18 Air Cannot be Bled from Fuel Circuit 1164
50 Disassembly and Assembly 1165
Table of Contents 1166
Abbreviation List 1170
Related Information on Disassembly and Assembly 1176
How to Read This Manual 1176
Coating Materials List 1178
Special Tool List 1183
Sketches of Special Tools 1199
Engine and Cooling System 1226
Remove and Install Supply Pump Assembly 1226
How to Remove Supply Pump Assembly 1226
How to Install Supply Pump Assembly 1229
Remove and Install Injector Assembly 1233
How to Remove Injector Assembly 1233
How to Install Injector Assembly 1235
Remove and Install Cylinder Head Assembly 1239
How to Remove Cylinder Head Assembly 1239
How to Install Cylinder Head Assembly 1248
Remove and Install Common Rail 1262
How to Remove Common Rail 1262
How to Install Common Rail 1263
Remove and Install Radiator Guard Assembly 1266
How to Remove Radiator Guard Assembly 1266
How to Install Radiator Guard Assembly 1271
Remove and Install Radiator Assembly 1277
How to Remove Radiator Assembly 1277
How to Install Radiator Assembly 1281
Remove and Install Radiator Tube 1286
How to Remove Radiator Tube 1286
How to Install Radiator Tube 1288
Remove and Install Hydraulic Oil Cooler Assembly 1290
How to Remove Hydraulic Oil Cooler Assembly 1290
How to Install Hydraulic Oil Cooler Assembly 1293
Remove and Install Aftercooler Assembly 1296
How to Remove Aftercooler Assembly 1296
How to Install Aftercooler Assembly 1298
Remove and Install Fan Drive Assembly 1302
How to Remove Fan Drive Assembly 1302
How to Install Fan Drive Assembly 1303
Remove and Install Fan Motor Assembly 1305
How to Remove Fan Motor Assembly 1305
How to Install Fan Motor Assembly 1306
Remove and Install Engine Assembly 1307
How to Remove Engine Assembly 1307
How to Install Engine Assembly 1312
Remove and Install Engine Front Oil Seal 1320
How to Remove Engine Front Oil Seal 1320
How to Install Engine Front Oil Seal 1321
Remove and Install Engine Rear Oil Seal 1324
How to Remove Engine Rear Oil Seal 1324
How to Install Engine Rear Oil Seal 1325
Remove and Install Engine Hood Assembly 1329
How to Remove Engine Hood Assembly 1329
How to Install Engine Hood Assembly 1331
Remove and Install Fuel Tank Assembly 1333
How to Remove Fuel Tank Assembly 1333
How to Install Fuel Tank Assembly 1335
Remove and Install Air Conditioner Condenser Assembly 1337
How to Remove Air Conditioner Condenser Assembly 1337
How to Install Air Conditioner Condenser Assembly 1339
Power Train 1341
Remove and Install Damper Assembly 1341
How to Remove Damper Assembly 1341
How to Install Damper Assembly 1343
Disassemble and Assemble Damper Assembly 1346
How to Disassemble Damper Assembly 1347
How to Assemble Damper Assembly 1349
Remove and Install Power Train Unit Assembly 1353
How to Remove Power Train Unit Assembly 1353
How to Install Power Train Unit Assembly 1359
Disconnect and Connect Power Train Unit Assembly 1366
How to Disconnect Power Train Unit Assembly 1366
How to Connect Power Train Unit Assembly 1376
Disassemble and Assemble PTO Assembly 1390
How to Disassemble PTO Assembly 1390
How to Assemble PTO Assembly 1394
Disassemble and Assemble Torque Converter Assembly 1400
How to Disassemble Torque Converter Assembly 1400
How to Assemble Torque Converter Assembly 1406
Disassemble and Assemble Torque Flow Transmission Assembly 1414
How to Disassemble Torque Flow Transmission Assembly 1414
How to Assemble Torque Flow Transmission Assembly 1425
Remove and Install Final Drive Assembly 1440
How to Remove Final Drive Assembly 1440
How to Install Final Drive Assembly 1442
Disassemble and Assemble Final Drive Assembly 1444
How to Disassemble Final Drive Assembly 1444
How to Assemble Final Drive Assembly 1451
Disassemble and Assemble HSS Assembly 1462
How to Disassemble HSS Assembly 1462
How to Assemble HSS Assembly 1474
Undercarriage and Frame 1490
Remove and Install Track Frame Assembly 1490
How to Remove Track Frame Assembly 1490
How to Install Track Frame Assembly 1495
Remove and Install Idler Assembly (Applicable Machine: 30001 to 40000) 1500
How to Remove Idler Assembly (Applicable Machine: 30001 to 40000) 1500
How to Install Idler Assembly (Applicable Machine: 30001 to 40000) 1501
Disassemble and Assemble Idler Assembly 1502
How to Disassemble Idler Assembly 1502
How to Assemble Idler Assembly 1503
Remove and Install Idler and Idler Cushion Assembly (Applicable Machine: 30001 to 40000) 1506
How to Remove Idler and Idler Cushion Assembly (Applicable Machine: 30001 to 40000) 1506
How to Install Idler and Idler Cushion Assembly (Applicable Machine: 30001 to 40000) 1511
Remove and Install Recoil Spring Assembly 1515
How to Remove Recoil Spring Assembly 1516
How to Install Recoil Spring Assembly 1524
Disassemble and Assemble Recoil Spring Assembly 1529
How to Disassemble Recoil Spring Assembly 1529
How to Assemble Recoil Spring Assembly 1529
Remove and Install Track Roller Assembly (Applicable Machine: 30001 to 40000) 1531
How to Remove Track Roller Assembly (Applicable Machine: 30001 to 40000) 1531
How to Install Track Roller Assembly (Applicable Machine: 30001 to 40000) 1533
Disassemble and Assemble Track Roller Assembly 1535
How to Disassemble Track Roller Assembly 1535
How to Assemble Track Roller Assembly 1536
Remove and Install No 1 Bogie Assembly (Applicable Machine: 30001 to 40000) 1538
How to Remove No 1 Bogie Assembly (Applicable Machine: 30001 to 40000) 1539
How to Install No 1 Bogie Assembly (Applicable Machines: 30001 to 40000) 1543
Remove and Install No 2, 3, 4 Bogie Assemblies (Applicable Machine: 30001 to 40000) 1547
How to Remove No 2, 3, 4 Bogie Assemblies (Applicable Machine: 30001 to 40000) 1548
How to Install No 2, 3, 4 Bogie Assemblies (Applicable Machines: 30001 to 40000) 1551
Disassemble and Assemble Bogie Assembly 1556
How to Disassemble Bogie Assembly 1556
How to Assemble Bogie Assembly 1557
Remove and Install Carrier Roller Assembly 1560
How to Remove Carrier Roller Assembly 1560
How to Install Carrier Roller Assembly 1560
Disassemble and Assemble Carrier Roller Assembly 1561
How to Disassemble Carrier Roller Assembly 1561
How to Assemble Carrier Roller Assembly 1562
Remove and Install Pivot Shaft Assembly 1565
How to Remove Pivot Shaft Assembly 1565
How to Install Pivot Shaft Assembly 1566
Separate and Connect Track Assembly 1567
How to Separate Track Assembly 1567
How to Install Track Assembly 1570
Disassemble and Assemble Track Assembly Generally 1572
How to Disassemble Full Track Shoe Assembly 1575
How to Assemble Full Track Shoe Assembly 1578
Remove and Install Equalizer Bar Assembly 1599
How to Remove Equalizer Bar Assembly 1599
How to Install Equalizer Bar Assembly 1601
Disassemble and Assemble Equalizer Bar Bushing 1604
How to Disassemble Equalizer Bar Bushing 1604
How to Assemble Equalizer Bar Bushing 1605
Hydraulic System 1606
Remove and Install Work Equipment Pump and HSS Pump Assembly 1606
How to Remove Work Equipment Pump and HSS Pump Assembly 1606
How to Install Work Equipment Pump and HSS Pump Assembly 1608
Remove and Install Work Equipment and HSS Charge Pump Assembly 1611
How to Remove Work Equipment and HSS Charge Pump Assembly 1611
How to Install Work Equipment and HSS Charge Pump Assembly 1613
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 1616
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 1616
How to Install Power Train Pump and Steering Lubrication Pump Assembly 1618
Remove and Install HSS Motor Assembly 1621
How to Remove HSS Motor Assembly 1621
How to Install HSS Motor Assembly 1622
Remove and Install Cooling Fan Pump Assembly 1623
How to Remove Cooling Fan Pump Assembly 1623
How to Install Cooling Fan Pump Assembly 1625
Remove and Install Control Valve Assembly 1628
How to Remove Control Valve Assembly 1629
How to Install Control Valve Assembly 1632
Disassemble and Assemble Control Valve Assembly 1637
How to Disassemble Control Valve Assembly 1637
How to Assemble Control Valve Assembly 1637
Disassemble and Assemble Hydraulic Cylinder Assembly 1638
How to Disassemble Hydraulic Cylinder Assembly 1638
How to Assemble Hydraulic Cylinder Assembly 1642
Remove and Install Scavenging Pump Assembly 1648
How to Remove Scavenging Pump Assembly 1648
How to Install Scavenging Pump Assembly 1648
Work Equipment 1650
Remove and Install Ripper Assembly 1650
How to Remove Ripper Assembly 1652
How to Install Ripper Assembly 1664
Remove and Install Blade Assembly 1676
How to Remove Blade Assembly 1676
How to Install Blade Assembly 1678
CAB Related Parts 1681
Remove and Install ROPS Guard 1681
How to Remove ROPS Guard 1681
How to Install ROPS Guard 1681
Remove and Install Operator Cab Assembly 1683
How to Remove Operator Cab Assembly 1683
How to Install Operator Cab Assembly 1687
Remove and Install Operator Cab Glass (Adhered Glass) 1691
How to Remove Operator Cab Glass (Adhered Glass) 1692
How to Install Operator Cab Glass (Adhered Glass) 1693
Remove and Install Floor Frame Assembly 1703
How to Remove Floor Frame Assembly 1703
How to Install Floor Frame Assembly 1708
Disassemble and Assemble Seismic Isolation Device for Operator Seat 1715
How to Disassemble Seismic Isolation Operator Seat 1715
How to Assemble Seismic Isolation Device for Operator Seat 1718
Remove and Install Air Conditioner Unit Assembly 1721
How to Remove Air Conditioner Unit Assembly 1721
How to Install Air Conditioner Unit Assembly 1724
Electrical System 1728
Remove and Install Transmission Controller Assembly 1728
How to Remove Transmission Controller Assembly 1728
How to Install Transmission Controller Assembly 1728
Remove and Install Steering Controller Assembly 1730
How to Remove Steering Controller Assembly 1730
How to Install Steering Controller Assembly 1730
Remove and Install Engine Controller Assembly 1732
How to Remove Engine Controller Assembly 1732
How to Install Engine Controller Assembly 1733
Remove and Install Machine Monitor Assembly 1735
How to Remove Machine Monitor Assembly 1735
How to Install Machine Monitor Assembly 1735
Remove and Install KOMTRAX Terminal Assembly 1737
How to Remove KOMTRAX Terminal Assembly 1737
How to Install KOMTRAX Terminal Assembly 1738
60 Maintenance Standard 1739
Table of Contents 1740
Engine and Cooling System 1742
Maintenance Standard for Engine Mount 1742
Maintenance Standard for Turbocharger 1744
Maintenance Standard for Damper 1746
Maintenance Standard for Cooling System 1748
Maintenance Standard for Cooling Fan Pump 1750
Maintenance Standard for Servo Valve 1753
Maintenance Standard for Cooling Fan Motor 1754
Power Train 1756
Maintenance Standard for Universal Joint 1756
Maintenance Standard for Power Train Mount 1757
Maintenance Standard for Torque Converter and PTO 1759
Maintenance Standard for Transmission 1762
Maintenance Standard for Power Train Pump and Steering Lubrication Pump 1767
Maintenance Standard for Transmission ECMV 1768
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 1769
Maintenance Standard for Lubrication Relief Valve 1770
Maintenance Standard for Bevel Gear Shaft and Steering 1771
Maintenance Standard for Steering Control Valve 1776
Maintenance Standard for Steering Clutch ECMV 1778
Maintenance Standard for Steering Brake ECMV 1779
Maintenance Standard for Parking Brake Valve 1780
Maintenance Standard for Sudden Stop Prevention Valve 1782
Maintenance Standard for Final Drive 1783
Maintenance Standard for Sprocket for Conventional Type Track Shoes 1786
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 1787
Undercarriage and Frame 1788
Maintenance Standard for Main Frame 1788
Maintenance Standard for Suspension 1790
Maintenance Standard for Track Frame and Idler Cushion 1794
Maintenance Standard for Idler 1798
Maintenance Standard for Track Roller Bogie 1800
Maintenance Standard for Track Roller for Conventional Type Track Shoes 1801
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 1804
Maintenance Standard for Conventional Type Track Shoes 1806
Maintenance Standard for Single Shoes 1808
Hydraulic System 1809
Maintenance Standard for Hydraulic Tank 1809
Maintenance Standard for Work Equipment Pump 1810
Maintenance Standard for Scavenging Pump 1812
Maintenance Standard for Control Valve 1813
Maintenance Standard for Self-Pressure Reducing Valve 1819
Maintenance Standard for Quick Drop Valve 1822
Work Equipment 1823
Maintenance Standard for Cylinder Stay 1823
Maintenance Standard for Front Work Equipment 1824
Maintenance Standard for Cutting Edge and End Bit 1828
Maintenance Standard for Blade Lift Cylinder 1829
Maintenance Standard for Blade Tilt Cylinder 1831
Maintenance Standard for Variable Multi-Shank Ripper 1832
Maintenance Standard for Variable Giant Ripper 1833
Maintenance Standard for Ripper Lift Cylinder 1835
Maintenance Standard for Ripper Tilt Cylinder 1836
CAB Related Parts 1837
Maintenance Standard for CAB Mount 1837
Maintenance Standard for ROPS 1839
80 Appendix 1841
Table of Contents 1842
Air Conditioner System 1843
Precautions for Refrigerant 1843
Air Conditioner Component 1844
Specifications of Air Conditioner 1845
Structure and Function of Refrigeration Cycle 1846
Outline of Refrigeration Cycle 1847
Component Parts of Air Conditioner System 1849
Air Conditioner Unit 1849
Configuration Diagram of Air Conditioner Unit 1849
Compressor 1852
Structure of Compressor 1852
Specifications of Compressor 1852
Function of Compressor 1852
Condenser 1853
Structure of Condenser 1853
Specifications of Condenser 1853
Function of Condenser 1853
Receiver Drier 1854
Structure of Receiver Dryer 1854
Specifications of Receiver Dryer 1854
Function of Receiver Dryer 1854
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 1855
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 1857
Installation Locations of Circuit Breakers 1859
Air Conditioner Troubleshooting Chart 1 1860
Air Conditioner Troubleshooting Chart 2 1861
Information Shown in Troubleshooting Table 1864
A-1 The Air Conditioner Does Not Operate (No Air Flow) 1865
A-1 The Air Conditioner Does Not Operate (Cooling is Not Possible) 1868
Connect Service Tool 1871
How to Connect Service Tool 1871
Precautions for Disconnection and Connection of Air Conditioner Piping 1873
Handle Compressor Oil 1875
90 Circuit Diagrams 1877
Table of Contents 1878
Hydraulic Circuit Diagram 1879
Symbols Used in Hydraulic Circuit Diagram 1879
Hydraulic Circuit Diagram 1883
Power Train Hydraulic Circuit Diagram 1885
Electrical Circuit Diagram 1887
Symbols Used in Electric Circuit Diagram 1887
Electrical Circuit Diagram (1/12) 1891
Electrical Circuit Diagram (2/12) 1893
Electrical Circuit Diagram (3/12) 1895
Electrical Circuit Diagram (4/12) 1897
Electrical Circuit Diagram (5/12) 1899
Electrical Circuit Diagram (6/12) 1901
Electrical Circuit Diagram (7/12) 1903
Electrical Circuit Diagram (8/12) 1905
Electrical Circuit Diagram (9/12) 1907
Electrical Circuit Diagram (10/12) 1909
Electrical Circuit Diagram (11/12) 1911
Electrical Circuit Diagram (12/12) 1913
Index 1915

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