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KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04343-08) – PDF DOWNLOAD
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- KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEN04343-08
- SERIAL NUMBERS:
D31EX-60001 and up
D31PX-60001 and up
D37EX-60001 and up
D37PX-60001 and up
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Description
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04343-08)
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04343-08) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04343-08)
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU D31EX-22 D31PX-22 D37EX-22 D37PX-22 BULLDOZER SERVICE REPAIR MANUAL (SEN04343-08)
COVER ....................................................................................................................................................... 1 00 Index and foreword........................................................................................................................................ 0 100 Index................................................................................................................................................ 3 Composition of shop manual........................................................................................................................... 4 Table of contents.................................................................................................................................... 6 200 Foreword and general information..................................................................................................................... 15 Safety notice........................................................................................................................................ 16 How to read the shop manual.......................................................................................................................... 21 Explanation of terms for maintenance standard........................................................................................................ 23 Handling of electric equipment and hydraulic component............................................................................................... 25 Handling of connectors newly used for engines........................................................................................................ 34 How to read electric wire code....................................................................................................................... 37 Precautions when carrying out operation.............................................................................................................. 40 Method of disassembling and connecting push-pull type coupler........................................................................................ 43 Standard tightening torque table..................................................................................................................... 46 Conversion table..................................................................................................................................... 50 01 General................................................................................................................................................... 0 100 Specification and technical data..................................................................................................................... 57 Specification dimensional drawing.................................................................................................................... 58 Specifications....................................................................................................................................... 60 Weight table......................................................................................................................................... 68 Table of fuel, coolant and lubricants................................................................................................................ 72 10 Structure, function and maintenance standard.............................................................................................................. 0 100 Engine and cooling system............................................................................................................................ 75 Engine system parts.................................................................................................................................. 76 Cooling system....................................................................................................................................... 77 Cooling fan pump..................................................................................................................................... 78 Cooling fan motor.................................................................................................................................... 79 Oil cooler bypass valve.............................................................................................................................. 84 200 Power train.......................................................................................................................................... 89 Power train.......................................................................................................................................... 90 Power train system................................................................................................................................... 91 Damper............................................................................................................................................... 92 HST hydraulic equipment arrangement diagram.......................................................................................................... 93 Steering and brake control........................................................................................................................... 94 Solenoid valve....................................................................................................................................... 96 Final drive.......................................................................................................................................... 103 HST pump............................................................................................................................................. 106 HST motor............................................................................................................................................ 118 Charge pump.......................................................................................................................................... 128 300 Undercarriage and frame.............................................................................................................................. 131 Main frame........................................................................................................................................... 132 Track frame and idler cushion........................................................................................................................ 134 Idler................................................................................................................................................ 136 Track roller......................................................................................................................................... 138 Carrier roller....................................................................................................................................... 140 Sprocket............................................................................................................................................. 142 Track shoe........................................................................................................................................... 144 410 Hydraulic system, Part 1............................................................................................................................. 149 Arrangement of hydraulic equipment for work equipment................................................................................................ 150 Work equipment control............................................................................................................................... 152 Hydraulic tank and filter............................................................................................................................ 154 Work equipment and fan pump.......................................................................................................................... 156 Control valve........................................................................................................................................ 164 CLSS................................................................................................................................................. 176 Functions and operation of each valve................................................................................................................ 179 420 Hydraulic system, Part 2............................................................................................................................. 189 Blade PPC valve...................................................................................................................................... 190 Accumulator.......................................................................................................................................... 199 500 Work equipment....................................................................................................................................... 201 Work equipment....................................................................................................................................... 202 Cutting edge and end bit............................................................................................................................. 206 Ripper............................................................................................................................................... 207 Work equipment cylinder.............................................................................................................................. 208 Piston valve......................................................................................................................................... 211 600 Cab and its attachments.............................................................................................................................. 213 ROPS cab............................................................................................................................................. 214 Cab mount............................................................................................................................................ 215 Canopy mount......................................................................................................................................... 216 Air conditioner...................................................................................................................................... 217 700 Electrical system.................................................................................................................................... 221 Monitor system....................................................................................................................................... 222 Engine control....................................................................................................................................... 224 Engine control system................................................................................................................................ 225 Cooling control system............................................................................................................................... 226 HST control system................................................................................................................................... 228 Parking brake control system......................................................................................................................... 234 KOMTRAX system....................................................................................................................................... 236 Component equipment of system........................................................................................................................ 238 PCCS lever (for steering)............................................................................................................................ 247 Sensor............................................................................................................................................... 250 20 Standard value table...................................................................................................................................... 0 100 Standard service value table......................................................................................................................... 263 Standard service value table for engine.............................................................................................................. 264 Standard service value table for chassis............................................................................................................. 266 30 Testing and adjusting..................................................................................................................................... 0 110 Testing and adjusting, Part 1........................................................................................................................ 277 Tools for testing, adjusting, and troubleshooting.................................................................................................... 279 Measuring engine speed............................................................................................................................... 283 Measuring intake air pressure (boost pressure)....................................................................................................... 284 Testing exhaust temperature.......................................................................................................................... 286 Measuring exhaust gas color (boost pressure)......................................................................................................... 287 Adjusting valve clearance............................................................................................................................ 288 Testing compression pressure......................................................................................................................... 290 Measuring blow-by pressure........................................................................................................................... 292 Testing oil pressure................................................................................................................................. 294 Handling fuel system equipment....................................................................................................................... 295 Releasing residual pressure in fuel system........................................................................................................... 295 Bleeding air from fuel circuit....................................................................................................................... 296 Testing fuel pressure................................................................................................................................ 299 Testing leakage from pressure limiter and return rate from injector.................................................................................. 300 Testing leakage in fuel system....................................................................................................................... 303 Measuring fan circuit pressure and fan speed......................................................................................................... 304 Adjustment of fan speed sensor....................................................................................................................... 305 Handling reduced cylinder mode operation............................................................................................................. 306 Handling no-injection cranking operation............................................................................................................. 306 Check of muffler and muffler stack for looseness and damage.......................................................................................... 307 Check of muffler function............................................................................................................................ 307 Check of installed condition of cylinder head and manifolds.......................................................................................... 308 Check of engine piping for damage and looseness...................................................................................................... 308 Testing and adjusting alternator belt tension........................................................................................................ 309 Testing and adjusting air conditioner compressor belt tension........................................................................................ 310 120 Testing and adjusting, Part 2........................................................................................................................ 313 Adjusting decelerator pedal.......................................................................................................................... 314 Testing and adjusting HST oil pressure............................................................................................................... 316 Measuring solenoid valve output oil pressure......................................................................................................... 321 Testing travel deviation............................................................................................................................. 324 Adjusting parking brake lever........................................................................................................................ 325 Simple brake performance test procedure.............................................................................................................. 327 Adjusting brake pedal................................................................................................................................ 328 Method of releasing parking brake (Procedure for emergency escape)................................................................................... 330 Testing and adjusting idler clearance................................................................................................................ 332 Testing and adjusting track shoe tension............................................................................................................. 333 Testing work equipment oil pressure.................................................................................................................. 334 Testing work equipment PPC valve output oil pressure................................................................................................. 336 Adjusting play of work equipment PPC valve........................................................................................................... 338 Adjusting work equipment lock lever.................................................................................................................. 339 Testing internal leakage of work equipment cylinder.................................................................................................. 340 Releasing residual pressure in hydraulic circuit..................................................................................................... 342 Bleeding air from hydraulic circuit.................................................................................................................. 343 Adjusting play of blade center ball.................................................................................................................. 344 Procedure for testing diodes......................................................................................................................... 345 Preparation work for troubleshooting for electrical system........................................................................................... 346 How to start operation of KOMTRAX terminal........................................................................................................... 350 Lamp display of KOMTRAX terminal..................................................................................................................... 353 130 Testing and adjusting, Part 3........................................................................................................................ 357 Special functions of monitor panel (EMMS)............................................................................................................ 358 Items to be adjusted when electric/hydraulic devices are adjusted/replaced........................................................................... 418 Adjustment procedure after replacement of HST controller............................................................................................. 419 Adjustment procedure after replacement of monitor panel.............................................................................................. 421 Pm-clinic service (D31EX-22, D31PX-22)............................................................................................................... 423 Pm-clinic service (D37EX-22, D37PX-22)............................................................................................................... 431 40 Troubleshooting........................................................................................................................................... 0 100 Failure code table and fuse locations................................................................................................................ 441 Failure code table................................................................................................................................... 442 Before carrying out troubleshooting for electrical system (E-mode)................................................................................... 448 200 General information on troubleshooting............................................................................................................... 453 Points to remember when troubleshooting.............................................................................................................. 454 Sequence of events in troubleshooting................................................................................................................ 455 Testing before troubleshooting....................................................................................................................... 456 Classification and procedures of troubleshooting..................................................................................................... 457 Information contained in troubleshooting table....................................................................................................... 460 Connection table for connector pin numbers........................................................................................................... 462 T- branch box and T- branch adapter table............................................................................................................ 498 310 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 503 Failure code [6091NX] HST charge filter element: Clogging............................................................................................ 505 Failure code [AA10NX] Air cleaner: Clogging.......................................................................................................... 506 Failure code [AB00MA] Alternator: Malfunction........................................................................................................ 508 Failure code [B@BAZG] Engine oil: Lowering of oil pressure........................................................................................... 509 Failure code [B@BCNS] Coolant: Overheat.............................................................................................................. 510 Failure code [B@CRNS] HST oil: Overheating........................................................................................................... 511 Failure code [B@CRZG] HST oil: Lowering of oil pressure.............................................................................................. 512 Failure code [CA111] Engine controller: Abnormality in controller.................................................................................... 513 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal......................................................... 516 Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected............................................................. 517 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................................ 519 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected........................................................... 520 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................................. 522 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.......................................................... 524 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected............................................................ 526 Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected....................................................... 528 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected............................................................. 530 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................................. 531 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected......................................................... 532 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected........................................................... 534 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................................... 536 Failure code [CA234] Engine over speed: Excessively high speed....................................................................................... 538 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected..................................................... 540 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................................... 542 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................................... 544 320 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 547 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.............................................. 550 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.............................................. 552 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.............................................. 554 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.............................................. 556 Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit............................................................................ 558 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................................. 560 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................................... 562 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................................... 564 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................................. 565 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..................... 566 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred................................................... 567 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected......................................................... 568 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected........................................................... 570 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........................................................... 571 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...................................................... 572 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................................ 576 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................................... 578 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................................ 579 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................................... 580 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................................ 582 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.............................................. 584 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected................................................ 586 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected..................................................... 587 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................................... 588 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................................... 590 Failure code [CA2556] Air intake heater relay short circuit: Short circuit........................................................................... 592 330 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 595 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................................ 598 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................................ 600 Failure code [DAFRKR] CAN communication (Monitor panel - HST controller): Defective communication (Abnormality in objective component system)........ 602 Failure code [DAFRMC] CAN communication (Monitor panel - ENGINE controller): Defective communication (Abnormality in objective component system)..... 605 Failure code [DAJ000] HST controller: Memory error................................................................................................... 608 Failure code [DAJ0KK] HST controller: Lowing of source voltage....................................................................................... 610 Failure code [DAJ0KQ] HST controller: Machine code error............................................................................................. 612 Failure code [DAJ0KT] HST controller: Memory error................................................................................................... 613 Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input.................................................... 614 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input.................................................... 616 Failure code [DAJRKR] CAN communication (HST controller - Monitor panel): Defective communication (Abnormality in objective component system)........ 618 Failure code [DB2RKR] CAN communication (HST controller - Engine controller): Defective communication (Abnormality in objective component system).... 621 Failure code [DD12KA] Shift up switch: Disconnection................................................................................................. 624 Failure code [DD12KB] Shift up switch: Short circuit................................................................................................. 626 Failure code [DD13KA] Shift down switch: Disconnection............................................................................................... 628 Failure code [DD13KB] Shift down switch: Short circuit............................................................................................... 630 Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................................................................................... 632 Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals.................................................................. 634 Failure code [DDDCKB] Reverse travel speed switch: Short circuit..................................................................................... 636 Failure code [DDP6KA] Brake oil pressure sensor: Disconnection....................................................................................... 638 Failure code [DDP6KB] Brake oil pressure sensor: Short circuit....................................................................................... 640 Failure code [DDP6MA] Brake oil pressure sensor: Malfunction......................................................................................... 642 Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection...................................................................................... 644 Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals............................................................................. 646 Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing..................................................................................... 648 Failure code [DDU1KA] Travel lock limit switch 2: Disconnection...................................................................................... 650 Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line............................................................... 652 Failure code [DGS1KA] HST oil temperature sensor: Disconnection...................................................................................... 654 Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.......................................................................... 656 340 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 659 Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection................................................................................... 662 Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit................................................................................... 664 Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................................................. 666 Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit.................................................................................. 668 Failure code [DK10KA] Fuel dial sensor: Disconnection................................................................................................ 670 Failure code [DK10KB] Fuel dial sensor: Short circuit................................................................................................ 672 Failure code [DK30KA] Steering angle sensor 1: Disconnection......................................................................................... 674 Failure code [DK30KB] Steering angle sensor 1: Short circuit......................................................................................... 676 Failure code [DK30KX] Steering angle sensor: Out of input signal range............................................................................... 678 Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.......................................................................... 679 Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals.......................................................................... 680 Failure code [DK31KA] Steering angle sensor 2: Disconnection......................................................................................... 682 Failure code [DK31KB] Steering angle sensor 2: Short circuit......................................................................................... 684 Failure code [DK40KA] Brake pedal sensor: Disconnection.............................................................................................. 686 Failure code [DK40KB] Brake pedal sensor: Short circuit.............................................................................................. 688 Failure code [DK55KX] Directional potentiometer: Out of input signal range........................................................................... 690 Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit...................................................................... 691 Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals...................................................................... 692 Failure code [DK56KA] Directional potentiometer 1: Disconnection..................................................................................... 694 Failure code [DK56KB] Directional potentiometer 1: Short circuit..................................................................................... 696 Failure code [DK57KA] Directional potentiometer 2: Disconnection..................................................................................... 698 Failure code [DK57KB] Directional potentiometer 2: Short circuit..................................................................................... 700 Failure code [DLM0KX] HST motor speed sensors: Out of input signal range............................................................................. 702 Failure code [DLM1KA] Left HST motor speed sensor: Disconnection..................................................................................... 704 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit..................................................................................... 706 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction....................................................................................... 708 Failure code [DLM2KA] Right HST motor speed sensor: Disconnection.................................................................................... 710 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.................................................................................... 712 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction...................................................................................... 714 Failure code [DLM3KA] Fan speed sensor: Disconnection................................................................................................ 716 Failure code [DLM3KB] Fan speed sensor: Short circuit................................................................................................ 718 350 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 721 Failure code [DN21FS] Brake pedal and proximity switch: Fixing....................................................................................... 724 Failure code [DV00KB] Caution buzzer: Short circuit.................................................................................................. 726 Failure code [DV20KB] Back alarm buzzer: Short circuit............................................................................................... 727 Failure code [DW4BKA] Parking brake solenoid valve: Disconnection.................................................................................... 728 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.................................................................................... 730 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line............................................................. 732 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection...................................................................................... 734 Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit...................................................................................... 736 Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line............................................................... 737 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection....................................................................................... 738 Failure code [DW7EKB] Slow brake solenoid valve: Short circuit....................................................................................... 742 Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line................................................................ 744 Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection.......................................................................................... 746 Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit.......................................................................................... 748 Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line................................................................... 750 Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection.................................................................................. 752 Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit.................................................................................. 754 Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 756 Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection.................................................................................. 758 Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit.................................................................................. 760 Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 762 Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection.................................................................................. 764 Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit.................................................................................. 766 Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 767 Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection.................................................................................. 768 Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit.................................................................................. 770 Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 772 Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection............................................................................... 773 Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit............................................................................... 774 Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line........................................................ 775 Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection.............................................................................. 776 Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.............................................................................. 777 Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line....................................................... 778 400 Troubleshooting of electrical system (E-mode)........................................................................................................ 781 E-1 Engine does not start (Starting motor does not rotate)........................................................................................... 784 E-2 Engine is not preheated.......................................................................................................................... 787 E-3 When starting switch is turned ON, any item does not light up.................................................................................... 790 E-4 Charge level caution flashes while engine is running............................................................................................. 792 E-5 Emergency warning items flash while engine is running............................................................................................ 794 E-6 Preheating pilot lamp does not light up during preheating operation.............................................................................. 800 E-7 The coolant temperature gauge does not indicate correctly........................................................................................ 802 E-8 The HST oil temperature gauge does not indicate correctly........................................................................................ 803 E-9 Fuel level gauge does not indicate properly...................................................................................................... 804 E-10 Gear speed, set travel speed, and shift mode indicator does not display normally................................................................ 806 E-11 Multi-information unit does not display normally................................................................................................ 806 E-12 Caution lamp does not flash or does not go off.................................................................................................. 807 E-13 Caution buzzer does not sound or does not stop.................................................................................................. 808 E-14 Reverse travel speed setting switch does not function........................................................................................... 810 E-15 Shift mode switch does not function............................................................................................................. 812 E-16 Buzzer cancel switch does not function.......................................................................................................... 814 E-17 Information switch does not function............................................................................................................ 816 E-18 The fan cleaning does not operate or cannot be reset............................................................................................ 818 E-19 Backup alarm does not sound..................................................................................................................... 820 E-20 The horn does not sound or does not stop........................................................................................................ 821 E-21 Work equipment does not move.................................................................................................................... 822 E-22 Headlamp or rear lamp does not light up......................................................................................................... 824 E-23 Foot heater does not operate.................................................................................................................... 827 E-24 Air conditioner does not operate................................................................................................................ 830 E-25 Windshield wiper and window washer do not operate............................................................................................... 835 E-26 KOMTRAX system does not operate normally........................................................................................................ 848 500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................... 851 Information in troubleshooting table................................................................................................................. 853 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate).................................................. 854 H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate).......................... 856 H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).............................................. 857 H-4 Speed or power of travel is low.................................................................................................................. 858 H-5 Gear is not shifted.............................................................................................................................. 859 H-6 Large shocks are made when machine starts and stops travel....................................................................................... 860 H-7 Machine deviates largely during travel........................................................................................................... 861 H-8 Hydraulic drift of travel is large............................................................................................................... 862 H-9 Engine stalls or engine speed lowers extremely during travel..................................................................................... 863 H-10 Abnormal sound comes out from around HST pump and motor......................................................................................... 864 H-11 Work equipment dose not operate at all.......................................................................................................... 865 H-12 Speed or power of whole work equipment is low................................................................................................... 866 H-13 Speed or power of lifting blade is low.......................................................................................................... 867 H-14 Speed or power of tilting blade is low.......................................................................................................... 868 H-15 Speed or power of angling blade is low.......................................................................................................... 869 H-16 Time lag in lifting blade is large.............................................................................................................. 870 H-17 Hydraulic drift of lifting blade is large....................................................................................................... 870 H-18 Hydraulic drift of tilting blade is large....................................................................................................... 870 H-19 Abnormal sound comes out from around work equipment pump and control valve...................................................................... 871 H-20 HST oil temperature (Hydraulic oil temperature) rises too high.................................................................................. 872 H-21 Fan speed is abnormal (High, low, or 0 rpm)..................................................................................................... 874 H-22 Abnormal sound is heard from around fan......................................................................................................... 875 600 Troubleshooting of engine (S-mode)................................................................................................................... 877 Troubleshooting of engine (S-mode)................................................................................................................... 879 S-1 Starting performance is poor..................................................................................................................... 882 S-2 Engine does not start............................................................................................................................ 883 S-3 Engine does not pick up smoothly................................................................................................................. 886 S-4 Engine stops during operations................................................................................................................... 887 S-5 Engine does not rotate smoothly.................................................................................................................. 888 S-6 Engine lacks output (or lacks power)............................................................................................................. 889 S-7 Exhaust smoke is black (incomplete combustion)................................................................................................... 890 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................................... 891 S-9 Oil becomes contaminated quickly................................................................................................................. 892 S-10 Fuel consumption is excessive................................................................................................................... 893 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................................................................... 894 S-12 Oil pressure drops.............................................................................................................................. 895 S-13 Oil level rises (Entry of coolant or fuel)...................................................................................................... 896 S-14 Coolant temperature becomes too high (overheating).............................................................................................. 897 S-15 Abnormal noise is made.......................................................................................................................... 898 S-16 Vibration is excessive.......................................................................................................................... 899 50 Disassembly and assembly.................................................................................................................................. 0 100 General information on disassembly and assembly...................................................................................................... 901 How to read this manual.............................................................................................................................. 902 Coating materials list............................................................................................................................... 904 Special tools list................................................................................................................................... 907 Sketches of special tools............................................................................................................................ 910 200 Engine and cooling system............................................................................................................................ 915 Removal and installation of fuel supply pump assembly................................................................................................ 916 Removal and installation of fuel injector assembly................................................................................................... 919 Removal and installation of front seal assembly...................................................................................................... 922 Removal and installation of rear seal assembly....................................................................................................... 924 Removal and installation of cylinder head assembly................................................................................................... 927 Removal and installation of engine and HST pump assembly............................................................................................. 934 Removal and installation of front guard assembly..................................................................................................... 938 Removal and installation of radiator assembly........................................................................................................ 940 Removal and installation of hydraulic oil cooler assembly............................................................................................ 942 Removal and installation of aftercooler assembly..................................................................................................... 944 Removal and installation of cooling fan and motor assembly........................................................................................... 946 Removal and installation of cooling fan drive motor assembly......................................................................................... 948 Removal and installation of fuel tank assembly....................................................................................................... 950 300 Power train.......................................................................................................................................... 953 Removal and installation of HST pump assembly........................................................................................................ 954 Removal and installation of HST motor and final drive assembly....................................................................................... 956 Disassembly and assembly of final drive assembly..................................................................................................... 958 400 Undercarriage and frame.............................................................................................................................. 969 Spreading and installation of track shoe assembly.................................................................................................... 970 Removal and installation of idler and recoil spring assembly......................................................................................... 972 Disassembly and assembly of idler assembly........................................................................................................... 973 Disassembly and assembly of recoil spring assembly................................................................................................... 976 Disassembly and assembly of track roller assembly.................................................................................................... 980 Disassembly and assembly of carrier roller assembly.................................................................................................. 984 500 Hydraulic system..................................................................................................................................... 989 Removal and installation of hydraulic tank assembly.................................................................................................. 990 Removal and installation of control valve assembly................................................................................................... 992 Disassembly and assembly of control valve assembly................................................................................................... 993 Disassembly and assembly of hydraulic cylinder assembly.............................................................................................. 995 600 Work equipment.......................................................................................................................................1001 Removal and installation of work equipment assembly..................................................................................................1002 700 Cab and its attachments..............................................................................................................................1007 Removal and installation of ROPS canopy and operator seat frame assembly.............................................................................1008 Removal and installation of ROPS cab and operator seat frame assembly................................................................................1011 Removal and installation of operator’s cab glass (Stuck glass).......................................................................................1015 800 Electrical system....................................................................................................................................1023 Removal and installation of HST controller assembly..................................................................................................1024 Removal and installation of KOMTRAX terminal assembly................................................................................................1025 90 Diagrams and drawings..................................................................................................................................... 0 100 Hydraulic diagrams and drawings......................................................................................................................1027 Work equipment hydraulic circuit diagram.............................................................................................................1029 200 Electrical diagrams and drawings.....................................................................................................................1034 Electrical circuit diagram...........................................................................................................................1036 Cab electrical circuit diagram.......................................................................................................................1041 Air conditioner circuit diagram......................................................................................................................1045 Connector list and stereogram........................................................................................................................1047
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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