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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06653-09 – PDF DOWNLOAD
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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06653-09 – PDF DOWNLOAD
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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06653-09 – PDF DOWNLOAD
Language : English
Pages : 3584
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06653-09 – PDF DOWNLOAD
Cover....................................................................................................................................... 1 00 Index and Foreword.................................................................................................................. 3 Index.............................................................................................................................. 4 Abbreviation List.................................................................................................................. 25 Foreword, Safety, Basic Information................................................................................................ 28 How to Read the Shop Manual.................................................................................................... 28 Safety Notice for Operation.................................................................................................... 30 Precautions to Prevent Fire.................................................................................................... 38 Procedures If Fire Occurs...................................................................................................... 40 Precautions When You Discard Waste Materials................................................................................... 41 Precautions for DEF............................................................................................................ 42 General Character and Precautions for Handling............................................................................. 42 Precautions for Adding..................................................................................................... 42 Precautions for Storage.................................................................................................... 42 Precautions for Fire Hazard and Leakage.................................................................................... 42 Other Precautions.......................................................................................................... 42 Store DEF...................................................................................................................... 43 Precautions When You Handle Hydraulic Equipment................................................................................ 44 Precautions When You Disconnect and Connect Pipings............................................................................ 47 Precautions When You Handle Electrical Equipment............................................................................... 53 Precautions When You Handle Fuel System Equipment.............................................................................. 55 Precautions When You Handle Intake System Equipment............................................................................ 56 Practical Use of KOMTRAX....................................................................................................... 57 Disconnect and Connect Push-Pull Type Coupler.................................................................................. 58 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................ 58 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................ 59 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................ 60 Precautions for Disconnection and Connection of Connectors..................................................................... 62 How to Disconnect and Connect Deutsch Connector................................................................................ 66 How to Disconnect and Connect Slide Lock Type Connector........................................................................ 67 How to Disconnect and Connect Connector with Lock to Pull...................................................................... 69 How to Disconnect and Connect Connector with Lock to Push...................................................................... 70 How to Disconnect and Connect Connector with Housing to Rotate................................................................. 72 How to Read the Codes for Electric Cable....................................................................................... 73 Explanation of Terms for Maintenance Standard.................................................................................. 77 Standard Tightening Torque Table............................................................................................... 80 Conversion Table............................................................................................................... 87 01 Specifications...................................................................................................................... 93 Table of Contents.................................................................................................................. 94 Specifications..................................................................................................................... 95 Specification Drawing.......................................................................................................... 95 Specification Drawing: D375AI-8............................................................................................ 95 Specifications................................................................................................................. 97 Specification: D375AI-8.................................................................................................... 97 Weight Table................................................................................................................... 103 Weight Table: D375AI-8..................................................................................................... 103 Fuel, Coolant, Lubricants (For North America).................................................................................. 105 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................. 105 10 Structure and Function.............................................................................................................. 107 Table of Contents.................................................................................................................. 108 Boot-up System..................................................................................................................... 112 System Operating Lamp System................................................................................................... 112 System Diagram of System Operating Lamp System............................................................................. 112 Function of Operation Lamp System.......................................................................................... 112 Battery Isolator............................................................................................................... 114 Layout Drawing of Battery Isolator......................................................................................... 114 Function of Battery Isolator............................................................................................... 114 Engine System...................................................................................................................... 116 Layout Drawing of Engine System................................................................................................ 116 Engine Control System.......................................................................................................... 118 Layout Drawing of Engine Control System.................................................................................... 118 System Diagram of Engine Control........................................................................................... 119 Function of Engine Control System.......................................................................................... 119 Automatic Idle Stop System..................................................................................................... 120 System Diagram of Automatic Idle Stop System............................................................................... 120 Function of Automatic Idle Stop System..................................................................................... 120 Component Parts of Engine System............................................................................................... 123 Damper..................................................................................................................... 123 VGT........................................................................................................................ 125 EGR System................................................................................................................. 129 EGR Valve.................................................................................................................. 132 EGR Cooler................................................................................................................. 134 KCCV System................................................................................................................ 135 KCCV Ventilator............................................................................................................ 137 KDPF....................................................................................................................... 139 Fuel System.................................................................................................................... 143 Fuel System Circuit Diagram................................................................................................ 143 Function of Fuel System.................................................................................................... 144 Operation of Fuel System................................................................................................... 144 CRI System................................................................................................................. 145 Cooling System..................................................................................................................... 149 Layout Drawing of Cooling System............................................................................................... 149 Specifications of Cooling System........................................................................................... 150 Component Parts of Cooling System.............................................................................................. 151 Cooling Fan Pump........................................................................................................... 151 Cooling Fan Motor.......................................................................................................... 171 Hydraulic Oil Cooler Bypass Valve.......................................................................................... 178 Control System..................................................................................................................... 179 Layout Drawing of Control System............................................................................................... 179 Machine Monitor System......................................................................................................... 180 System Diagram of Machine Monitor System................................................................................... 180 Function of Machine Monitor System......................................................................................... 181 KOMTRAX Plus System............................................................................................................ 183 System Diagram of KOMTRAX Plus System...................................................................................... 183 Function of KOMTRAX Plus System............................................................................................ 183 Component Parts of Control System.............................................................................................. 185 Machine Monitor............................................................................................................ 185 KOMTRAX Terminal........................................................................................................... 202 KOMTRAX Plus Controller.................................................................................................... 204 Wireless LAN Unit.......................................................................................................... 209 Power Train Controller..................................................................................................... 210 Work Equipment Controller.................................................................................................. 218 Engine Controller.......................................................................................................... 222 Option Controller.......................................................................................................... 234 Fuel Feed Pump............................................................................................................. 238 Fuel Feed Pump Switch...................................................................................................... 239 Hydraulic System................................................................................................................... 240 Layout Drawing of Hydraulic System............................................................................................. 240 CLSS........................................................................................................................... 241 Structure of CLSS.......................................................................................................... 241 Function of CLSS........................................................................................................... 242 Component Parts of Hydraulic System............................................................................................ 244 Hydraulic Tank............................................................................................................. 244 Work Equipment Pump........................................................................................................ 246 LS Valve................................................................................................................... 250 PTO, Transmission Lubrication Pump, and Power Train Pump................................................................... 255 Control Valve.............................................................................................................. 257 Power Train System................................................................................................................. 277 Layout Drawing of Power Train System........................................................................................... 277 Operation of Power Train System................................................................................................ 280 Transmission, Steering, and Brake Control...................................................................................... 281 Layout Drawing of Transmission, Steering, and Brake Control System......................................................... 281 Function of Transmission, Steering, and Brake Control System............................................................... 282 Layout of Transmission, Steering, and Brake Control System Parts (Machine with FCCS)....................................... 283 Function of Transmission, Steering, and Brake Control System (Machine with FCCS)........................................... 285 Palm Command Control System.................................................................................................... 286 Palm Command Control System Diagram........................................................................................ 286 Centralized Pressure Pickup Port............................................................................................... 290 Layout Drawing of Centralized Pressure Pickup Port......................................................................... 290 Function of Centralized Pressure Pickup Port............................................................................... 291 Component Parts of Power Train System.......................................................................................... 292 Universal Joint............................................................................................................ 292 Power Train Mount.......................................................................................................... 293 Torque Converter and PTO................................................................................................... 295 Torque Converter Control Valve............................................................................................. 302 Lockup Clutch ECMV......................................................................................................... 304 Stator Clutch ECMV......................................................................................................... 308 Transmission............................................................................................................... 312 Transmission ECMV.......................................................................................................... 325 Main Relief Valve and Torque Converter Relief Valve........................................................................ 331 Transmission Lubrication Relief Valve...................................................................................... 333 Transfer and Bevel Pinion.................................................................................................. 334 Bevel Gear Shaft, Steering Clutch, and Brake............................................................................... 335 Final Drive................................................................................................................ 343 Scavenging Pump............................................................................................................ 347 Electric Steering Electric Lever........................................................................................... 348 Work Equipment System.............................................................................................................. 354 Work Equipment Control......................................................................................................... 354 Layout Drawing of Work Equipment Control................................................................................... 354 Function of Work Equipment Control......................................................................................... 355 Layout Drawing of Front Work Equipment......................................................................................... 356 Layout Drawing of Variable Giant Ripper........................................................................................ 357 Layout Drawing of Variable Multi-Shank Ripper.................................................................................. 358 Shoe Slip Control System....................................................................................................... 359 Function of Shoes Slip Control System...................................................................................... 359 Component Parts of Work Equipment System....................................................................................... 360 Self-Pressure Reducing Valve............................................................................................... 360 Work Equipment Lock Solenoid Valve......................................................................................... 365 Pilot Circuit Accumulator.................................................................................................. 367 Quick Drop Valve........................................................................................................... 368 Piston Valve............................................................................................................... 370 Electric Blade Control Lever............................................................................................... 371 Ripper Electric Lever...................................................................................................... 372 Pin Puller Switch.......................................................................................................... 373 ICT System......................................................................................................................... 374 Layout Drawing of ICT System................................................................................................... 374 System Diagram of ICT Control System........................................................................................... 375 Blade Control System........................................................................................................... 377 Function of Blade Control System........................................................................................... 377 Leveling Mode System Diagram............................................................................................... 379 Function of Leveling Mode.................................................................................................. 380 Operation of Leveling Mode................................................................................................. 380 Dozing Mode System Diagram................................................................................................. 381 Function of Dozing Mode.................................................................................................... 381 Operation of Dozing Mode................................................................................................... 381 Smooth Start System............................................................................................................ 383 Smooth Start System Diagram................................................................................................ 383 Function of Smooth Start System............................................................................................ 383 Operation of Smooth Start System........................................................................................... 383 Slip Control System............................................................................................................ 385 Slip Control System Diagram................................................................................................ 385 Function of Slip Control System............................................................................................ 385 Operation of Slip Control System........................................................................................... 385 Assist Control System.......................................................................................................... 387 Assist Control System Diagram.............................................................................................. 387 Function of Assist Control System.......................................................................................... 387 Operation of Assist Control System......................................................................................... 388 Straight Travel Correction System.............................................................................................. 389 Straight Travel Correction System Diagram.................................................................................. 389 Function of Straight Travel Correction System.............................................................................. 390 Operation of Straight Travel Correction System............................................................................. 390 Smooth Carry System............................................................................................................ 391 Smooth Carry System Diagram................................................................................................ 391 Function of Smooth Carry System............................................................................................ 392 Operation of Smooth Carry System........................................................................................... 392 Component Parts of ICT System.................................................................................................. 393 Navigation Controller...................................................................................................... 393 Control Box................................................................................................................ 397 AUX BOX.................................................................................................................... 399 IMU Sensor................................................................................................................. 402 Stroke and Reset Sensor for Blade Lift Cylinder............................................................................ 405 Lifting System..................................................................................................................... 408 Power Ladder System............................................................................................................ 408 Layout Drawing of Power Ladder System...................................................................................... 408 Hydraulic Circuit Diagram of Power Ladder System........................................................................... 409 Function of Power Ladder System............................................................................................ 409 Component Parts of Lifting System.............................................................................................. 411 Switch Box................................................................................................................. 411 Power Ladder Limit Switch Part............................................................................................. 412 Control Valve Assembly..................................................................................................... 413 Radio Control System............................................................................................................... 414 Layout Drawing of Radio Control System......................................................................................... 414 Specifications of Radio Control System......................................................................................... 415 Component Parts of Radio Control System........................................................................................ 416 Radio Control Transmitter.................................................................................................. 416 Radio Control Receiver..................................................................................................... 418 Radio Control On-board Selector Switch..................................................................................... 419 Undercarriage and Frame............................................................................................................ 421 Main Frame..................................................................................................................... 421 Structure of Main Frame.................................................................................................... 421 Suspension..................................................................................................................... 423 Structure of Suspension.................................................................................................... 423 Function of Suspension..................................................................................................... 425 Track Frame and Idler Cushion.................................................................................................. 426 Structure of Track Frame and Idler Cushion................................................................................. 426 Specifications of Track Frame and Idler Cushion............................................................................ 427 Function of Track Frame and Idler Cushion.................................................................................. 427 Work Equipment..................................................................................................................... 428 Structure of Front Work Equipment.............................................................................................. 428 Structure of Cylinder Stay..................................................................................................... 430 Structure of Variable Giant Ripper............................................................................................. 431 Structure of Variable Multi-Shank Ripper....................................................................................... 432 CAB Related Parts.................................................................................................................. 433 ROPS........................................................................................................................... 433 Structure of ROPS.......................................................................................................... 433 Function of ROPS........................................................................................................... 433 CAB............................................................................................................................ 434 Structure of CAB........................................................................................................... 434 CAB Mount...................................................................................................................... 435 Structure of CAB Mount..................................................................................................... 435 20 Standard Value Table................................................................................................................ 437 Table of Contents.................................................................................................................. 438 Standard Value Table for Engine.................................................................................................... 439 Standard Value Table for Engine: D375AI-8...................................................................................... 439 Standard Value Table for Machine................................................................................................... 445 Standard Value Table for Machine: D375AI-8..................................................................................... 445 Machine Posture and Procedures to Measure Performance.......................................................................... 472 30 Testing and Adjusting............................................................................................................... 475 Table of Contents.................................................................................................................. 476 Precautions Before Work............................................................................................................ 480 Related Information on Testing and Adjusting....................................................................................... 481 Tools for Testing and Adjusting................................................................................................ 481 Sketch of Tools for Testing and Adjusting...................................................................................... 487 Engine and Cooling System.......................................................................................................... 490 Examine Engine Speed........................................................................................................... 490 How to Examine Engine Speed................................................................................................ 490 Examine Boost Pressure......................................................................................................... 494 How to Examine Boost Pressure on Machine Monitor........................................................................... 494 How to Examine Boost Pressure by Testing Tool.............................................................................. 495 Examine Exhaust Gas Temperature................................................................................................ 497 How to Test Exhaust Gas Temperature by the Machine Monitor................................................................. 497 How to Examine Exhaust Temperature by Testing Tools........................................................................ 498 Examine Exhaust Gas Color...................................................................................................... 501 How to Examine Exhaust Gas Color with the Handy Smoke Checker.............................................................. 501 How to Examine Exhaust Gas Color with Smoke Meter.......................................................................... 502 Examine Mass Air Flow and Temperature Sensor................................................................................... 505 How to Examine Mass Air Flow and Temperature Sensor........................................................................ 505 Examine and Adjust Valve Clearance............................................................................................. 507 How to Examine Valve Clearance............................................................................................. 507 How to Adjust Valve Clearance.............................................................................................. 508 Examine Compression Pressure................................................................................................... 510 How to Examine Compression Pressure........................................................................................ 510 Examine Blowby Pressure........................................................................................................ 514 How to Examine Blowby Pressure............................................................................................. 514 Examine Engine Oil Pressure.................................................................................................... 516 How to Examine Engine Oil Pressure on Machine Monitor...................................................................... 516 How to Examine Engine Oil Pressure by Testing Tool......................................................................... 516 Examine EGR Valve and VGT Oil Pressure......................................................................................... 518 How to Examine EGR Valve and VGT Oil Pressure.............................................................................. 518 Examine Fuel Pressure.......................................................................................................... 519 How to Examine Fuel Pressure............................................................................................... 519 Examine Fuel Return Rate and Leakage........................................................................................... 521 How to Examine Fuel Return Rate and Leakage................................................................................ 522 Bleed Air from Fuel System..................................................................................................... 527 How to Bleed Air from Fuel System.......................................................................................... 527 Examine Fuel Circuit for Leakage............................................................................................... 529 How to Examine Fuel System for Leakage..................................................................................... 529 Examine Supply Pump............................................................................................................ 531 How to Examine Supply Pump................................................................................................. 531 Handle Cylinder Cut-out Mode Operation......................................................................................... 534 Handle No-Injection Cranking Operation......................................................................................... 535 Clean Fuel Doser............................................................................................................... 536 How to Clean Fuel Doser.................................................................................................... 536 Write Injector Compensation Value to Engine Controller......................................................................... 539 How to Write Injector Compensation Value................................................................................... 539 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................. 545 How to Write Correction for Ash in Soot Accumulation to Engine Controller.................................................. 545 Adjust Decelerator Pedal....................................................................................................... 546 How to Adjust Decelerator Pedal............................................................................................ 546 Power Train........................................................................................................................ 549 Examine Power Train Oil Pressure............................................................................................... 549 How to Examine Power Train Oil Pressure.................................................................................... 550 Adjust Transmission Output Shaft Speed Sensor.................................................................................. 567 How to Adjust Transmission Output Shaft Speed Sensor....................................................................... 567 Examine Brake Performance Simply............................................................................................... 569 How to Examine Brake Performance Simply.................................................................................... 569 Examine and Adjust Brake Pedal................................................................................................. 570 How to Examine Brake Pedal................................................................................................. 570 How to Adjust Brake Pedal.................................................................................................. 571 Adjust Parking Brake Lever..................................................................................................... 574 How to Adjust Parking Brake Lever.......................................................................................... 574 Move Machine by Parking Brake Release When Machine Does Not Travel............................................................. 576 How to Move Machine with Hydraulic Type Parking Brake Release System....................................................... 576 How to Move Machine with Electric Type Parking Brake Release System........................................................ 577 Undercarriage and Frame............................................................................................................ 580 Examine and Adjust Track Tension............................................................................................... 580 How to Examine Track Tension............................................................................................... 580 How to Adjust Track Tension................................................................................................ 580 Hydraulic System................................................................................................................... 582 Release Remained Pressure in Hydraulic Circuit................................................................................. 582 How to Release Remained Pressure in Hydraulic System....................................................................... 582 Examine and Adjust Work Equipment Oil Pressure................................................................................. 583 How to Examine Work Equipment Oil Pressure................................................................................. 583 How to Adjust Work Equipment Oil Pressure.................................................................................. 585 Examine Oil Pressure of Control Circuit........................................................................................ 586 How to Examine Oil Pressure in Control Circuit............................................................................. 586 Examine Work Equipment Lock Solenoid Valve Outlet Pressure..................................................................... 588 How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure.......................................................... 588 Examine Ripper Pin Puller Solenoid Valve Outlet Pressure....................................................................... 590 How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure............................................................ 590 Bleed Air from Work Equipment Pump............................................................................................. 592 How to Bleed Air from Work Equipment Pump.................................................................................. 592 Examine Cooling Fan Speed...................................................................................................... 593 How to Examine Cooling Fan Speed........................................................................................... 593 Examine Cooling Fan Circuit Oil Pressure....................................................................................... 594 How to Examine Cooling Fan Circuit Oil Pressure............................................................................ 594 Bleed Air in Cooling Fan Pump.................................................................................................. 596 How to Bleed Air in Cooling Fan Pump....................................................................................... 596 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................................................... 597 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder.................................................... 597 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder................................................ 597 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder............................................... 598 Examine Oil Leakage from Work Equipment Cylinder............................................................................... 599 How to Examine Internal Oil Leakage of Work Equipment Cylinder............................................................. 599 Bleed Air from Work Equipment Cylinders........................................................................................ 601 How to Bleed Air from Work Equipment Cylinder.............................................................................. 601 Operation When Work Equipment is Disabled...................................................................................... 602 How to Operate When Work Equipment is Disabled............................................................................. 602 Power Ladder....................................................................................................................... 604 Bleed Air from Power Ladder Cylinder........................................................................................... 604 How to Bleed Air in Power Ladder Cylinder.................................................................................. 604 Examine and Adjust Power Ladder Limit Switch................................................................................... 609 How to Examine and Adjust Power Ladder Limit Switch........................................................................ 609 How to Adjust Power Ladder Limit Switch.................................................................................... 609 Work Equipment..................................................................................................................... 618 Adjust Work Equipment Lock Lever............................................................................................... 618 How to Adjust Work Equipment Lock Lever.................................................................................... 618 Examine and Adjust Play of Blade Electric Lever................................................................................ 620 How to Examine Play of Blade Electric Lever................................................................................ 622 How to Adjust Play of Blade Electric Lever................................................................................. 622 How to Replace Universal Joint............................................................................................. 623 CAB Related Parts.................................................................................................................. 630 Examine and Adjust Operator Cab................................................................................................ 630 How to Examine Operator Cab................................................................................................ 630 How to Adjust Operator Cab................................................................................................. 633 Adjust Play of Operator Seat................................................................................................... 636 How to Adjust Play of Operator Seat........................................................................................ 636 Electrical System.................................................................................................................. 637 Set and Operate Machine Monitor................................................................................................ 637 Operator Mode.............................................................................................................. 640 Function to Show Technician Identification Status Screen................................................................... 640 Function to Show Operator Identification Input Screen...................................................................... 640 Examine Function by LCD (Liquid Crystal Display)........................................................................... 641 Examine Function of Service Meter.......................................................................................... 642 How to Set Usage Limitation and Change Maintenance Password................................................................ 642 Service Mode............................................................................................................... 644 How to Operate Service Mode................................................................................................ 644 How to See Pre-defined Monitoring Information.............................................................................. 646 How to Examine Self-Define Monitor Information............................................................................. 652 Abnormality Record Menu.................................................................................................... 665 How to See Maintenance Record.............................................................................................. 670 Maintenance Mode Setting................................................................................................... 671 How to Set Phone Number Entry.............................................................................................. 674 Default Menu............................................................................................................... 675 Diagnostic Tests Menu...................................................................................................... 684 Adjustment Menu............................................................................................................ 694 No-Injection Cranking Operation............................................................................................ 788 KOMTRAX Settings Menu...................................................................................................... 789 How to Show Service Message................................................................................................ 791 How to Operate Snap Shot................................................................................................... 792 How to Start Up KOMTRAX Terminal............................................................................................... 795 Default Setting of KOMTRAX Plus Controller..................................................................................... 800 How to do the Default Setting of KOMTRAX Plus Controller................................................................... 800 Default Setting of Wireless LAN Modem.......................................................................................... 803 Default Setting of Wireless LAN Modem...................................................................................... 803 How to Examine Wireless LAN Modem Communication............................................................................ 804 Download Data from KOMTRAX Plus Controller..................................................................................... 805 How to Download Data from KOMTRAX Plus Controller.......................................................................... 805 Adjust After Replacement of KOMTRAX Plus Controller............................................................................ 808 How to Adjust After Replacement of KOMTRAX Plus Controller................................................................. 808 Adjust After Replacement of Wireless LAN Modem................................................................................. 811 How to Adjust After Replacement of Wireless LAN Modem...................................................................... 811 Adjust Rearview Camera Angle................................................................................................... 814 How to Adjust Rearview Camera Angle........................................................................................ 814 Handle Voltage Circuit of Engine Controller.................................................................................... 815 Handle Battery Disconnect Switch............................................................................................... 816 Handle Battery Isolator and Starting Motor Isolator............................................................................ 817 Examine Diodes................................................................................................................. 818 How to Examine Diodes by Digital Tester.................................................................................... 818 How to Examine Diodes by Analog Tester..................................................................................... 818 ICT System......................................................................................................................... 819 Set and Operate Control Box.................................................................................................... 819 Examine and Adjust ICT Related Devices..................................................................................... 819 Calibrate Blade Edge Position.................................................................................................. 824 How to Operate Blade Calibration Menu (Machine Cal Step A)................................................................. 824 How to Operate Blade Calibration Menu (Machine Cal Step B)................................................................. 830 Calibrate IMU Sensor........................................................................................................... 846 How to Calibrate IMU Sensor................................................................................................ 846 Reset Cylinder Stroke End...................................................................................................... 851 Reset Lift Cylinder Stroke End............................................................................................. 851 Set Standard Angle of Blade Edge............................................................................................... 854 How to Input Wear Volume of Blade Edge and Track Shoes......................................................................... 856 Examine and Adjust Blade Elevation............................................................................................. 859 Examine Blade Elevation.................................................................................................... 859 Adjust Blade Elevation..................................................................................................... 863 Examine Stroke Sensor for Lift Cylinder........................................................................................ 865 How to Examine Stroke Sensor for Lift Cylinder............................................................................. 865 Examine and Adjust Reset Sensor for Lift Cylinder.............................................................................. 869 How to Examine Reset Sensor for Lift Cylinder.............................................................................. 869 How to Adjust Reset Sensor for Lift Cylinder............................................................................... 870 Adjust When Work Equipment Controller is Replaced.............................................................................. 871 How to Adjust When Work Equipment Controller is Replaced................................................................... 871 How to Adjust When ICT Related Devices are Repaired or Replaced................................................................ 874 Radio Control...................................................................................................................... 878 ID Setup....................................................................................................................... 878 How to Set Radio Control Transmitter ID.................................................................................... 878 How to Set Radio Control Receiver ID....................................................................................... 879 Pm Clinic.......................................................................................................................... 882 Pm Clinic Service.............................................................................................................. 882 Pm Clinic Check Sheet: D375AI-8............................................................................................ 883 Pm Clinic Check Sheet for Undercarriage: D375AI-8.......................................................................... 904 Perform Quick Pm............................................................................................................... 909 How to Perform Quick Pm.................................................................................................... 909 40 Troubleshooting..................................................................................................................... 913 Table of Contents.................................................................................................................. 914 Precautions Before Work............................................................................................................ 928 Related Information to Troubleshooting............................................................................................. 929 General Troubleshooting Points................................................................................................. 929 Troubleshooting Points for Aftertreatment System............................................................................... 930 Sequence of Events in Troubleshooting.......................................................................................... 937 Troubleshooting for Radio Control System....................................................................................... 939 Checks Before Troubleshooting (Specifications of Radio Control)............................................................ 939 Examine Operating State of Radio Control Receiver.......................................................................... 940 Examine Operating State of Radio Control Transmitter....................................................................... 941 Checks Before Troubleshooting.................................................................................................. 942 Inspection Procedure Before Troubleshooting.................................................................................... 944 Walk-Around Check.......................................................................................................... 944 Test in Accordance with Testing Procedure...................................................................................... 946 How to Drain Water and Sediment from Fuel Tank............................................................................. 946 How to Examine Water Separator, Drain Water and Sediment................................................................... 946 Examine Fuel Main Filter................................................................................................... 947 How to Examine Oil Level in Hydraulic Tank, Add Oil........................................................................ 948 How to Examine Coolant Level, Add Coolant.................................................................................. 950 How to Examine Oil Level in Engine Oil Pan, Add Oil........................................................................ 951 How to Examine Oil Level in Power Train Case, Add Oil...................................................................... 952 How to Examine Dust Indicator.............................................................................................. 953 How to Examine Brake Operation............................................................................................. 954 How to Examine Electric Wiring............................................................................................. 954 How to Examine Fuel Level, Add Fuel........................................................................................ 954 How to Examine Operation of Lamps.......................................................................................... 955 How to Examine Machine Monitor............................................................................................. 955 How to Remove Sediment in Engine Room...................................................................................... 956 How to Examine Operation State of Horn..................................................................................... 956 How to Examine Operation State of Backup Alarm............................................................................. 957 How to Examine Electric Equipment.......................................................................................... 957 Preparation for Troubleshooting of Electrical System........................................................................... 962 Preparation for Troubleshooting of Machine Monitor......................................................................... 962 Preparation for Troubleshooting of Engine Controller....................................................................... 962 Preparation for Troubleshooting of Work Equipment Controller............................................................... 962 Preparation for Troubleshooting of Power Train Controller.................................................................. 963 Preparation for Troubleshooting of KOMTRAX Terminal........................................................................ 963 How to Disconnect and Connect Connector with a Special Lock................................................................ 963 Procedure for Troubleshooting.................................................................................................. 968 Symptom and Troubleshooting Numbers............................................................................................ 971 Information Shown in Troubleshooting Table..................................................................................... 974 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................ 976 Connector List and Layout...................................................................................................... 979 Connector Contact Connection Table.............................................................................................1002 T-Branch Box and T-Branch Adapter Table........................................................................................1042 Fuse Location Table............................................................................................................1048 Precautions When You Clean and Replace KDPF (KCSF and KDOC)....................................................................1052 Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])..................................1056 Failure Code Table.............................................................................................................1058 Troubleshooting by Failure Code (Display of Code)..................................................................................1085 Failure Code [1500L0]..........................................................................................................1085 Failure Code [15B0NX]..........................................................................................................1086 Failure Code [15SAL1]..........................................................................................................1088 Failure Code [15SALH]..........................................................................................................1090 Failure Code [15SBL1]..........................................................................................................1092 Failure Code [15SBLH]..........................................................................................................1094 Failure Code [15SEL1]..........................................................................................................1096 Failure Code [15SELH]..........................................................................................................1098 Failure Code [15SFL1]..........................................................................................................1100 Failure Code [15SFLH]..........................................................................................................1102 Failure Code [15SGL1]..........................................................................................................1104 Failure Code [15SGLH]..........................................................................................................1106 Failure Code [15SJL1]..........................................................................................................1108 Failure Code [15SJLH]..........................................................................................................1110 Failure Code [1800MW]..........................................................................................................1112 Failure Code [2201L1]..........................................................................................................1113 Failure Code [2201LH]..........................................................................................................1115 Failure Code [2202L1]..........................................................................................................1117 Failure Code [2202LH]..........................................................................................................1118 Failure Code [2300NR]..........................................................................................................1120 Failure Code [2301L1]..........................................................................................................1121 Failure Code [2301LH]..........................................................................................................1123 Failure Code [2301NR]..........................................................................................................1125 Failure Code [2301NT]..........................................................................................................1126 Failure Code [2302L1]..........................................................................................................1127 Failure Code [2302LH]..........................................................................................................1129 Failure Code [2302NR]..........................................................................................................1131 Failure Code [2302NT]..........................................................................................................1132 Failure Code [851PKA]..........................................................................................................1133 Failure Code [851QKA]..........................................................................................................1134 Failure Code [851RKA]..........................................................................................................1135 Failure Code [851SKA]..........................................................................................................1136 Failure Code [851TKA]..........................................................................................................1137 Failure Code [851UKA]..........................................................................................................1138 Failure Code [851VKA]..........................................................................................................1139 Failure Code [851XKA]..........................................................................................................1140 Failure Code [852RKR]..........................................................................................................1141 Failure Code [8590KA]..........................................................................................................1142 Failure Code [8590KY]..........................................................................................................1147 Failure Code [879AKA]..........................................................................................................1150 Failure Code [879AKB]..........................................................................................................1151 Failure Code [879BKA]..........................................................................................................1152 Failure Code [879BKB]..........................................................................................................1154 Failure Code [879CKA]..........................................................................................................1156 Failure Code [879CKB]..........................................................................................................1157 Failure Code [879DKZ]..........................................................................................................1158 Failure Code [879EMC]..........................................................................................................1160 Failure Code [879FMC]..........................................................................................................1161 Failure Code [879GKX]..........................................................................................................1162 Failure Code [989L00]..........................................................................................................1164 Failure Code [989M00]..........................................................................................................1165 Failure Code [989N00]..........................................................................................................1166 Failure Code [A1U0N3]..........................................................................................................1167 Failure Code [A1U0N4]..........................................................................................................1169 Failure Code [A900FR]..........................................................................................................1171 Failure Code [A900N6]..........................................................................................................1172 Failure Code [A900NY]..........................................................................................................1173 Failure Code [AA10NX]..........................................................................................................1174 Failure Code [AB00KE]..........................................................................................................1176 Failure Code [AQ00N3]..........................................................................................................1178 Failure Code [AQ00N4]..........................................................................................................1179 Failure Code [AQ10N3]..........................................................................................................1180 Failure Code [B@BAZG]..........................................................................................................1181 Failure Code [B@BAZK]..........................................................................................................1182 Failure Code [B@BCNS]..........................................................................................................1183 Failure Code [B@BCZK]..........................................................................................................1184 Failure Code [B@CENS]..........................................................................................................1186 Failure Code [B@HANS]..........................................................................................................1188 Failure Code [B@HAZK]..........................................................................................................1190 Failure Code [CA115]...........................................................................................................1191 Failure Code [CA122]...........................................................................................................1195 Failure Code [CA123]...........................................................................................................1197 Failure Code [CA131]...........................................................................................................1199 Failure Code [CA132]...........................................................................................................1201 Failure Code [CA135]...........................................................................................................1203 Failure Code [CA141]...........................................................................................................1205 Failure Code [CA144]...........................................................................................................1207 Failure Code [CA145]...........................................................................................................1209 Failure Code [CA153]...........................................................................................................1211 Failure Code [CA154]...........................................................................................................1213 Failure Code [CA187]...........................................................................................................1215 Failure Code [CA212]...........................................................................................................1217 Failure Code [CA213]...........................................................................................................1219 Failure Code [CA221]...........................................................................................................1221 Failure Code [CA222]...........................................................................................................1223 Failure Code [CA227]...........................................................................................................1225 Failure Code [CA234]...........................................................................................................1227 Failure Code [CA238]...........................................................................................................1228 Failure Code [CA239]...........................................................................................................1230 Failure Code [CA271]...........................................................................................................1232 Failure Code [CA272]...........................................................................................................1234 Failure Code [CA273]...........................................................................................................1235 Failure Code [CA274]...........................................................................................................1237 Failure Code [CA322]...........................................................................................................1238 Failure Code [CA323]...........................................................................................................1240 Failure Code [CA324]...........................................................................................................1242 Failure Code [CA325]...........................................................................................................1244 Failure Code [CA331]...........................................................................................................1246 Failure Code [CA332]...........................................................................................................1248 Failure Code [CA343]...........................................................................................................1250 Failure Code [CA351]...........................................................................................................1252 Failure Code [CA352]...........................................................................................................1254 Failure Code [CA356]...........................................................................................................1256 Failure Code [CA357]...........................................................................................................1258 Failure Code [CA386]...........................................................................................................1260 Failure Code [CA441]...........................................................................................................1262 Failure Code [CA442]...........................................................................................................1264 Failure Code [CA449]...........................................................................................................1266 Failure Code [CA451]...........................................................................................................1267 Failure Code [CA452]...........................................................................................................1269 Failure Code [CA515]...........................................................................................................1271 Failure Code [CA516]...........................................................................................................1272 Failure Code [CA553]...........................................................................................................1273 Failure Code [CA555]...........................................................................................................1274 Failure Code [CA556]...........................................................................................................1276 Failure Code [CA559]...........................................................................................................1278 Failure Code [CA595]...........................................................................................................1284 Failure Code [CA687]...........................................................................................................1286 Failure Code [CA689]...........................................................................................................1288 Failure Code [CA691]...........................................................................................................1290 Failure Code [CA692]...........................................................................................................1292 Failure Code [CA697]...........................................................................................................1294 Failure Code [CA698]...........................................................................................................1295 Failure Code [CA731]...........................................................................................................1296 Failure Code [CA778]...........................................................................................................1300 Failure Code [CA1117]..........................................................................................................1302 Failure Code [CA1135]..........................................................................................................1304 Failure Code [CA1257]..........................................................................................................1307 Failure Code [CA1664]..........................................................................................................1308 Failure Code [CA1691]..........................................................................................................1310 Failure Code [CA1695]..........................................................................................................1313 Failure Code [CA1696]..........................................................................................................1315 Failure Code [CA1843]..........................................................................................................1317 Failure Code [CA1844]..........................................................................................................1319 Failure Code [CA1879]..........................................................................................................1321 Failure Code [CA1881]..........................................................................................................1323 Failure Code [CA1883]..........................................................................................................1325 Failure Code [CA1921]..........................................................................................................1328 Failure Code [CA1922]..........................................................................................................1330 Failure Code [CA1923]..........................................................................................................1334 Failure Code [CA1924]..........................................................................................................1336 Failure Code [CA1925]..........................................................................................................1338 Failure Code [CA1927]..........................................................................................................1340 Failure Code [CA1928]..........................................................................................................1342 Failure Code [CA1942]..........................................................................................................1344 Failure Code [CA1963]..........................................................................................................1346 Failure Code [CA1977]..........................................................................................................1350 Failure Code [CA1993]..........................................................................................................1352 Failure Code [CA2185]..........................................................................................................1355 Failure Code [CA2186]..........................................................................................................1357 Failure Code [CA2249]..........................................................................................................1359 Failure Code [CA2265]..........................................................................................................1364 Failure Code [CA2266]..........................................................................................................1366 Failure Code [CA2271]..........................................................................................................1368 Failure Code [CA2272]..........................................................................................................1370 Failure Code [CA2349]..........................................................................................................1372 Failure Code [CA2353]..........................................................................................................1374 Failure Code [CA2357]..........................................................................................................1376 Failure Code [CA2381]..........................................................................................................1379 Failure Code [CA2382]..........................................................................................................1381 Failure Code [CA2383]..........................................................................................................1383 Failure Code [CA2386]..........................................................................................................1385 Failure Code [CA2387]..........................................................................................................1387 Troubleshooting Flowchart..................................................................................................1391 Failure Code [CA2637]..........................................................................................................1392 Failure Code [CA2639]..........................................................................................................1395 Failure Code [CA2732]..........................................................................................................1397 Failure Code [CA2733]..........................................................................................................1399 Failure Code [CA2741]..........................................................................................................1401 Failure Code [CA2765]..........................................................................................................1402 Failure Code [CA2777]..........................................................................................................1403 Failure Code [CA2878]..........................................................................................................1405 Failure Code [CA2881]..........................................................................................................1408 Failure Code [CA3133]..........................................................................................................1411 Failure Code [CA3134]..........................................................................................................1413 Failure Code [CA3135]..........................................................................................................1415 Failure Code [CA3167]..........................................................................................................1418 Failure Code [CA3251]..........................................................................................................1421 Failure Code [CA3253]..........................................................................................................1423 Failure Code [CA3254]..........................................................................................................1427 Failure Code [CA3255]..........................................................................................................1430 Failure Code [CA3256]..........................................................................................................1433 Failure Code [CA3311]..........................................................................................................1435 Failure Code [CA3312]..........................................................................................................1437 Failure Code [CA3313]..........................................................................................................1439 Failure Code [CA3314]..........................................................................................................1440 Failure Code [CA3315]..........................................................................................................1441 Failure Code [CA3316]..........................................................................................................1444 Failure Code [CA3317]..........................................................................................................1445 Failure Code [CA3318]..........................................................................................................1446 Failure Code [CA3319]..........................................................................................................1449 Failure Code [CA3321]..........................................................................................................1450 Failure Code [CA3322]..........................................................................................................1451 Failure Code [CA3419]..........................................................................................................1454 Failure Code [CA3421]..........................................................................................................1456 Failure Code [CA4151]..........................................................................................................1458 Failure Code [CA4158]..........................................................................................................1462 Failure Code [CA4161]..........................................................................................................1463 Failure Code [CA4162]..........................................................................................................1465 Failure Code [CA4163]..........................................................................................................1467 Failure Code [CA4259]..........................................................................................................1469 Failure Code [CA4952]..........................................................................................................1472 Failure Code [CA5383]..........................................................................................................1474 Failure Code [CB115]...........................................................................................................1475 Failure Code [CB187]...........................................................................................................1478 Failure Code [CB227]...........................................................................................................1480 Failure Code [CB238]...........................................................................................................1481 Failure Code [CB239]...........................................................................................................1483 Failure Code [CB271]...........................................................................................................1485 Failure Code [CB272]...........................................................................................................1487 Failure Code [CB273]...........................................................................................................1488 Failure Code [CB274]...........................................................................................................1490 Failure Code [CB343]...........................................................................................................1491 Failure Code [CB352]...........................................................................................................1493 Failure Code [CB386]...........................................................................................................1495 Failure Code [CB441]...........................................................................................................1497 Failure Code [CB442]...........................................................................................................1499 Failure Code [CB689]...........................................................................................................1501 Failure Code [CB697]...........................................................................................................1503 Failure Code [CB698]...........................................................................................................1504 Failure Code [CB731]...........................................................................................................1505 Failure Code [CB778]...........................................................................................................1509 Failure Code [CB1117]..........................................................................................................1511 Failure Code [CB1257]..........................................................................................................1513 Failure Code [CB1664]..........................................................................................................1514 Failure Code [CB1691]..........................................................................................................1516 Failure Code [CB1695]..........................................................................................................1519 Failure Code [CB1696]..........................................................................................................1521 Failure Code [CB1879]..........................................................................................................1523 Failure Code [CB1881]..........................................................................................................1525 Failure Code [CB1883]..........................................................................................................1527 Failure Code [CB1921]..........................................................................................................1530 Failure Code [CB1922]..........................................................................................................1532 Failure Code [CB1923]..........................................................................................................1536 Failure Code [CB1924]..........................................................................................................1538 Failure Code [CB1925]..........................................................................................................1540 Failure Code [CB1927]..........................................................................................................1542 Failure Code [CB1928]..........................................................................................................1544 Failure Code [CB1963]..........................................................................................................1546 Failure Code [CB1977]..........................................................................................................1550 Failure Code [CB1993]..........................................................................................................1552 Failure Code [CB2265]..........................................................................................................1555 Failure Code [CB2266]..........................................................................................................1557 Failure Code [CB2637]..........................................................................................................1559 Failure Code [CB2639]..........................................................................................................1562 Failure Code [CB2732]..........................................................................................................1564 Failure Code [CB2733]..........................................................................................................1566 Failure Code [CB2741]..........................................................................................................1568 Failure Code [CB2777]..........................................................................................................1570 Failure Code [CB2878]..........................................................................................................1572 Failure Code [CB2881]..........................................................................................................1575 Failure Code [CB3133]..........................................................................................................1578 Failure Code [CB3134]..........................................................................................................1580 Failure Code [CB3135]..........................................................................................................1582 Failure Code [CB3167]..........................................................................................................1585 Failure Code [CB3251]..........................................................................................................1588 Failure Code [CB3253]..........................................................................................................1590 Failure Code [CB3254]..........................................................................................................1595 Failure Code [CB3255]..........................................................................................................1598 Failure Code [CB3256]..........................................................................................................1601 Failure Code [CB3311]..........................................................................................................1603 Failure Code [CB3312]..........................................................................................................1605 Failure Code [CB3313]..........................................................................................................1607 Failure Code [CB3314]..........................................................................................................1608 Failure Code [CB3315]..........................................................................................................1609 Failure Code [CB3316]..........................................................................................................1612 Failure Code [CB3317]..........................................................................................................1613 Failure Code [CB3318]..........................................................................................................1614 Failure Code [CB3319]..........................................................................................................1617 Failure Code [CB3321]..........................................................................................................1618 Failure Code [CB3322]..........................................................................................................1619 Failure Code [CB4151]..........................................................................................................1622 Failure Code [CB4158]..........................................................................................................1626 Failure Code [CB4161]..........................................................................................................1627 Failure Code [CB4162]..........................................................................................................1629 Failure Code [CB4163]..........................................................................................................1631 Failure Code [CB4259]..........................................................................................................1634 Failure Code [CB4952]..........................................................................................................1637 Failure Code [CB5383]..........................................................................................................1639 Failure Code [D130KA]..........................................................................................................1640 Failure Code [D130KB]..........................................................................................................1642 Failure Code [D141KA]..........................................................................................................1643 Failure Code [D141KB]..........................................................................................................1645 Failure Code [D141KY]..........................................................................................................1647 Failure Code [D162KA]..........................................................................................................1649 Failure Code [D162KB]..........................................................................................................1651 Failure Code [D162KY]..........................................................................................................1653 Failure Code [D16CKA]..........................................................................................................1655 Failure Code [D16CKB]..........................................................................................................1657 Failure Code [D16CKY]..........................................................................................................1658 Failure Code [D182KZ]..........................................................................................................1660 Failure Code [D19CKA]..........................................................................................................1662 Failure Code [D19CKB]..........................................................................................................1664 Failure Code [D19CKY]..........................................................................................................1666 Failure Code [D19EKA]..........................................................................................................1668 Failure Code [D19EKB]..........................................................................................................1670 Failure Code [D19EKY]..........................................................................................................1672 Failure Code [D19FKA]..........................................................................................................1674 Failure Code [D19FKB]..........................................................................................................1676 Failure Code [D19FKY]..........................................................................................................1678 Failure Code [D19GKA]..........................................................................................................1680 Failure Code [D19GKB]..........................................................................................................1682 Failure Code [D19GKY]..........................................................................................................1684 Failure Code [D19JKZ]..........................................................................................................1686 Failure Code [D1D5KA]..........................................................................................................1688 Failure Code [D1D5KB]..........................................................................................................1690 Failure Code [D1D5KY]..........................................................................................................1692 Failure Code [D1EFKA]..........................................................................................................1693 Failure Code [D1EFKB]..........................................................................................................1695 Failure Code [D1EWKA]..........................................................................................................1697 Failure Code [D1EWKB]..........................................................................................................1698 Failure Code [D1EWKY]..........................................................................................................1699 Failure Code [D862KA]..........................................................................................................1700 Failure Code [DAF0MB]..........................................................................................................1701 Failure Code [DAF0MC]..........................................................................................................1702 Failure Code [DAF8KB]..........................................................................................................1703 Failure Code [DAF9KQ]..........................................................................................................1704 Failure Code [DAFGMC]..........................................................................................................1705 Failure Code [DAFLKA]..........................................................................................................1706 Failure Code [DAFLKB]..........................................................................................................1709 Failure Code [DAFQKR]..........................................................................................................1711 Failure Code [DAQW00]..........................................................................................................1716 Failure Code [DAZ9KQ]..........................................................................................................1717 Failure Code [DAZQKR]..........................................................................................................1718 Failure Code [DB2QKR]..........................................................................................................1722 Failure Code [DB2RKR]..........................................................................................................1728 Failure Code [DB90KT]..........................................................................................................1733 Failure Code [DB90MC]..........................................................................................................1734 Failure Code [DB91KK]..........................................................................................................1735 Failure Code [DB92KK]..........................................................................................................1738 Failure Code [DB95KK]..........................................................................................................1741 Failure Code [DB97KK]..........................................................................................................1743 Failure Code [DB99KQ]..........................................................................................................1745 Failure Code [DB9LKA]..........................................................................................................1746 Failure Code [DB9LKB]..........................................................................................................1748 Failure Code [DB9QKR]..........................................................................................................1750 Failure Code [DB9RKR]..........................................................................................................1755 Failure Code [DBE0KT]..........................................................................................................1760 Failure Code [DBE0MC]..........................................................................................................1761 Failure Code [DBE1KK]..........................................................................................................1762 Failure Code [DBE2KK]..........................................................................................................1765 Failure Code [DBE5KK]..........................................................................................................1768 Failure Code [DBE6KK]..........................................................................................................1770 Failure Code [DBE9KQ]..........................................................................................................1772 Failure Code [DBELKA]..........................................................................................................1773 Failure Code [DBELKB]..........................................................................................................1776 Failure Code [DBEQKR]..........................................................................................................1778 Failure Code [DBERKR]..........................................................................................................1783 Failure Code [DBU0KR]..........................................................................................................1788 Failure Code [DBUSKR]..........................................................................................................1789 Failure Code [DBUTKA]..........................................................................................................1790 Failure Code [DBUTKN]..........................................................................................................1791 Failure Code [DBV0MC]..........................................................................................................1792 Failure Code [DBV1KK]..........................................................................................................1793 Failure Code [DBVLKA]..........................................................................................................1795 Failure Code [DBVLKB]..........................................................................................................1797 Failure Code [DBVQKR]..........................................................................................................1799 Failure Code [DBVRKR]..........................................................................................................1800 Failure Code [DBVVKR]..........................................................................................................1801 Failure Code [DBVWKR]..........................................................................................................1802 Failure Code [DD12KA]..........................................................................................................1803 Failure Code [DD12KB]..........................................................................................................1805 Failure Code [DD13KA]..........................................................................................................1807 Failure Code [DD13KB]..........................................................................................................1809 Failure Code [DD14KA]..........................................................................................................1811 Failure Code [DD14KB]..........................................................................................................1813 Failure Code [DDDDKA]..........................................................................................................1815 Failure Code [DDDDKB]..........................................................................................................1817 Failure Code [DDDDKX]..........................................................................................................1819 Failure Code [DDDHKB]..........................................................................................................1820 Failure Code [DDDKKA]..........................................................................................................1822 Failure Code [DDDKKB]..........................................................................................................1824 Failure Code [DDDLKA]..........................................................................................................1826 Failure Code [DDDLKB]..........................................................................................................1828 Failure Code [DDE2KA]..........................................................................................................1830 Failure Code [DDKAKA]..........................................................................................................1831 Failure Code [DDKAKB]..........................................................................................................1833 Failure Code [DDKBKA]..........................................................................................................1835 Failure Code [DDKBKB]..........................................................................................................1837 Failure Code [DDKCL4]..........................................................................................................1839 Failure Code [DDKEL4]..........................................................................................................1841 Failure Code [DDKHKA]..........................................................................................................1843 Failure Code [DDKHKB]..........................................................................................................1845 Failure Code [DDKQKA]..........................................................................................................1847 Failure Code [DDKQKB]..........................................................................................................1849 Failure Code [DDKRKA]..........................................................................................................1851 Failure Code [DDKRKB]..........................................................................................................1853 Failure Code [DDKSKA]..........................................................................................................1855 Failure Code [DDKSKB]..........................................................................................................1857 Failure Code [DDN7L4]..........................................................................................................1859 Failure Code [DDN8L4]..........................................................................................................1861 Failure Code [DDNLKA]..........................................................................................................1863 Failure Code [DDNLKB]..........................................................................................................1865 Failure Code [DDTSL1]..........................................................................................................1867 Failure Code [DDTSLH]..........................................................................................................1869 Failure Code [DFA4KX]..........................................................................................................1871 Failure Code [DFA4KZ]..........................................................................................................1872 Failure Code [DFA4L8]..........................................................................................................1873 Failure Code [DFA5KA]..........................................................................................................1875 Failure Code [DFA5KY]..........................................................................................................1877 Failure Code [DFA6KA]..........................................................................................................1879 Failure Code [DFA6KY]..........................................................................................................1881 Failure Code [DFA7KX]..........................................................................................................1883 Failure Code [DFA7KZ]..........................................................................................................1884 Failure Code [DFA7L8]..........................................................................................................1885 Failure Code [DFA8KA]..........................................................................................................1887 Failure Code [DFA8KY]..........................................................................................................1889 Failure Code [DFA9KA]..........................................................................................................1891 Failure Code [DFA9KY]..........................................................................................................1893 Failure Code [DFAAKX]..........................................................................................................1895 Failure Code [DFAAKZ]..........................................................................................................1896 Failure Code [DFAAL8]..........................................................................................................1897 Failure Code [DFABKA]..........................................................................................................1899 Failure Code [DFABKY]..........................................................................................................1901 Failure Code [DFACKA]..........................................................................................................1903 Failure Code [DFACKY]..........................................................................................................1905 Failure Code [DGS1KA]..........................................................................................................1907 Failure Code [DGS1KX]..........................................................................................................1909 Failure Code [DGT1KA]..........................................................................................................1911 Failure Code [DGT1KX]..........................................................................................................1913 Failure Code [DGT4KA]..........................................................................................................1915 Failure Code [DGT4KY]..........................................................................................................1917 Failure Code [DH21KA]..........................................................................................................1919 Failure Code [DH21KY]..........................................................................................................1921 Failure Code [DHA4KA]..........................................................................................................1923 Failure Code [DHAAMA]..........................................................................................................1925 Failure Code [DHABMA]..........................................................................................................1926 Failure Code [DHACMA]..........................................................................................................1927 Failure Code [DHADMA]..........................................................................................................1928 Failure Code [DHT2L6]..........................................................................................................1929 Failure Code [DHT3KX]..........................................................................................................1930 Failure Code [DHT5KA]..........................................................................................................1931 Failure Code [DHT5KY]..........................................................................................................1933 Failure Code [DHT7KA]..........................................................................................................1935 Failure Code [DHT7KY]..........................................................................................................1937 Failure Code [DK10KA]..........................................................................................................1939 Failure Code [DK10KB]..........................................................................................................1941 Failure Code [DK30KA]..........................................................................................................1943 Failure Code [DK30KX]..........................................................................................................1945 Failure Code [DK30KY]..........................................................................................................1946 Failure Code [DK30KZ]..........................................................................................................1948 Failure Code [DK30L8]..........................................................................................................1949 Failure Code [DK31KA]..........................................................................................................1951 Failure Code [DK31KY]..........................................................................................................1953 Failure Code [DK40KA]..........................................................................................................1955 Failure Code [DK40KY]..........................................................................................................1957 Failure Code [DK55KX]..........................................................................................................1959 Failure Code [DK55KZ]..........................................................................................................1960 Failure Code [DK55L8]..........................................................................................................1961 Failure Code [DK56KA]..........................................................................................................1962 Failure Code [DK56KY]..........................................................................................................1964 Failure Code [DK57KA]..........................................................................................................1966 Failure Code [DK57KY]..........................................................................................................1968 Failure Code [DK60KA]..........................................................................................................1970 Failure Code [DK60KY]..........................................................................................................1972 Failure Code [DK80KR]..........................................................................................................1974 Failure Code [DK80KT]..........................................................................................................1977 Failure Code [DKH1KA]..........................................................................................................1978 Failure Code [DKH1KY]..........................................................................................................1980 Failure Code [DKSGL8]..........................................................................................................1982 Failure Code [DKSHKA]..........................................................................................................1984 Failure Code [DKSHKB]..........................................................................................................1987 Failure Code [DKSJKA]..........................................................................................................1989 Failure Code [DKSJKB]..........................................................................................................1992 Failure Code [DKSKKA]..........................................................................................................1994 Failure Code [DKSKKB]..........................................................................................................1997 Failure Code [DKSKMB]..........................................................................................................1999 Failure Code [DKSLL8]..........................................................................................................2001 Failure Code [DKSMKA]..........................................................................................................2003 Failure Code [DKSMKB]..........................................................................................................2006 Failure Code [DKSNKA]..........................................................................................................2008 Failure Code [DKSNKB]..........................................................................................................2011 Failure Code [DKSPKA]..........................................................................................................2013 Failure Code [DKSPKB]..........................................................................................................2016 Failure Code [DKSPMB]..........................................................................................................2018 Failure Code [DLM3KA]..........................................................................................................2020 Failure Code [DLM3MB]..........................................................................................................2021 Failure Code [DLT3KA]..........................................................................................................2022 Failure Code [DLT3KB]..........................................................................................................2024 Failure Code [DNDAMC]..........................................................................................................2026 Failure Code [DNDBKA]..........................................................................................................2028 Failure Code [DNDBKB]..........................................................................................................2030 Failure Code [DNDCKA]..........................................................................................................2032 Failure Code [DNDCKB]..........................................................................................................2034 Failure Code [DNDDKA]..........................................................................................................2036 Failure Code [DNDDKB]..........................................................................................................2038 Failure Code [DNDEKA]..........................................................................................................2040 Failure Code [DNDEKB]..........................................................................................................2042 Failure Code [DR21KX]..........................................................................................................2044 Failure Code [DR31KX]..........................................................................................................2045 Failure Code [DV20KB]..........................................................................................................2046 Failure Code [DW7BKA]..........................................................................................................2048 Failure Code [DW7BKB]..........................................................................................................2050 Failure Code [DWN3KA]..........................................................................................................2051 Failure Code [DWN3KB]..........................................................................................................2053 Failure Code [DWN3KY]..........................................................................................................2055 Failure Code [DWN5KA]..........................................................................................................2056 Failure Code [DWN5KB]..........................................................................................................2058 Failure Code [DWN5KY]..........................................................................................................2060 Failure Code [DWNCKA]..........................................................................................................2061 Failure Code [DWNCKB]..........................................................................................................2063 Failure Code [DWNCKY]..........................................................................................................2064 Failure Code [DWNVKA]..........................................................................................................2065 Failure Code [DWNVKB]..........................................................................................................2067 Failure Code [DWNWKA]..........................................................................................................2069 Failure Code [DWNWKB]..........................................................................................................2071 Failure Code [DWNXKA]..........................................................................................................2073 Failure Code [DWNXKB]..........................................................................................................2075 Failure Code [DWNYKA]..........................................................................................................2077 Failure Code [DWNYKB]..........................................................................................................2079 Failure Code [DXH1KA]..........................................................................................................2081 Failure Code [DXH1KB]..........................................................................................................2083 Failure Code [DXH1KY]..........................................................................................................2085 Failure Code [DXH4KA]..........................................................................................................2086 Failure Code [DXH4KB]..........................................................................................................2088 Failure Code [DXH4KY]..........................................................................................................2090 Failure Code [DXH5KA]..........................................................................................................2091 Failure Code [DXH5KB]..........................................................................................................2093 Failure Code [DXH5KY]..........................................................................................................2095 Failure Code [DXH6KA]..........................................................................................................2096 Failure Code [DXH6KB]..........................................................................................................2098 Failure Code [DXH6KY]..........................................................................................................2100 Failure Code [DXH7KA]..........................................................................................................2101 Failure Code [DXH7KB]..........................................................................................................2103 Failure Code [DXH7KY]..........................................................................................................2105 Failure Code [DXH8KA]..........................................................................................................2106 Failure Code [DXH8KB]..........................................................................................................2108 Failure Code [DXH8KY]..........................................................................................................2110 Failure Code [DXH9KA]..........................................................................................................2111 Failure Code [DXH9KB]..........................................................................................................2113 Failure Code [DXH9KY]..........................................................................................................2115 Failure Code [DXHAKA]..........................................................................................................2116 Failure Code [DXHAKB]..........................................................................................................2118 Failure Code [DXHAKY]..........................................................................................................2120 Failure Code [DXHBKA]..........................................................................................................2121 Failure Code [DXHBKB]..........................................................................................................2123 Failure Code [DXHBKY]..........................................................................................................2125 Failure Code [DXHCKA]..........................................................................................................2126 Failure Code [DXHCKB]..........................................................................................................2128 Failure Code [DXHCKY]..........................................................................................................2130 Failure Code [DXHRKA]..........................................................................................................2131 Failure Code [DXHRKB]..........................................................................................................2133 Failure Code [DXHRKY]..........................................................................................................2135 Failure Code [DXHSKA]..........................................................................................................2136 Failure Code [DXHSKB]..........................................................................................................2138 Failure Code [DXHSKY]..........................................................................................................2140 Failure Code [DXHTKA]..........................................................................................................2141 Failure Code [DXHTKB]..........................................................................................................2143 Failure Code [DXHTKY]..........................................................................................................2145 Failure Code [DXHUKA]..........................................................................................................2146 Failure Code [DXHUKB]..........................................................................................................2148 Failure Code [DXHUKY]..........................................................................................................2150 Failure Code [DXHWKA]..........................................................................................................2151 Failure Code [DXHWKB]..........................................................................................................2153 Failure Code [DXHWKY]..........................................................................................................2155 Failure Code [DXHXKA]..........................................................................................................2156 Failure Code [DXHXKB]..........................................................................................................2158 Failure Code [DXHXKY]..........................................................................................................2160 Failure Code [DXHYKA]..........................................................................................................2161 Failure Code [DXHYKB]..........................................................................................................2163 Failure Code [DXHYKY]..........................................................................................................2165 Failure Code [DXHZKA]..........................................................................................................2166 Failure Code [DXHZKB]..........................................................................................................2168 Failure Code [DXHZKY]..........................................................................................................2170 Failure Code [DXJ4KA]..........................................................................................................2171 Failure Code [DXJ4KB]..........................................................................................................2173 Failure Code [DXJ8KA]..........................................................................................................2174 Failure Code [DXJ8KB]..........................................................................................................2176 Failure Code [DXJ8KY]..........................................................................................................2178 Failure Code [DXJ9KA]..........................................................................................................2179 Failure Code [DXJ9KB]..........................................................................................................2181 Failure Code [DXJ9KY]..........................................................................................................2183 Failure Code [DXJBKA]..........................................................................................................2184 Failure Code [DXJBKB]..........................................................................................................2186 Failure Code [DXJBKY]..........................................................................................................2187 Failure Code [DY2HKA]..........................................................................................................2188 Failure Code [F7A0KT]..........................................................................................................2190 Failure Code [F7A1KK]..........................................................................................................2191 Failure Code [F7A8KB]..........................................................................................................2194 Failure Code [F7ALKA]..........................................................................................................2195 Failure Code [F7ALKB]..........................................................................................................2198 Failure Code [F7AQKR]..........................................................................................................2200 Failure Code [F7ARKR]..........................................................................................................2205 Failure Code [F7ASKA]..........................................................................................................2210 Failure Code [F7BSKR]..........................................................................................................2214 Failure Code [F7BTKR]..........................................................................................................2216 Failure Code [F7C0KR]..........................................................................................................2217 Failure Code [F7CRKT]..........................................................................................................2221 Failure Code [F9A0KT]..........................................................................................................2222 Failure Code [F9A0MC]..........................................................................................................2223 Failure Code [F9A1KK]..........................................................................................................2224 Failure Code [F9A2KK]..........................................................................................................2226 Failure Code [F9AQKR]..........................................................................................................2228 Failure Code [F9ARKR]..........................................................................................................2233 Failure Code [F9ATKA]..........................................................................................................2238 Failure Code [F9ATKB]..........................................................................................................2241 Failure Code [F9AUMC]..........................................................................................................2243 Failure Code [F@BYNR]..........................................................................................................2245 Failure Code [F@BYNS]..........................................................................................................2246 Troubleshooting of Electrical System (E-Mode)......................................................................................2247 E-1 Engine Does Not Start (Engine Does Not Crank)..............................................................................2247 E-2 Engine Does Not Start in Radio Control Mode (Engine Does Not Crank)........................................................2251 E-3 Engine Stops During Operation (Specifications of Radio Control)............................................................2254 E-4 Manual Preheating System Does Not Work.....................................................................................2259 E-5 Automatic Preheating System Does Not Work..................................................................................2262 E-6 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................2264 E-7 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................2266 E-8 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....2270 E-9 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................2272 E-10 Charge Level Monitor Comes On in Red While Engine Runs....................................................................2273 E-11 Engine Coolant Temperature Monitor Comes on in Red While Engine is in Operation...........................................2275 E-12 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation..................................................2276 E-13 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs.....................................................2277 E-14 Hydraulic Oil Temperature Monitor Comes on in Red While Engine Runs.......................................................2278 E-15 Engine Coolant Temperature Gauge Does Not Show Correct Temperature........................................................2279 E-16 Fuel Level Gauge Does Not Show Correct Level..............................................................................2280 E-17 Power Train Oil Temperature Gauge Does Not Show Correct Temperature.......................................................2282 E-18 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature.........................................................2284 E-19 Operation Mode Does Not Change............................................................................................2286 E-20 Gear Shift Mode Does Not Change...........................................................................................2287 E-21 Movement of Machine Does Not Align to Instructions in Radio Control Transmitter Operation.................................2288 E-22 Radio Control/on-Board Can Not be Changed.................................................................................2291 E-23 All Radio Control Can Not be Operated.....................................................................................2295 E-24 Operating Customize Switch Does Not Display Customize Screen..............................................................2298 E-25 Modifying Setting on Customize Screen Does Not Change Setting of Machine..................................................2299 E-26 Some Areas of Machine Monitor Screen are Not Shown........................................................................2300 E-27 Alarm Buzzer Does Not Sound or Cannot be Stopped..........................................................................2301 E-28 Service Meter is Not Shown, While Starting Switch is in OFF Position......................................................2302 E-29 Service Mode Cannot be Selected...........................................................................................2303 E-30 Horn Does Not Sound.......................................................................................................2304 E-31 Horn Does Not Stop........................................................................................................2306 E-32 Horn Does Not Sound or Does Not Stop (Specifications of Radio Control)....................................................2307 E-33 Backup Alarm Does Not Sound...............................................................................................2309 E-34 Backup Alarm Does Not Stop................................................................................................2310 E-35 Headlamp Does Not Come On.................................................................................................2311 E-36 Rear Lamp and Ripper Point Lamp Do Not Come On............................................................................2315 E-37 Working Lamp Does Not Come On or Go Out (Specifications of Radio Control).................................................2319 E-38 Red Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control)...........................................2322 E-39 Blue Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control)..........................................2325 E-40 Green Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control).........................................2328 E-41 No Wiper Operates.........................................................................................................2331 E-42 Front Wiper Does Not Operate..............................................................................................2336 E-43 Rear Wiper Does Not Operate...............................................................................................2340 E-44 Left Door Wiper Does Not Operate..........................................................................................2344 E-45 Right Door Wiper Does Not Operate.........................................................................................2348 E-1 Fuel Feed Pump Does Not Operate or Stop Automatically......................................................................2352 E-47 Fan Does Not Rotate in Reverse............................................................................................2354 E-48 Gear Cannot be Shifted....................................................................................................2355 E-49 Front Washer Does Not Operate.............................................................................................2356 E-50 Rear Washer Does Not Operate..............................................................................................2358 E-51 Left Door Washer Does Not Operate.........................................................................................2360 E-52 Right Door Washer Does Not Operate........................................................................................2362 E-53 Ripper Pin Puller Does Not Work...........................................................................................2364 E-54 KOMTRAX Plus System Does Not Operate Normally.............................................................................2366 E-55 Cannot Download Data with Wireless LAN....................................................................................2367 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)......................................................................2368 Information Shown in Troubleshooting Table (H-Mode)............................................................................2368 H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull)..............................................................2369 H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed).........................................................................2372 H-3 Machine Does Not Move Off at All Gear Speeds...............................................................................2374 H-4 Machine Travels Only in One Direction, Forward or in Reverse...............................................................2376 H-5 Large Time Lag is in Gear Shifting or Directional Change...................................................................2377 H-6 Brake Does Not Work........................................................................................................2379 H-7 Power Train Oil Overheats..................................................................................................2380 H-8 Torque Converter Lockup Clutch Does Not Engage.............................................................................2381 H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)............................................................2382 H-10 Machine Can Turn (Steering) Only in One Direction.........................................................................2383 H-11 Machine Falls Over Too Much (Steering)....................................................................................2384 H-12 All Work Equipment Operate Slowly.........................................................................................2385 H-13 All Work Equipment Do Not Operate.........................................................................................2387 H-14 Blade Lift Speed or Power is Low..........................................................................................2389 H-15 Blade Tilt Speed or Power is Low..........................................................................................2391 H-16 Ripper Lift Speed or Power is Low.........................................................................................2393 H-17 Ripper Tilt Speed or Power is Low.........................................................................................2395 H-18 Hydraulic Drift of Blade Lift is Large....................................................................................2397 H-19 Hydraulic Drift of Tilted Blade is Large..................................................................................2398 H-20 Hydraulic Drift of Lifted Ripper is Large.................................................................................2399 H-21 Ripper Pin Puller Cylinder Does Not Operate...............................................................................2400 H-22 Blade Pitch Cylinder Does Not Operate.....................................................................................2401 H-23 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve...................................2402 H-24 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...............................................................2403 H-25 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock.......................................................2404 Troubleshooting of Engine (S-Mode).................................................................................................2405 Information Shown in Troubleshooting Table (S-Mode)............................................................................2405 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................................2406 S-2 Engine Cranks but No Exhaust Smoke Comes Out...............................................................................2407 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...................................2408 S-4 Engine Startability is Unsatisfactory......................................................................................2409 S-5 Engine Does Not Pick Up Smoothly...........................................................................................2411 S-6 Engine Stops During Operation..............................................................................................2413 S-7 Engine Runs Rough or is Not Stable.........................................................................................2415 S-8 Engine Lacks Power.........................................................................................................2416 S-9 KDPF Becomes Clogged in a Short Time.......................................................................................2418 S-10 Engine Oil Consumption is Excessive.......................................................................................2420 S-11 Oil Becomes Dirty Quickly.................................................................................................2421 S-1 Fuel Consumption is Excessive..............................................................................................2422 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant......................................................................2423 S-14 Oil Pressure Drops........................................................................................................2424 S-15 Fuel Mixes Into Engine Oil................................................................................................2426 S-16 Water Mixes Into Engine Oil (Milky).......................................................................................2427 S-17 Coolant Temperature Increases Too High (Overheating)......................................................................2428 S-18 Unusual Noise is Heard....................................................................................................2430 S-19 Vibration is Excessive....................................................................................................2431 S-2 Air Cannot be Bled from Fuel Circuit.......................................................................................2432 S-21 Active Regeneration is Done Frequently....................................................................................2433 S-22 Active Regeneration Continues Long........................................................................................2434 S-23 White Smoke is Exhausted During Active Regeneration.......................................................................2435 50 Disassembly and Assembly............................................................................................................2437 Table of Contents..................................................................................................................2438 Precautions Before Work............................................................................................................2444 Related Information on Disassembly and Assembly....................................................................................2445 How to Read This Manual........................................................................................................2445 Coating Materials List.........................................................................................................2447 Special Tool List..............................................................................................................2452 Sketches of Special Tools......................................................................................................2477 Engine and Cooling System..........................................................................................................2503 Remove and Install Supply Pump Assembly........................................................................................2503 How to Remove Supply Pump Assembly.........................................................................................2503 How to Install Supply Pump Assembly........................................................................................2511 Remove and Install Injector Assembly...........................................................................................2522 How to Remove Injector Assembly............................................................................................2523 How to Install Injector Assembly...........................................................................................2531 Remove and Install Fuel Doser Assembly.........................................................................................2544 How to Remove Fuel Doser Assembly..........................................................................................2544 How to Install Fuel Doser Assembly.........................................................................................2546 Remove and Install Cylinder Head Assembly......................................................................................2549 How to Remove Cylinder Head Assembly.......................................................................................2550 How to Install Cylinder Head Assembly......................................................................................2572 Remove and Install Common Rail.................................................................................................2603 How to Remove Common Rail..................................................................................................2603 How to Install Common Rail.................................................................................................2609 Remove and Install EGR Valve Assembly..........................................................................................2616 How to Remove EGR Valve Assembly...........................................................................................2616 How to Install EGR Valve Assembly..........................................................................................2617 Remove and Install EGR Cooler Assembly.........................................................................................2618 How to Remove EGR Cooler Assembly..........................................................................................2618 How to Install EGR Cooler Assembly.........................................................................................2623 Remove and Install Starter Assembly............................................................................................2628 How to Remove Starting Motor Assembly......................................................................................2628 How to Install Starting Motor Assembly.....................................................................................2629 Remove and Install Radiator Guard Assembly.....................................................................................2631 How to Remove Radiator Guard Assembly......................................................................................2631 How to Install Radiator Guard Assembly.....................................................................................2637 Remove and Install Cooler Assembly.............................................................................................2644 How to Remove Cooling Assembly.............................................................................................2644 How to Install Cooling Assembly............................................................................................2649 Remove and Install Radiator Assembly...........................................................................................2653 How to Remove Radiator Assembly............................................................................................2653 How to Install Radiator Assembly...........................................................................................2655 Remove and Install Hydraulic Oil Cooler Assembly...............................................................................2657 How to Remove Hydraulic Oil Cooler Assembly................................................................................2657 How to Install Hydraulic Oil Cooler Assembly...............................................................................2659 Remove and Install Aftercooler Assembly........................................................................................2661 How to Remove Aftercooler Assembly.........................................................................................2661 How to Install Aftercooler Assembly........................................................................................2663 Open and Close Cooling Fan Drive Assembly......................................................................................2665 How to Open Cooling Fan Drive Assembly.....................................................................................2665 How to Close Cooling Fan Drive Assembly....................................................................................2668 Remove and Install Cooling Fan Drive Assembly..................................................................................2671 How to Remove Cooling Fan Drive Assembly...................................................................................2671 How to Install Cooling Fan Drive Assembly..................................................................................2675 Remove and Install Cooling Fan Motor Assembly..................................................................................2678 How to Remove Cooling Fan Motor Assembly...................................................................................2678 How to Install Cooling Fan Motor Assembly..................................................................................2680 Remove and Install Engine Assembly.............................................................................................2682 How to Remove Engine Assembly..............................................................................................2682 How to Install Engine Assembly.............................................................................................2695 Remove and Install Engine Front Oil Seal.......................................................................................2708 How to Remove Engine Front Oil Seal........................................................................................2708 How to Install Engine Front Oil Seal.......................................................................................2709 Remove and Install Engine Rear Oil Seal........................................................................................2711 How to Remove Engine Rear Oil Seal.........................................................................................2711 How to Install Engine Rear Oil Seal........................................................................................2712 Remove and Install Engine Hood Assembly........................................................................................2716 How to Remove Engine Hood Assembly.........................................................................................2716 How to Install Engine Hood Assembly........................................................................................2721 Remove and Install Fuel Tank Assembly..........................................................................................2728 How to Remove Fuel Tank Assembly...........................................................................................2728 How to Install Fuel Tank Assembly..........................................................................................2732 Remove and Install KDPF Assembly...............................................................................................2737 How to Remove KDPF Assembly................................................................................................2737 How to Install KDPF Assembly...............................................................................................2742 Disassemble and Assemble KDPF Assembly.........................................................................................2747 How to Disassemble KDPF Assembly...........................................................................................2748 How to Assemble KDPF Assembly..............................................................................................2753 Remove and Install KCCV Assembly...............................................................................................2760 How to Remove KCCV Assembly................................................................................................2760 How to Install KCCV Assembly...............................................................................................2762 Remove and Install VGT Assembly................................................................................................2766 How to Remove VGT Assembly.................................................................................................2766 How to Install VGT Assembly................................................................................................2774 Remove and Install Air Cleaner Bracket Assembly................................................................................2784 How to Remove Air Cleaner Bracket Assembly.................................................................................2784 How to Install Air Cleaner Bracket Assembly................................................................................2789 Remove and Install Air Cleaner Assembly........................................................................................2794 How to Remove Air Cleaner Assembly.........................................................................................2794 How to Install Air Cleaner Assembly........................................................................................2795 Remove and Install Air Conditioner Compressor Assembly.........................................................................2796 How to Remove Air Conditioner Compressor Assembly..........................................................................2796 How to Install Air Conditioner Compressor Assembly.........................................................................2799 Remove and Install Air Conditioner Condenser Assembly..........................................................................2802 How to Remove Air Conditioner Condenser Assembly...........................................................................2802 How to Install Air Conditioner Condenser Assembly..........................................................................2805 Power Train........................................................................................................................2808 Remove and Install Damper Assembly.............................................................................................2808 How to Remove Damper Assembly..............................................................................................2808 How to Install Damper Assembly.............................................................................................2816 Disassemble and Assemble Damper Assembly.......................................................................................2826 How to Disassemble Damper Assembly.........................................................................................2826 How to Assemble Damper Assembly............................................................................................2827 Remove and Install Power Train Unit Assembly...................................................................................2830 How to Remove Power Train Unit Assembly....................................................................................2830 How to Install Power Train Unit Assembly...................................................................................2843 Disconnect and Connect Power Train Unit Assembly...............................................................................2856 How to Disconnect Power Train Unit Assembly................................................................................2856 How to Connect Power Train Unit Assembly...................................................................................2865 Disassemble and Assemble PTO Assembly..........................................................................................2875 How to Disassemble PTO Assembly............................................................................................2875 How to Assemble PTO Assembly...............................................................................................2878 Disassemble and Assemble Torque Converter Assembly.............................................................................2883 How to Disassemble Torque Converter Assembly...............................................................................2883 How to Assemble Torque Converter Assembly..................................................................................2887 Disassemble and Assemble Transmission Assembly.................................................................................2894 How to Disassemble Transmission Assembly...................................................................................2895 How to Assemble Transmission Assembly......................................................................................2907 Disassemble and Assemble Steering Case Assembly................................................................................2925 How to Disassemble Steering Case Assembly..................................................................................2925 How to Assemble Steering Case Assembly.....................................................................................2932 Remove and Install Final Drive Assembly........................................................................................2942 How to Remove Final Drive Assembly.........................................................................................2942 How to Install Final Drive Assembly........................................................................................2943 Disassemble and Assemble Final Drive Assembly..................................................................................2945 How to Disassemble Final Drive Assembly....................................................................................2946 How to Assemble Final Drive Assembly.......................................................................................2952 Undercarriage and Frame............................................................................................................2962 Remove and Install Track Frame Assembly........................................................................................2962 How to Remove Track Frame Assembly.........................................................................................2962 How to Install Track Frame Assembly........................................................................................2966 Remove and Install Idler Assembly..............................................................................................2971 How to Remove Idler Assembly...............................................................................................2971 How to Install Idler Assembly..............................................................................................2972 Disassemble and Assemble Idler Assembly........................................................................................2973 How to Disassemble Idler Assembly..........................................................................................2973 How to Assemble Idler Assembly.............................................................................................2974 Remove and Install Recoil Spring Assembly......................................................................................2977 How to Remove Recoil Spring Assembly.......................................................................................2978 How to Install Recoil Spring Assembly......................................................................................2986 Disassemble and Assemble Recoil Spring Assembly................................................................................2991 How to Disassemble Recoil Spring Assembly..................................................................................2991 How to Assemble Recoil Spring Assembly.....................................................................................2992 Remove and Install Track Roller Assembly.......................................................................................2993 How to Remove Track Roller Assembly........................................................................................2993 How to Install Track Roller Assembly.......................................................................................2995 Disassemble and Assemble Track Roller Assembly.................................................................................2997 How to Disassemble Track Roller Assembly...................................................................................2997 How to Assemble Track Roller Assembly......................................................................................2998 Remove and Install No. 1 Bogie Assembly........................................................................................3000 How to Remove No.1 Bogie Assembly..........................................................................................3001 How to Install No. 1 Bogie Assembly........................................................................................3003 Remove and Install Bogie Assembly..............................................................................................3006 How to Remove Bogie Assembly...............................................................................................3007 How to Install Bogie Assembly..............................................................................................3010 Disassemble and Assemble Bogie Assembly........................................................................................3012 How to Disassemble Bogie Assembly..........................................................................................3012 How to Assemble Bogie Assembly.............................................................................................3013 Remove and Install Carrier Roller Assembly.....................................................................................3015 How to Remove Carrier Roller Assembly......................................................................................3015 How to Install Carrier Roller Assembly.....................................................................................3015 Disassemble and Assemble Carrier Roller Assembly...............................................................................3017 How to Disassemble Carrier Roller Assembly.................................................................................3017 How to Assemble Carrier Roller Assembly....................................................................................3018 Remove and Install Pivot Shaft Assembly........................................................................................3022 How to Remove Pivot Shaft Assembly.........................................................................................3022 How to Install Pivot Shaft Assembly........................................................................................3023 Separate and Connect Track Assembly............................................................................................3024 How to Separate Track Assembly.............................................................................................3024 How to Install Track Assembly..............................................................................................3026 Disassemble and Assemble Track Assembly Generally..............................................................................3028 How to Disassemble Full Track Shoes Assembly...............................................................................3028 How to Assemble Full Track Shoes Assembly..................................................................................3031 Disassemble and Assemble One Track Link Assembly in Field......................................................................3045 How to Disassemble One Track Link Assembly in Field........................................................................3046 How to Assemble One Track Link Assembly in Field...........................................................................3048 Disassemble and Assemble Master Link...........................................................................................3050 How to Disassemble Master Link.............................................................................................3052 How to Assemble Master Link................................................................................................3052 Remove and Install Equalizer Bar Assembly......................................................................................3055 How to Remove Equalizer Bar Assembly.......................................................................................3055 How to Install Equalizer Bar Assembly......................................................................................3060 Disassemble and Assemble Equalizer Bar Bushing.................................................................................3065 How to Disassemble Equalizer Bar Bushing...................................................................................3065 How to Assemble Equalizer Bar Bushing......................................................................................3066 Remove and Install Segment Teeth...............................................................................................3068 How to Remove Segment Teeth................................................................................................3068 How to Install Segment Teeth...............................................................................................3068 Remove and Install Power Ladder Assembly.......................................................................................3070 How to Remove Power Ladder Assembly........................................................................................3070 How to Install Power Ladder Assembly.......................................................................................3073 Open and Close Underguard Assembly.............................................................................................3076 How to Open Underguard Assembly............................................................................................3076 How to Close Underguard Assembly...........................................................................................3082 Remove and Install Under Guard Assembly........................................................................................3088 How to Remove Underguard Assembly..........................................................................................3088 How to Install Underguard Assembly.........................................................................................3095 Hydraulic System...................................................................................................................3101 Remove and Install Hydraulic Tank Assembly.....................................................................................3101 How to Remove Hydraulic Tank Assembly......................................................................................3101 How to Install Hydraulic Tank Assembly.....................................................................................3105 Remove and Install Work Equipment Pump Assembly................................................................................3110 How to Remove Work Equipment Pump Assembly.................................................................................3110 How to Install Work Equipment Pump Assembly................................................................................3114 Remove and Install Power Train Pump and Steering Lubrication Pump Assembly.....................................................3119 How to Remove Power Train Pump and Steering Lubrication Pump Assembly......................................................3119 How to Install Power Train Pump and Steering Lubrication Pump Assembly.....................................................3119 Remove and Install Cooling Fan Pump Assembly...................................................................................3121 How to Remove Cooling Fan Pump Assembly....................................................................................3121 How to Install Cooling Fan Pump Assembly...................................................................................3122 Remove and Install Scavenging Pump Assembly....................................................................................3124 How to Remove Scavenging Pump Assembly.....................................................................................3124 How to Install Scavenging Pump Assembly....................................................................................3124 Disassemble and Assemble Control Valve Assembly................................................................................3126 How to Assemble Control Valve Assembly.....................................................................................3126 Remove and Install Control Valve Assembly......................................................................................3129 How to Remove Control Valve Assembly.......................................................................................3129 How to Install Control Valve Assembly......................................................................................3135 Work Equipment.....................................................................................................................3142 Remove and Install Blade Assembly..............................................................................................3142 How to Remove Blade Assembly...............................................................................................3142 How to Install Blade Assembly..............................................................................................3145 Disassemble and Assemble Blade Assembly........................................................................................3149 How to Disassemble Blade Assembly..........................................................................................3149 How to Assemble Blade Assembly.............................................................................................3152 Disassemble and Assemble Giant Ripper Assembly.................................................................................3156 How to Disassemble Giant Ripper Assembly...................................................................................3156 How to Assemble Giant Ripper Assembly......................................................................................3158 Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly.......................................................3161 How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly........................................................3163 How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly.......................................................3168 Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly.................................................3173 How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly...................................................3174 How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly......................................................3180 Disassemble and Assemble Blade Tilt Cylinder Assembly..........................................................................3190 How to Disassemble Blade Tilt Cylinder Assembly............................................................................3190 How to Assemble Blade Tilt Cylinder Assembly...............................................................................3192 Disassemble and Assemble Ripper Pin Puller Cylinder Assembly...................................................................3195 How to Disassemble Ripper Pin Puller Cylinder Assembly.....................................................................3195 How to Assemble Ripper Pin Puller Cylinder Assembly........................................................................3196 CAB Related Parts..................................................................................................................3198 Remove and Install ROPS Guard..................................................................................................3198 How to Remove ROPS Guard...................................................................................................3198 How to Install ROPS Guard..................................................................................................3199 Remove and Install Operator Cab Assembly.......................................................................................3200 How to Remove Operator Cab Assembly........................................................................................3200 How to Install Operator Cab Assembly.......................................................................................3204 Remove and Install Operator Cab Glass (Adhered Glass)..........................................................................3208 How to Remove Operator Cab Glass (Adhered Glass)...........................................................................3209 How to Install Operator Cab Glass (Adhered Glass)..........................................................................3209 Remove and Install Air Conditioner Unit Assembly...............................................................................3213 How to Remove Air Conditioner Unit Assembly................................................................................3213 How to Install Air Conditioner Unit Assembly...............................................................................3219 Remove and Install Operator Seat...............................................................................................3225 How to Remove Operator Seat................................................................................................3225 How to Install Operator Seat...............................................................................................3226 How to Remove and Install Seat Belt............................................................................................3228 How to Remove Seat Belt....................................................................................................3228 How to Install Seatbelt....................................................................................................3229 Remove and Install FCCS........................................................................................................3230 How to Remove FCCS.........................................................................................................3230 How to Install FCCS........................................................................................................3231 Electrical System..................................................................................................................3233 Remove and Install Engine Controller Assembly..................................................................................3233 How to Remove Engine Controller Assembly...................................................................................3233 How to Install Engine Controller Assembly..................................................................................3237 Remove and Install Power Train Controller Assembly.............................................................................3242 How to Remove Power Train Controller Assembly..............................................................................3242 How to Install Power Train Controller Assembly.............................................................................3243 Remove and Install Work Equipment Controller Assembly..........................................................................3244 How to Remove Work Equipment Controller Assembly...........................................................................3244 How to Install Work Equipment Controller Assembly..........................................................................3245 Remove and Install Machine Monitor Assembly....................................................................................3246 How to Remove Machine Monitor Assembly.....................................................................................3246 How to Install Machine Monitor Assembly....................................................................................3247 Remove and Install Mass Air Flow and Temperature Sensor........................................................................3249 How to Remove Mass Air Flow and Temperature Sensor.........................................................................3249 How to Install Mass Air Flow and Temperature Sensor........................................................................3250 Remove and Install KCCV Crankcase Pressure Sensor..............................................................................3252 How to Remove KCCV Crankcase Pressure Sensor...............................................................................3252 How to Install KCCV Crankcase Pressure Sensor..............................................................................3253 Remove and Install KOMTRAX Terminal Assembly...................................................................................3254 How to Remove KOMTRAX Terminal Assembly....................................................................................3254 How to Install KOMTRAX Terminal Assembly...................................................................................3254 Remove And Install KOMTRAX Plus Controller Assembly............................................................................3256 How to Remove KOMTRAX Plus Controller Assembly.............................................................................3256 How to Install KOMTRAX Plus Controller Assembly............................................................................3257 Remove and Install Wireless LAN Unit Assembly..................................................................................3259 How to Remove Wireless LAN Unit Assembly...................................................................................3259 How to Install Wireless LAN Unit Assembly..................................................................................3260 Remove and Install Control Box.................................................................................................3262 How to Remove Control Box..................................................................................................3262 How to Install Control Box.................................................................................................3263 Remove and Install Option Controller Assembly..................................................................................3264 How to Remove Option Controller Assembly...................................................................................3264 How to Install Option Controller Assembly..................................................................................3267 Remove and Install Navigation Controller Assembly..............................................................................3272 How to Remove Navigation Controller Assembly...............................................................................3272 How to Install Navigation Controller Assembly..............................................................................3273 Remove and Install AUX BOX.....................................................................................................3275 How to Remove AUX BOX......................................................................................................3275 How to Install AUX BOX.....................................................................................................3277 Remove and Install IMU Sensor..................................................................................................3279 How to Remove IMU Sensor...................................................................................................3279 How to Install IMU Sensor..................................................................................................3280 Remove and Install Radio Control Receiver......................................................................................3283 How to Remove Radio Control Receiver.......................................................................................3283 How to Install Radio Control Receiver......................................................................................3284 60 Maintenance Standard................................................................................................................3287 Table of Contents..................................................................................................................3288 Engine and Cooling System..........................................................................................................3290 Maintenance Standard for Engine Mount..........................................................................................3290 Maintenance Standard for Damper................................................................................................3292 Maintenance Standard for Cooling System........................................................................................3294 Maintenance Standard for Cooling Fan Pump......................................................................................3296 Maintenance Standard for Servo Valve.......................................................................................3304 Maintenance Standard for Cooling Fan Motor.....................................................................................3306 Power Train........................................................................................................................3309 Maintenance Standard for Universal Joint.......................................................................................3309 Maintenance Standard for Power Train Mount.....................................................................................3310 Maintenance Standard for Torque Converter and PTO..............................................................................3312 Maintenance Standard for Torque Converter Control Valve........................................................................3317 Maintenance Standard for Lockup Clutch ECMV....................................................................................3319 Maintenance Standard for Stator Clutch ECMV....................................................................................3320 Maintenance Standard for Transmission..........................................................................................3321 Maintenance Standard for PTO, Transmission Lubrication Pump, and Power Train Pump..............................................3327 Maintenance Standard for Transmission ECMV.....................................................................................3329 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve...................................................3330 Maintenance Standard for Transmission Lubrication Relief Valve.................................................................3331 Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering..............................................................3332 Maintenance Standard for Brake Solenoid Valve..................................................................................3338 Maintenance Standard for Sudden Stop Prevention Valve..........................................................................3339 Maintenance Standard for Final Drive...........................................................................................3340 Maintenance Standard for Sprocket for Conventional Type Track Shoes............................................................3344 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes...........................3345 Undercarriage and Frame............................................................................................................3347 Maintenance Standard for Main Frame............................................................................................3347 Maintenance Standard for Suspension............................................................................................3350 Maintenance Standard for Track Frame and Idler Cushion.........................................................................3353 Maintenance Standard for Idler.................................................................................................3357 Maintenance Standard for Track Roller Bogie....................................................................................3359 Maintenance Standard for Track Roller for Conventional Type Track Shoes........................................................3360 Maintenance Standard for Carrier Roller for Conventional Type Track Shoes......................................................3363 Maintenance Standard for Conventional Type Track Shoes.........................................................................3364 Maintenance Standard for Single Shoes and Heavy Duty Shoes.....................................................................3366 Hydraulic System...................................................................................................................3367 Maintenance Standard for Hydraulic Tank........................................................................................3367 Maintenance Standard for Work Equipment Pump...................................................................................3368 Maintenance Standard for Scavenging Pump.......................................................................................3371 Maintenance Standard for Control Valve.........................................................................................3372 Maintenance Standard for Self-Pressure Reducing Valve..........................................................................3382 Maintenance Standard for Quick Drop Valve......................................................................................3385 Work Equipment.....................................................................................................................3386 Maintenance Standard for Cylinder Stay.........................................................................................3386 Maintenance Standard for Front Work Equipment..................................................................................3387 Maintenance Standard for Cutting Edge and End Bit..............................................................................3393 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder..........................................................3394 Maintenance Standard for Pin Puller Cylinder...................................................................................3395 Maintenance Standard for Blade Tilt Cylinder...................................................................................3396 Maintenance Standard for Variable Multi-Shank Ripper...........................................................................3398 Maintenance Standard for Variable Giant Ripper.................................................................................3400 Maintenance Standard for Ripper Lift Cylinder..................................................................................3402 Maintenance Standard for Ripper Tilt Cylinder..................................................................................3403 CAB Related Parts..................................................................................................................3404 Maintenance Standard for CAB Mount.............................................................................................3404 Maintenance Standard for ROPS..................................................................................................3405 80 Appendix............................................................................................................................3407 Table of Contents..................................................................................................................3408 Precautions Before Work............................................................................................................3410 Air Conditioner System.............................................................................................................3411 Precautions for Refrigerant....................................................................................................3411 Air Conditioner Component......................................................................................................3412 Specifications of Air Conditioner..............................................................................................3414 Structure and Function of Refrigeration Cycle..................................................................................3415 Outline of Refrigeration Cycle.................................................................................................3416 Component Parts of Air Conditioner System..........................................................................................3418 Air Conditioner Unit...........................................................................................................3418 Configuration Diagram of Air Conditioner Unit..............................................................................3418 Function of Air Conditioner Unit...........................................................................................3420 Component Parts of Air Conditioner Unit........................................................................................3422 Function of Evaporator as Air Conditioner Unit Component...................................................................3423 Function of Heater Core as Air Conditioner Unit Component..................................................................3423 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component................................................3423 Function of Servo Motor as Air Conditioner Unit Component..................................................................3423 Structure of Expansion Valve as Air Conditioner Unit Component.............................................................3424 Function of Expansion Valve as Air Conditioner Unit Component..............................................................3424 Operate Expansion Valve as Air Conditioner Unit Component..................................................................3424 Function of Triple Pressure Switch.........................................................................................3425 Air Conditioner Controller.....................................................................................................3426 Structure of Air Conditioner Controller....................................................................................3426 Compressor.....................................................................................................................3427 Structure of Compressor....................................................................................................3427 Specifications of Compressor...............................................................................................3427 Function of Compressor.....................................................................................................3427 Condenser......................................................................................................................3428 Structure of Condenser.....................................................................................................3428 Specifications of Condenser................................................................................................3428 Function of Condenser......................................................................................................3428 Receiver Drier.................................................................................................................3429 Structure of Receiver Dryer................................................................................................3429 Specifications of Receiver Dryer...........................................................................................3429 Function of Receiver Dryer.................................................................................................3429 Air Conditioner Related Sensors................................................................................................3430 Structure of Sunlight Sensor...............................................................................................3430 Function of Sunlight Sensor................................................................................................3430 Structure of Outside Temperature Sensor....................................................................................3430 Function of Outside Air Temperature Sensor.................................................................................3430 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner........................................................3432 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.............................................................3434 System Diagram of Air Conditioner..................................................................................................3436 Input and Output Signals of Air Conditioner Controller.........................................................................3437 Function of Air Conditioner Controller.....................................................................................3438 Locations of Air Conditioner Parts and Layout of Connectors........................................................................3439 Examine Air Leakage (Duct).........................................................................................................3448 How to Examine Air Leakage (Duct)..............................................................................................3448 Examine Air Conditioner with Self-Diagnosis Function...............................................................................3451 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor............................................3452 Examine Vent (Mode) Changeover.....................................................................................................3453 How to Examine Vent (Mode) Changeover..........................................................................................3453 Examine Fresh/Recirc Air Changeover................................................................................................3454 How to Examine Fresh/Recirc Air Changeover.....................................................................................3454 Examine Sunlight Sensor............................................................................................................3455 How to Examine Sunlight Sensor.................................................................................................3455 Examine Refrigerant (Triple) Pressure Switch.......................................................................................3456 How to Examine Refrigerant (Triple) Pressure Switch............................................................................3456 Examine Relay......................................................................................................................3457 How to Examine Relay...........................................................................................................3457 Air Conditioner Troubleshooting Chart 1............................................................................................3458 Air Conditioner Troubleshooting Chart 2............................................................................................3459 Information Shown in Troubleshooting Table.........................................................................................3462 Failure Code [879AKA]..............................................................................................................3463 Failure Code [879AKB]..............................................................................................................3464 Failure Code [879BKA]..............................................................................................................3465 Failure Code [879BKB]..............................................................................................................3467 Failure Code [879CKA]..............................................................................................................3469 Failure Code [879CKB]..............................................................................................................3470 Failure Code [879DKZ]..............................................................................................................3471 Failure Code [879EMC]..............................................................................................................3473 Failure Code [879FMC]..............................................................................................................3474 Failure Code [879GKX]..............................................................................................................3475 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).....................................................3477 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)......................................................3479 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal).............................................3483 A-4 Troubleshooting for Fresh/Recirc Air Changeover................................................................................3485 Troubleshooting by Gauge Pressure..................................................................................................3487 Connect Service Tool...............................................................................................................3490 How to Connect Service Tool....................................................................................................3490 Precautions for Disconnection and Connection of Air Conditioner Piping.............................................................3492 Handle Compressor Oil..............................................................................................................3494 90 Circuit Diagrams....................................................................................................................3497 Table of Contents..................................................................................................................3498 Hydraulic Circuit Diagram..........................................................................................................3499 Symbols Used in Hydraulic Circuit Diagram......................................................................................3499 Hydraulic Circuit Diagram......................................................................................................3503 Power Train Hydraulic Circuit Diagram..........................................................................................3505 Electrical Circuit Diagram.........................................................................................................3507 Symbols Used in Electric Circuit Diagram.......................................................................................3507 Electrical Circuit Diagram (1/12)..............................................................................................3511 Electrical Circuit Diagram (2/12)..............................................................................................3513 Electrical Circuit Diagram (3/12)..............................................................................................3515 Electrical Circuit Diagram (4/12)..............................................................................................3517 Electrical Circuit Diagram (5/12)..............................................................................................3519 Electrical Circuit Diagram (6/12)..............................................................................................3521 Electrical Circuit Diagram (7/12)..............................................................................................3523 Electrical Circuit Diagram (8/12)..............................................................................................3525 Electrical Circuit Diagram (9/12)..............................................................................................3527 Electrical Circuit Diagram (10/12).............................................................................................3529 Electrical Circuit Diagram (11/12).............................................................................................3531 Electrical Circuit Diagram (12/12).............................................................................................3533 Electrical Circuit Diagram of Inside of CAB (1/14).............................................................................3535 Electrical Circuit Diagram of Inside of CAB (2/14).............................................................................3537 Electrical Circuit Diagram of Inside of CAB (3/14).............................................................................3539 Electrical Circuit Diagram of Inside of CAB (4/14).............................................................................3541 Electrical Circuit Diagram of Inside of CAB (5/14).............................................................................3543 Electrical Circuit Diagram of Inside of CAB (6/14).............................................................................3545 Electrical Circuit Diagram of Inside of CAB (7/14).............................................................................3547 Electrical Circuit Diagram of Inside of CAB (8/14).............................................................................3549 Electrical Circuit Diagram of Inside of CAB (9/14).............................................................................3551 Electrical Circuit Diagram of Inside of CAB (10/14)............................................................................3553 Electrical Circuit Diagram of Inside of CAB (11/14)............................................................................3555 Electrical Circuit Diagram of Inside of CAB (12/14)............................................................................3557 Electrical Circuit Diagram of Inside of CAB (13/14)............................................................................3559 Electrical Circuit Diagram of Inside of CAB (14/14)............................................................................3561 Index...................................................................................................................................3563
DESCRIPTION:
KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06653-09 – PDF DOWNLOAD
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.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 25/12/24
