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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – PDF DOWNLOAD
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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – PDF DOWNLOAD
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KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – PDF DOWNLOAD
Language : English
Pages : 3570
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS 80001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – 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........................................................................................................................ 124 EGR System................................................................................................................. 128 EGR Valve.................................................................................................................. 130 EGR Cooler................................................................................................................. 132 KCCV System................................................................................................................ 133 KCCV Ventilator............................................................................................................ 135 KDPF....................................................................................................................... 137 Fuel System.................................................................................................................... 142 Fuel System Circuit Diagram................................................................................................ 142 Function of Fuel System.................................................................................................... 143 Operation of Fuel System................................................................................................... 143 CRI System................................................................................................................. 143 Cooling System..................................................................................................................... 148 Layout Drawing of Cooling System............................................................................................... 148 Specifications of Cooling System........................................................................................... 149 Component Parts of Cooling System.............................................................................................. 150 Cooling Fan Pump........................................................................................................... 150 Cooling Fan Motor.......................................................................................................... 170 Hydraulic Oil Cooler Bypass Valve.......................................................................................... 177 Control System..................................................................................................................... 178 Layout Drawing of Control System............................................................................................... 178 Machine Monitor System......................................................................................................... 179 System Diagram of Machine Monitor System................................................................................... 179 Function of Machine Monitor System......................................................................................... 179 KOMTRAX Plus System............................................................................................................ 182 System Diagram of KOMTRAX Plus System...................................................................................... 182 Function of KOMTRAX Plus System............................................................................................ 182 Component Parts of Control System.............................................................................................. 184 Machine Monitor............................................................................................................ 184 KOMTRAX Terminal........................................................................................................... 199 KOMTRAX Plus Controller.................................................................................................... 201 Wireless LAN Unit.......................................................................................................... 205 Power Train Controller..................................................................................................... 206 Work Equipment Controller.................................................................................................. 214 Engine Controller.......................................................................................................... 218 Option Controller.......................................................................................................... 230 Fuel Feed Pump............................................................................................................. 234 Fuel Feed Pump Switch...................................................................................................... 235 Hydraulic System................................................................................................................... 236 Layout Drawing of Hydraulic System............................................................................................. 236 CLSS........................................................................................................................... 237 Structure of CLSS.......................................................................................................... 237 Function of CLSS........................................................................................................... 238 Component Parts of Hydraulic System............................................................................................ 240 Hydraulic Tank............................................................................................................. 240 Work Equipment Pump........................................................................................................ 242 LS Valve................................................................................................................... 245 PTO, Transmission Lubrication Pump, and Power Train Pump................................................................... 250 Control Valve.............................................................................................................. 251 Power Train System................................................................................................................. 271 Layout Drawing of Power Train System........................................................................................... 271 Operation of Power Train System................................................................................................ 274 Transmission, Steering, and Brake Control...................................................................................... 275 Layout Drawing of Transmission, Steering, and Brake Control System......................................................... 275 Function of Transmission, Steering, and Brake Control System............................................................... 276 Layout of Transmission, Steering, and Brake Control System Parts (Machine with FCCS)....................................... 277 Function of Transmission, Steering, and Brake Control System (Machine with FCCS)........................................... 279 Palm Command Control System.................................................................................................... 280 Palm Command Control System Diagram........................................................................................ 280 Centralized Pressure Pickup Port............................................................................................... 284 Layout Drawing of Centralized Pressure Pickup Port......................................................................... 284 Function of Centralized Pressure Pickup Port............................................................................... 285 Component Parts of Power Train System.......................................................................................... 286 Universal Joint............................................................................................................ 286 Power Train Mount.......................................................................................................... 287 Torque Converter and PTO................................................................................................... 288 Torque Converter Control Valve............................................................................................. 295 Lockup Clutch ECMV......................................................................................................... 296 Stator Clutch ECMV......................................................................................................... 299 Transmission............................................................................................................... 303 Transmission ECMV.......................................................................................................... 315 Main Relief Valve and Torque Converter Relief Valve........................................................................ 321 Transmission Lubrication Relief Valve...................................................................................... 323 Transfer and Bevel Pinion.................................................................................................. 324 Bevel Gear Shaft, Steering Clutch, and Brake............................................................................... 325 Final Drive................................................................................................................ 332 Scavenging Pump............................................................................................................ 335 Electric Steering Electric Lever........................................................................................... 336 Work Equipment System.............................................................................................................. 342 Work Equipment Control......................................................................................................... 342 Layout Drawing of Work Equipment Control................................................................................... 342 Function of Work Equipment Control......................................................................................... 343 Layout Drawing of Front Work Equipment......................................................................................... 344 Layout Drawing of Variable Giant Ripper........................................................................................ 345 Layout Drawing of Variable Multi-Shank Ripper.................................................................................. 346 Shoe Slip Control System....................................................................................................... 347 Function of Shoes Slip Control System...................................................................................... 347 Component Parts of Work Equipment System....................................................................................... 348 Self-Pressure Reducing Valve............................................................................................... 348 Work Equipment Lock Solenoid Valve......................................................................................... 353 Pilot Circuit Accumulator.................................................................................................. 354 Quick Drop Valve........................................................................................................... 355 Piston Valve............................................................................................................... 357 Electric Blade Control Lever............................................................................................... 358 Ripper Electric Lever...................................................................................................... 359 Pin Puller Switch.......................................................................................................... 360 ICT System......................................................................................................................... 361 Layout Drawing of ICT System................................................................................................... 361 System Diagram of ICT Control System........................................................................................... 362 Blade Control System........................................................................................................... 364 Function of Blade Control System........................................................................................... 364 Leveling Mode System Diagram............................................................................................... 366 Function of Leveling Mode.................................................................................................. 367 Operation of Leveling Mode................................................................................................. 367 Dozing Mode System Diagram................................................................................................. 368 Function of Dozing Mode.................................................................................................... 368 Operation of Dozing Mode................................................................................................... 368 Smooth Start System............................................................................................................ 370 Smooth Start System Diagram................................................................................................ 370 Function of Smooth Start System............................................................................................ 370 Operation of Smooth Start System........................................................................................... 370 Slip Control System............................................................................................................ 372 Slip Control System Diagram................................................................................................ 372 Function of Slip Control System............................................................................................ 372 Operation of Slip Control System........................................................................................... 372 Assist Control System.......................................................................................................... 374 Assist Control System Diagram.............................................................................................. 374 Function of Assist Control System.......................................................................................... 374 Operation of Assist Control System......................................................................................... 375 Straight Travel Correction System.............................................................................................. 376 Straight Travel Correction System Diagram.................................................................................. 376 Function of Straight Travel Correction System.............................................................................. 377 Operation of Straight Travel Correction System............................................................................. 377 Smooth Carry System............................................................................................................ 378 Smooth Carry System Diagram................................................................................................ 378 Function of Smooth Carry System............................................................................................ 379 Operation of Smooth Carry System........................................................................................... 379 Component Parts of ICT System.................................................................................................. 380 Navigation Controller...................................................................................................... 380 Control Box................................................................................................................ 384 AUX BOX.................................................................................................................... 386 IMU Sensor................................................................................................................. 388 Stroke and Reset Sensor for Blade Lift Cylinder............................................................................ 391 Lifting System..................................................................................................................... 394 Power Ladder System............................................................................................................ 394 Layout Drawing of Power Ladder System...................................................................................... 394 Hydraulic Circuit Diagram of Power Ladder System........................................................................... 395 Function of Power Ladder System............................................................................................ 395 Component Parts of Lifting System.............................................................................................. 397 Switch Box................................................................................................................. 397 Power Ladder Limit Switch Part............................................................................................. 398 Control Valve Assembly..................................................................................................... 399 Radio Control System............................................................................................................... 400 Layout Drawing of Radio Control System......................................................................................... 400 Specifications of Radio Control System......................................................................................... 401 Component Parts of Radio Control System........................................................................................ 402 Radio Control Transmitter.................................................................................................. 402 Radio Control Receiver..................................................................................................... 404 Radio Control On-board Selector Switch..................................................................................... 405 Undercarriage and Frame............................................................................................................ 407 Main Frame..................................................................................................................... 407 Structure of Main Frame.................................................................................................... 407 Suspension..................................................................................................................... 409 Structure of Suspension.................................................................................................... 409 Function of Suspension..................................................................................................... 411 Track Frame and Idler Cushion.................................................................................................. 412 Structure of Track Frame and Idler Cushion................................................................................. 412 Specifications of Track Frame and Idler Cushion............................................................................ 413 Function of Track Frame and Idler Cushion.................................................................................. 413 Work Equipment..................................................................................................................... 414 Structure of Front Work Equipment.............................................................................................. 414 Structure of Cylinder Stay..................................................................................................... 416 Structure of Variable Giant Ripper............................................................................................. 417 Structure of Variable Multi-Shank Ripper....................................................................................... 418 CAB Related Parts.................................................................................................................. 419 ROPS........................................................................................................................... 419 Structure of ROPS.......................................................................................................... 419 Function of ROPS........................................................................................................... 419 CAB............................................................................................................................ 420 Structure of CAB........................................................................................................... 420 CAB Mount...................................................................................................................... 421 Structure of CAB Mount..................................................................................................... 421 20 Standard Value Table................................................................................................................ 423 Table of Contents.................................................................................................................. 424 Standard Value Table for Engine.................................................................................................... 425 Standard Value Table for Engine: D375AI-8...................................................................................... 425 Standard Value Table for Machine................................................................................................... 431 Standard Value Table for Machine: D375AI-8..................................................................................... 431 Machine Posture and Procedures to Measure Performance.......................................................................... 458 30 Testing and Adjusting............................................................................................................... 461 Table of Contents.................................................................................................................. 462 Precautions Before Work............................................................................................................ 466 Related Information on Testing and Adjusting....................................................................................... 467 Tools for Testing and Adjusting................................................................................................ 467 Sketch of Tools for Testing and Adjusting...................................................................................... 473 Engine and Cooling System.......................................................................................................... 476 Examine Engine Speed........................................................................................................... 476 How to Examine Engine Speed................................................................................................ 476 Examine Boost Pressure......................................................................................................... 480 How to Examine Boost Pressure on Machine Monitor........................................................................... 480 How to Examine Boost Pressure by Testing Tool.............................................................................. 481 Examine Exhaust Gas Temperature................................................................................................ 483 How to Test Exhaust Gas Temperature by the Machine Monitor................................................................. 483 How to Examine Exhaust Temperature by Testing Tools........................................................................ 484 Examine Exhaust Gas Color...................................................................................................... 487 How to Examine Exhaust Gas Color with the Handy Smoke Checker.............................................................. 487 How to Examine Exhaust Gas Color with Smoke Meter.......................................................................... 488 Examine Mass Air Flow and Temperature Sensor................................................................................... 491 How to Examine Mass Air Flow and Temperature Sensor........................................................................ 491 Examine and Adjust Valve Clearance............................................................................................. 493 How to Examine Valve Clearance............................................................................................. 493 How to Adjust Valve Clearance.............................................................................................. 494 Examine Compression Pressure................................................................................................... 496 How to Examine Compression Pressure........................................................................................ 496 Examine Blowby Pressure........................................................................................................ 500 How to Examine Blowby Pressure............................................................................................. 500 Examine Engine Oil Pressure.................................................................................................... 502 How to Examine Engine Oil Pressure on Machine Monitor...................................................................... 502 How to Examine Engine Oil Pressure by Testing Tool......................................................................... 502 Examine EGR Valve and VGT Oil Pressure......................................................................................... 504 How to Examine EGR Valve and VGT Oil Pressure.............................................................................. 504 Examine Fuel Pressure.......................................................................................................... 505 How to Examine Fuel Pressure............................................................................................... 505 Examine Fuel Return Rate and Leakage........................................................................................... 507 How to Examine Fuel Return Rate and Leakage................................................................................ 508 Bleed Air from Fuel System..................................................................................................... 513 How to Bleed Air from Fuel System.......................................................................................... 513 Examine Fuel Circuit for Leakage............................................................................................... 515 How to Examine Fuel System for Leakage..................................................................................... 515 Examine Supply Pump............................................................................................................ 517 How to Examine Supply Pump................................................................................................. 517 Handle Cylinder Cut-out Mode Operation......................................................................................... 520 Handle No-Injection Cranking Operation......................................................................................... 521 Clean Fuel Doser............................................................................................................... 522 How to Clean Fuel Doser.................................................................................................... 522 Write Injector Compensation Value to Engine Controller......................................................................... 525 How to Write Injector Compensation Value................................................................................... 525 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................. 531 How to Write Correction for Ash in Soot Accumulation to Engine Controller.................................................. 531 Adjust Decelerator Pedal....................................................................................................... 532 How to Adjust Decelerator Pedal............................................................................................ 532 Power Train........................................................................................................................ 535 Examine Power Train Oil Pressure............................................................................................... 535 How to Examine Power Train Oil Pressure.................................................................................... 536 Adjust Transmission Output Shaft Speed Sensor.................................................................................. 553 How to Adjust Transmission Output Shaft Speed Sensor....................................................................... 553 Examine Brake Performance Simply............................................................................................... 555 How to Examine Brake Performance Simply.................................................................................... 555 Examine and Adjust Brake Pedal................................................................................................. 556 How to Examine Brake Pedal................................................................................................. 556 How to Adjust Brake Pedal.................................................................................................. 557 Adjust Parking Brake Lever..................................................................................................... 560 How to Adjust Parking Brake Lever.......................................................................................... 560 Move Machine by Parking Brake Release When Machine Does Not Travel............................................................. 562 How to Move Machine with Hydraulic Type Parking Brake Release System....................................................... 562 How to Move Machine with Electric Type Parking Brake Release System........................................................ 563 Undercarriage and Frame............................................................................................................ 566 Examine and Adjust Track Tension............................................................................................... 566 How to Examine Track Tension............................................................................................... 566 How to Adjust Track Tension................................................................................................ 566 Hydraulic System................................................................................................................... 568 Release Remained Pressure in Hydraulic Circuit................................................................................. 568 How to Release Remained Pressure in Hydraulic System....................................................................... 568 Examine and Adjust Work Equipment Oil Pressure................................................................................. 569 How to Examine Work Equipment Oil Pressure................................................................................. 569 How to Adjust Work Equipment Oil Pressure.................................................................................. 571 Examine Oil Pressure of Control Circuit........................................................................................ 572 How to Examine Oil Pressure in Control Circuit............................................................................. 572 Examine Work Equipment Lock Solenoid Valve Outlet Pressure..................................................................... 574 How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure.......................................................... 574 Examine Ripper Pin Puller Solenoid Valve Outlet Pressure....................................................................... 576 How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure............................................................ 576 Bleed Air from Work Equipment Pump............................................................................................. 578 How to Bleed Air from Work Equipment Pump.................................................................................. 578 Examine Cooling Fan Speed...................................................................................................... 579 How to Examine Cooling Fan Speed........................................................................................... 579 Examine Cooling Fan Circuit Oil Pressure....................................................................................... 580 How to Examine Cooling Fan Circuit Oil Pressure............................................................................ 580 Bleed Air in Cooling Fan Pump.................................................................................................. 582 How to Bleed Air in Cooling Fan Pump....................................................................................... 582 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................................................... 583 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder.................................................... 583 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder................................................ 583 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder............................................... 584 Examine Oil Leakage from Work Equipment Cylinder............................................................................... 585 How to Examine Internal Oil Leakage of Work Equipment Cylinder............................................................. 585 Bleed Air from Work Equipment Cylinders........................................................................................ 587 How to Bleed Air from Work Equipment Cylinder.............................................................................. 587 Operation When Work Equipment is Disabled...................................................................................... 588 How to Operate When Work Equipment is Disabled............................................................................. 588 Power Ladder....................................................................................................................... 590 Bleed Air from Power Ladder Cylinder........................................................................................... 590 How to Bleed Air in Power Ladder Cylinder.................................................................................. 590 Examine and Adjust Power Ladder Limit Switch................................................................................... 595 How to Examine and Adjust Power Ladder Limit Switch........................................................................ 595 How to Adjust Power Ladder Limit Switch.................................................................................... 595 Work Equipment..................................................................................................................... 604 Adjust Work Equipment Lock Lever............................................................................................... 604 How to Adjust Work Equipment Lock Lever.................................................................................... 604 Examine and Adjust Play of Blade Electric Lever................................................................................ 606 How to Examine Play of Blade Electric Lever................................................................................ 608 How to Adjust Play of Blade Electric Lever................................................................................. 608 How to Replace Universal Joint............................................................................................. 609 CAB Related Parts.................................................................................................................. 616 Examine and Adjust Operator Cab................................................................................................ 616 How to Examine Operator Cab................................................................................................ 616 How to Adjust Operator Cab................................................................................................. 619 Adjust Play of Operator Seat................................................................................................... 622 How to Adjust Play of Operator Seat........................................................................................ 622 Electrical System.................................................................................................................. 623 Set and Operate Machine Monitor................................................................................................ 623 Operator Mode.............................................................................................................. 626 Function to Show Technician Identification Status Screen................................................................... 626 Function to Show Operator Identification Input Screen...................................................................... 626 Examine Function by LCD (Liquid Crystal Display)........................................................................... 627 Examine Function of Service Meter.......................................................................................... 628 How to Set Usage Limitation and Change Maintenance Password................................................................ 628 Service Mode............................................................................................................... 630 How to Operate Service Mode................................................................................................ 630 How to See Pre-defined Monitoring Information.............................................................................. 632 How to Examine Self-Define Monitor Information............................................................................. 638 Abnormality Record Menu.................................................................................................... 651 How to See Maintenance Record.............................................................................................. 656 Maintenance Mode Setting................................................................................................... 657 How to Set Phone Number Entry.............................................................................................. 660 Default Menu............................................................................................................... 661 Diagnostic Tests Menu...................................................................................................... 670 Adjustment Menu............................................................................................................ 680 No-Injection Cranking Operation............................................................................................ 774 KOMTRAX Settings Menu...................................................................................................... 775 How to Show Service Message................................................................................................ 777 How to Operate Snap Shot................................................................................................... 778 How to Start Up KOMTRAX Terminal............................................................................................... 781 Default Setting of KOMTRAX Plus Controller..................................................................................... 786 How to do the Default Setting of KOMTRAX Plus Controller................................................................... 786 Default Setting of Wireless LAN Modem.......................................................................................... 789 Default Setting of Wireless LAN Modem...................................................................................... 789 How to Examine Wireless LAN Modem Communication............................................................................ 790 Download Data from KOMTRAX Plus Controller..................................................................................... 791 How to Download Data from KOMTRAX Plus Controller.......................................................................... 791 Adjust After Replacement of KOMTRAX Plus Controller............................................................................ 794 How to Adjust After Replacement of KOMTRAX Plus Controller................................................................. 794 Adjust After Replacement of Wireless LAN Modem................................................................................. 797 How to Adjust After Replacement of Wireless LAN Modem...................................................................... 797 Adjust Rearview Camera Angle................................................................................................... 800 How to Adjust Rearview Camera Angle........................................................................................ 800 Handle Voltage Circuit of Engine Controller.................................................................................... 801 Handle Battery Disconnect Switch............................................................................................... 802 Handle Battery Isolator and Starting Motor Isolator............................................................................ 803 Examine Diodes................................................................................................................. 804 How to Examine Diodes by Digital Tester.................................................................................... 804 How to Examine Diodes by Analog Tester..................................................................................... 804 ICT System......................................................................................................................... 805 Set and Operate Control Box.................................................................................................... 805 Examine and Adjust ICT Related Devices..................................................................................... 805 Calibrate Blade Edge Position.................................................................................................. 810 How to Operate Blade Calibration Menu (Machine Cal Step A)................................................................. 810 How to Operate Blade Calibration Menu (Machine Cal Step B)................................................................. 816 Calibrate IMU Sensor........................................................................................................... 832 How to Calibrate IMU Sensor................................................................................................ 832 Reset Cylinder Stroke End...................................................................................................... 837 Reset Lift Cylinder Stroke End............................................................................................. 837 Set Standard Angle of Blade Edge............................................................................................... 840 How to Input Wear Volume of Blade Edge and Track Shoes......................................................................... 842 Examine and Adjust Blade Elevation............................................................................................. 845 Examine Blade Elevation.................................................................................................... 845 Adjust Blade Elevation..................................................................................................... 849 Examine Stroke Sensor for Lift Cylinder........................................................................................ 851 How to Examine Stroke Sensor for Lift Cylinder............................................................................. 851 Examine and Adjust Reset Sensor for Lift Cylinder.............................................................................. 855 How to Examine Reset Sensor for Lift Cylinder.............................................................................. 855 How to Adjust Reset Sensor for Lift Cylinder............................................................................... 856 Adjust When Work Equipment Controller is Replaced.............................................................................. 857 How to Adjust When Work Equipment Controller is Replaced................................................................... 857 How to Adjust When ICT Related Devices are Repaired or Replaced................................................................ 860 Radio Control...................................................................................................................... 864 ID Setup....................................................................................................................... 864 How to Set Radio Control Transmitter ID.................................................................................... 864 How to Set Radio Control Receiver ID....................................................................................... 865 Pm Clinic.......................................................................................................................... 868 Pm Clinic Service.............................................................................................................. 868 Pm Clinic Check Sheet: D375AI-8............................................................................................ 869 Pm Clinic Check Sheet for Undercarriage: D375AI-8.......................................................................... 890 Perform Quick Pm............................................................................................................... 895 How to Perform Quick Pm.................................................................................................... 895 40 Troubleshooting..................................................................................................................... 899 Table of Contents.................................................................................................................. 900 Precautions Before Work............................................................................................................ 914 Related Information to Troubleshooting............................................................................................. 915 General Troubleshooting Points................................................................................................. 915 Troubleshooting Points for Aftertreatment System............................................................................... 916 Sequence of Events in Troubleshooting.......................................................................................... 923 Troubleshooting for Radio Control System....................................................................................... 925 Checks Before Troubleshooting (Specifications of Radio Control)............................................................ 925 Examine Operating State of Radio Control Receiver.......................................................................... 926 Examine Operating State of Radio Control Transmitter....................................................................... 927 Checks Before Troubleshooting.................................................................................................. 928 Inspection Procedure Before Troubleshooting.................................................................................... 930 Walk-Around Check.......................................................................................................... 930 Test in Accordance with Testing Procedure...................................................................................... 932 How to Drain Water and Sediment from Fuel Tank............................................................................. 932 How to Examine Water Separator, Drain Water and Sediment................................................................... 932 Examine Fuel Main Filter................................................................................................... 933 How to Examine Oil Level in Hydraulic Tank, Add Oil........................................................................ 934 How to Examine Coolant Level, Add Coolant.................................................................................. 936 How to Examine Oil Level in Engine Oil Pan, Add Oil........................................................................ 937 How to Examine Oil Level in Power Train Case, Add Oil...................................................................... 938 How to Examine Dust Indicator.............................................................................................. 939 How to Examine Brake Operation............................................................................................. 940 How to Examine Electric Wiring............................................................................................. 940 How to Examine Fuel Level, Add Fuel........................................................................................ 940 How to Examine Operation of Lamps.......................................................................................... 941 How to Examine Machine Monitor............................................................................................. 941 How to Remove Sediment in Engine Room...................................................................................... 942 How to Examine Operation State of Horn..................................................................................... 942 How to Examine Operation State of Backup Alarm............................................................................. 943 How to Examine Electric Equipment.......................................................................................... 943 Preparation for Troubleshooting of Electrical System........................................................................... 948 Preparation for Troubleshooting of Machine Monitor......................................................................... 948 Preparation for Troubleshooting of Engine Controller....................................................................... 948 Preparation for Troubleshooting of Work Equipment Controller............................................................... 948 Preparation for Troubleshooting of Power Train Controller.................................................................. 949 Preparation for Troubleshooting of KOMTRAX Terminal........................................................................ 949 How to Disconnect and Connect Connector with a Special Lock................................................................ 949 Procedure for Troubleshooting.................................................................................................. 954 Symptom and Troubleshooting Numbers............................................................................................ 957 Information Shown in Troubleshooting Table..................................................................................... 960 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................ 962 Connector List and Layout...................................................................................................... 965 Connector Contact Connection Table............................................................................................. 988 T-Branch Box and T-Branch Adapter Table........................................................................................1028 Fuse Location Table............................................................................................................1034 Precautions When You Clean and Replace KDPF (KCSF and KDOC)....................................................................1038 Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])..................................1042 Failure Code Table.............................................................................................................1044 Troubleshooting by Failure Code (Display of Code)..................................................................................1071 Failure Code [1500L0]..........................................................................................................1071 Failure Code [15B0NX]..........................................................................................................1072 Failure Code [15SAL1]..........................................................................................................1074 Failure Code [15SALH]..........................................................................................................1076 Failure Code [15SBL1]..........................................................................................................1078 Failure Code [15SBLH]..........................................................................................................1080 Failure Code [15SEL1]..........................................................................................................1082 Failure Code [15SELH]..........................................................................................................1084 Failure Code [15SFL1]..........................................................................................................1086 Failure Code [15SFLH]..........................................................................................................1088 Failure Code [15SGL1]..........................................................................................................1090 Failure Code [15SGLH]..........................................................................................................1092 Failure Code [15SJL1]..........................................................................................................1094 Failure Code [15SJLH]..........................................................................................................1096 Failure Code [1800MW]..........................................................................................................1098 Failure Code [2201L1]..........................................................................................................1099 Failure Code [2201LH]..........................................................................................................1101 Failure Code [2202L1]..........................................................................................................1103 Failure Code [2202LH]..........................................................................................................1104 Failure Code [2300NR]..........................................................................................................1106 Failure Code [2301L1]..........................................................................................................1107 Failure Code [2301LH]..........................................................................................................1109 Failure Code [2301NR]..........................................................................................................1111 Failure Code [2301NT]..........................................................................................................1112 Failure Code [2302L1]..........................................................................................................1113 Failure Code [2302LH]..........................................................................................................1115 Failure Code [2302NR]..........................................................................................................1117 Failure Code [2302NT]..........................................................................................................1118 Failure Code [851PKA]..........................................................................................................1119 Failure Code [851QKA]..........................................................................................................1120 Failure Code [851RKA]..........................................................................................................1121 Failure Code [851SKA]..........................................................................................................1122 Failure Code [851TKA]..........................................................................................................1123 Failure Code [851UKA]..........................................................................................................1124 Failure Code [851VKA]..........................................................................................................1125 Failure Code [851XKA]..........................................................................................................1126 Failure Code [852RKR]..........................................................................................................1127 Failure Code [8590KA]..........................................................................................................1128 Failure Code [8590KY]..........................................................................................................1133 Failure Code [879AKA]..........................................................................................................1136 Failure Code [879AKB]..........................................................................................................1137 Failure Code [879BKA]..........................................................................................................1138 Failure Code [879BKB]..........................................................................................................1140 Failure Code [879CKA]..........................................................................................................1142 Failure Code [879CKB]..........................................................................................................1143 Failure Code [879DKZ]..........................................................................................................1144 Failure Code [879EMC]..........................................................................................................1146 Failure Code [879FMC]..........................................................................................................1147 Failure Code [879GKX]..........................................................................................................1148 Failure Code [989L00]..........................................................................................................1150 Failure Code [989M00]..........................................................................................................1151 Failure Code [989N00]..........................................................................................................1152 Failure Code [A1U0N3]..........................................................................................................1153 Failure Code [A1U0N4]..........................................................................................................1155 Failure Code [A900FR]..........................................................................................................1157 Failure Code [A900N6]..........................................................................................................1158 Failure Code [A900NY]..........................................................................................................1159 Failure Code [AA10NX]..........................................................................................................1160 Failure Code [AB00KE]..........................................................................................................1162 Failure Code [AQ00N3]..........................................................................................................1164 Failure Code [AQ00N4]..........................................................................................................1165 Failure Code [AQ10N3]..........................................................................................................1166 Failure Code [B@BAZG]..........................................................................................................1167 Failure Code [B@BAZK]..........................................................................................................1168 Failure Code [B@BCNS]..........................................................................................................1169 Failure Code [B@BCZK]..........................................................................................................1170 Failure Code [B@CENS]..........................................................................................................1172 Failure Code [B@HANS]..........................................................................................................1174 Failure Code [B@HAZK]..........................................................................................................1176 Failure Code [CA115]...........................................................................................................1177 Failure Code [CA122]...........................................................................................................1181 Failure Code [CA123]...........................................................................................................1183 Failure Code [CA131]...........................................................................................................1185 Failure Code [CA132]...........................................................................................................1187 Failure Code [CA135]...........................................................................................................1189 Failure Code [CA141]...........................................................................................................1191 Failure Code [CA144]...........................................................................................................1193 Failure Code [CA145]...........................................................................................................1195 Failure Code [CA153]...........................................................................................................1197 Failure Code [CA154]...........................................................................................................1199 Failure Code [CA187]...........................................................................................................1201 Failure Code [CA212]...........................................................................................................1203 Failure Code [CA213]...........................................................................................................1205 Failure Code [CA221]...........................................................................................................1207 Failure Code [CA222]...........................................................................................................1209 Failure Code [CA227]...........................................................................................................1211 Failure Code [CA234]...........................................................................................................1213 Failure Code [CA238]...........................................................................................................1214 Failure Code [CA239]...........................................................................................................1216 Failure Code [CA271]...........................................................................................................1218 Failure Code [CA272]...........................................................................................................1220 Failure Code [CA273]...........................................................................................................1221 Failure Code [CA274]...........................................................................................................1223 Failure Code [CA322]...........................................................................................................1224 Failure Code [CA323]...........................................................................................................1226 Failure Code [CA324]...........................................................................................................1228 Failure Code [CA325]...........................................................................................................1230 Failure Code [CA331]...........................................................................................................1232 Failure Code [CA332]...........................................................................................................1234 Failure Code [CA343]...........................................................................................................1236 Failure Code [CA351]...........................................................................................................1238 Failure Code [CA352]...........................................................................................................1240 Failure Code [CA356]...........................................................................................................1242 Failure Code [CA357]...........................................................................................................1244 Failure Code [CA386]...........................................................................................................1246 Failure Code [CA441]...........................................................................................................1248 Failure Code [CA442]...........................................................................................................1250 Failure Code [CA449]...........................................................................................................1252 Failure Code [CA451]...........................................................................................................1253 Failure Code [CA452]...........................................................................................................1255 Failure Code [CA515]...........................................................................................................1257 Failure Code [CA516]...........................................................................................................1258 Failure Code [CA553]...........................................................................................................1259 Failure Code [CA555]...........................................................................................................1260 Failure Code [CA556]...........................................................................................................1262 Failure Code [CA559]...........................................................................................................1264 Failure Code [CA595]...........................................................................................................1270 Failure Code [CA687]...........................................................................................................1272 Failure Code [CA689]...........................................................................................................1274 Failure Code [CA691]...........................................................................................................1276 Failure Code [CA692]...........................................................................................................1278 Failure Code [CA697]...........................................................................................................1280 Failure Code [CA698]...........................................................................................................1281 Failure Code [CA731]...........................................................................................................1282 Failure Code [CA778]...........................................................................................................1286 Failure Code [CA1117]..........................................................................................................1288 Failure Code [CA1135]..........................................................................................................1290 Failure Code [CA1257]..........................................................................................................1293 Failure Code [CA1664]..........................................................................................................1294 Failure Code [CA1691]..........................................................................................................1296 Failure Code [CA1695]..........................................................................................................1299 Failure Code [CA1696]..........................................................................................................1301 Failure Code [CA1843]..........................................................................................................1303 Failure Code [CA1844]..........................................................................................................1305 Failure Code [CA1879]..........................................................................................................1307 Failure Code [CA1881]..........................................................................................................1309 Failure Code [CA1883]..........................................................................................................1311 Failure Code [CA1921]..........................................................................................................1314 Failure Code [CA1922]..........................................................................................................1316 Failure Code [CA1923]..........................................................................................................1320 Failure Code [CA1924]..........................................................................................................1322 Failure Code [CA1925]..........................................................................................................1324 Failure Code [CA1927]..........................................................................................................1326 Failure Code [CA1928]..........................................................................................................1328 Failure Code [CA1942]..........................................................................................................1330 Failure Code [CA1963]..........................................................................................................1332 Failure Code [CA1977]..........................................................................................................1336 Failure Code [CA1993]..........................................................................................................1338 Failure Code [CA2185]..........................................................................................................1341 Failure Code [CA2186]..........................................................................................................1343 Failure Code [CA2249]..........................................................................................................1345 Failure Code [CA2265]..........................................................................................................1350 Failure Code [CA2266]..........................................................................................................1352 Failure Code [CA2271]..........................................................................................................1354 Failure Code [CA2272]..........................................................................................................1356 Failure Code [CA2349]..........................................................................................................1358 Failure Code [CA2353]..........................................................................................................1360 Failure Code [CA2357]..........................................................................................................1362 Failure Code [CA2381]..........................................................................................................1365 Failure Code [CA2382]..........................................................................................................1367 Failure Code [CA2383]..........................................................................................................1369 Failure Code [CA2386]..........................................................................................................1371 Failure Code [CA2387]..........................................................................................................1373 Troubleshooting Flowchart..................................................................................................1377 Failure Code [CA2637]..........................................................................................................1378 Failure Code [CA2639]..........................................................................................................1381 Failure Code [CA2732]..........................................................................................................1383 Failure Code [CA2733]..........................................................................................................1385 Failure Code [CA2741]..........................................................................................................1387 Failure Code [CA2765]..........................................................................................................1388 Failure Code [CA2777]..........................................................................................................1389 Failure Code [CA2878]..........................................................................................................1391 Failure Code [CA2881]..........................................................................................................1394 Failure Code [CA3133]..........................................................................................................1397 Failure Code [CA3134]..........................................................................................................1399 Failure Code [CA3135]..........................................................................................................1401 Failure Code [CA3167]..........................................................................................................1404 Failure Code [CA3251]..........................................................................................................1407 Failure Code [CA3253]..........................................................................................................1409 Failure Code [CA3254]..........................................................................................................1413 Failure Code [CA3255]..........................................................................................................1416 Failure Code [CA3256]..........................................................................................................1419 Failure Code [CA3311]..........................................................................................................1421 Failure Code [CA3312]..........................................................................................................1423 Failure Code [CA3313]..........................................................................................................1425 Failure Code [CA3314]..........................................................................................................1426 Failure Code [CA3315]..........................................................................................................1427 Failure Code [CA3316]..........................................................................................................1430 Failure Code [CA3317]..........................................................................................................1431 Failure Code [CA3318]..........................................................................................................1432 Failure Code [CA3319]..........................................................................................................1435 Failure Code [CA3321]..........................................................................................................1436 Failure Code [CA3322]..........................................................................................................1437 Failure Code [CA3419]..........................................................................................................1440 Failure Code [CA3421]..........................................................................................................1442 Failure Code [CA4151]..........................................................................................................1444 Failure Code [CA4158]..........................................................................................................1448 Failure Code [CA4161]..........................................................................................................1449 Failure Code [CA4162]..........................................................................................................1451 Failure Code [CA4163]..........................................................................................................1453 Failure Code [CA4259]..........................................................................................................1455 Failure Code [CA4952]..........................................................................................................1458 Failure Code [CA5383]..........................................................................................................1460 Failure Code [CB115]...........................................................................................................1461 Failure Code [CB187]...........................................................................................................1464 Failure Code [CB227]...........................................................................................................1466 Failure Code [CB238]...........................................................................................................1467 Failure Code [CB239]...........................................................................................................1469 Failure Code [CB271]...........................................................................................................1471 Failure Code [CB272]...........................................................................................................1473 Failure Code [CB273]...........................................................................................................1474 Failure Code [CB274]...........................................................................................................1476 Failure Code [CB343]...........................................................................................................1477 Failure Code [CB352]...........................................................................................................1479 Failure Code [CB386]...........................................................................................................1481 Failure Code [CB441]...........................................................................................................1483 Failure Code [CB442]...........................................................................................................1485 Failure Code [CB689]...........................................................................................................1487 Failure Code [CB697]...........................................................................................................1489 Failure Code [CB698]...........................................................................................................1490 Failure Code [CB731]...........................................................................................................1491 Failure Code [CB778]...........................................................................................................1495 Failure Code [CB1117]..........................................................................................................1497 Failure Code [CB1257]..........................................................................................................1499 Failure Code [CB1664]..........................................................................................................1500 Failure Code [CB1691]..........................................................................................................1502 Failure Code [CB1695]..........................................................................................................1505 Failure Code [CB1696]..........................................................................................................1507 Failure Code [CB1879]..........................................................................................................1509 Failure Code [CB1881]..........................................................................................................1511 Failure Code [CB1883]..........................................................................................................1513 Failure Code [CB1921]..........................................................................................................1516 Failure Code [CB1922]..........................................................................................................1518 Failure Code [CB1923]..........................................................................................................1522 Failure Code [CB1924]..........................................................................................................1524 Failure Code [CB1925]..........................................................................................................1526 Failure Code [CB1927]..........................................................................................................1528 Failure Code [CB1928]..........................................................................................................1530 Failure Code [CB1963]..........................................................................................................1532 Failure Code [CB1977]..........................................................................................................1536 Failure Code [CB1993]..........................................................................................................1538 Failure Code [CB2265]..........................................................................................................1541 Failure Code [CB2266]..........................................................................................................1543 Failure Code [CB2637]..........................................................................................................1545 Failure Code [CB2639]..........................................................................................................1548 Failure Code [CB2732]..........................................................................................................1550 Failure Code [CB2733]..........................................................................................................1552 Failure Code [CB2741]..........................................................................................................1554 Failure Code [CB2777]..........................................................................................................1556 Failure Code [CB2878]..........................................................................................................1558 Failure Code [CB2881]..........................................................................................................1561 Failure Code [CB3133]..........................................................................................................1564 Failure Code [CB3134]..........................................................................................................1566 Failure Code [CB3135]..........................................................................................................1568 Failure Code [CB3167]..........................................................................................................1571 Failure Code [CB3251]..........................................................................................................1574 Failure Code [CB3253]..........................................................................................................1576 Failure Code [CB3254]..........................................................................................................1581 Failure Code [CB3255]..........................................................................................................1584 Failure Code [CB3256]..........................................................................................................1587 Failure Code [CB3311]..........................................................................................................1589 Failure Code [CB3312]..........................................................................................................1591 Failure Code [CB3313]..........................................................................................................1593 Failure Code [CB3314]..........................................................................................................1594 Failure Code [CB3315]..........................................................................................................1595 Failure Code [CB3316]..........................................................................................................1598 Failure Code [CB3317]..........................................................................................................1599 Failure Code [CB3318]..........................................................................................................1600 Failure Code [CB3319]..........................................................................................................1603 Failure Code [CB3321]..........................................................................................................1604 Failure Code [CB3322]..........................................................................................................1605 Failure Code [CB4151]..........................................................................................................1608 Failure Code [CB4158]..........................................................................................................1612 Failure Code [CB4161]..........................................................................................................1613 Failure Code [CB4162]..........................................................................................................1615 Failure Code [CB4163]..........................................................................................................1617 Failure Code [CB4259]..........................................................................................................1620 Failure Code [CB4952]..........................................................................................................1623 Failure Code [CB5383]..........................................................................................................1625 Failure Code [D130KA]..........................................................................................................1626 Failure Code [D130KB]..........................................................................................................1628 Failure Code [D141KA]..........................................................................................................1629 Failure Code [D141KB]..........................................................................................................1631 Failure Code [D141KY]..........................................................................................................1633 Failure Code [D162KA]..........................................................................................................1635 Failure Code [D162KB]..........................................................................................................1637 Failure Code [D162KY]..........................................................................................................1639 Failure Code [D16CKA]..........................................................................................................1641 Failure Code [D16CKB]..........................................................................................................1643 Failure Code [D16CKY]..........................................................................................................1644 Failure Code [D182KZ]..........................................................................................................1646 Failure Code [D19CKA]..........................................................................................................1648 Failure Code [D19CKB]..........................................................................................................1650 Failure Code [D19CKY]..........................................................................................................1652 Failure Code [D19EKA]..........................................................................................................1654 Failure Code [D19EKB]..........................................................................................................1656 Failure Code [D19EKY]..........................................................................................................1658 Failure Code [D19FKA]..........................................................................................................1660 Failure Code [D19FKB]..........................................................................................................1662 Failure Code [D19FKY]..........................................................................................................1664 Failure Code [D19GKA]..........................................................................................................1666 Failure Code [D19GKB]..........................................................................................................1668 Failure Code [D19GKY]..........................................................................................................1670 Failure Code [D19JKZ]..........................................................................................................1672 Failure Code [D1D5KA]..........................................................................................................1674 Failure Code [D1D5KB]..........................................................................................................1676 Failure Code [D1D5KY]..........................................................................................................1678 Failure Code [D1EFKA]..........................................................................................................1679 Failure Code [D1EFKB]..........................................................................................................1681 Failure Code [D1EWKA]..........................................................................................................1683 Failure Code [D1EWKB]..........................................................................................................1684 Failure Code [D1EWKY]..........................................................................................................1685 Failure Code [D862KA]..........................................................................................................1686 Failure Code [DAF0MB]..........................................................................................................1687 Failure Code [DAF0MC]..........................................................................................................1688 Failure Code [DAF8KB]..........................................................................................................1689 Failure Code [DAF9KQ]..........................................................................................................1690 Failure Code [DAFGMC]..........................................................................................................1691 Failure Code [DAFLKA]..........................................................................................................1692 Failure Code [DAFLKB]..........................................................................................................1695 Failure Code [DAFQKR]..........................................................................................................1697 Failure Code [DAQW00]..........................................................................................................1702 Failure Code [DAZ9KQ]..........................................................................................................1703 Failure Code [DAZQKR]..........................................................................................................1704 Failure Code [DB2QKR]..........................................................................................................1708 Failure Code [DB2RKR]..........................................................................................................1714 Failure Code [DB90KT]..........................................................................................................1719 Failure Code [DB90MC]..........................................................................................................1720 Failure Code [DB91KK]..........................................................................................................1721 Failure Code [DB92KK]..........................................................................................................1724 Failure Code [DB95KK]..........................................................................................................1727 Failure Code [DB97KK]..........................................................................................................1729 Failure Code [DB99KQ]..........................................................................................................1731 Failure Code [DB9LKA]..........................................................................................................1732 Failure Code [DB9LKB]..........................................................................................................1734 Failure Code [DB9QKR]..........................................................................................................1736 Failure Code [DB9RKR]..........................................................................................................1741 Failure Code [DBE0KT]..........................................................................................................1746 Failure Code [DBE0MC]..........................................................................................................1747 Failure Code [DBE1KK]..........................................................................................................1748 Failure Code [DBE2KK]..........................................................................................................1751 Failure Code [DBE5KK]..........................................................................................................1754 Failure Code [DBE6KK]..........................................................................................................1756 Failure Code [DBE9KQ]..........................................................................................................1758 Failure Code [DBELKA]..........................................................................................................1759 Failure Code [DBELKB]..........................................................................................................1762 Failure Code [DBEQKR]..........................................................................................................1764 Failure Code [DBERKR]..........................................................................................................1769 Failure Code [DBU0KR]..........................................................................................................1774 Failure Code [DBUSKR]..........................................................................................................1775 Failure Code [DBUTKA]..........................................................................................................1776 Failure Code [DBUTKN]..........................................................................................................1777 Failure Code [DBV0MC]..........................................................................................................1778 Failure Code [DBV1KK]..........................................................................................................1779 Failure Code [DBVLKA]..........................................................................................................1781 Failure Code [DBVLKB]..........................................................................................................1783 Failure Code [DBVQKR]..........................................................................................................1785 Failure Code [DBVRKR]..........................................................................................................1786 Failure Code [DBVVKR]..........................................................................................................1787 Failure Code [DBVWKR]..........................................................................................................1788 Failure Code [DD12KA]..........................................................................................................1789 Failure Code [DD12KB]..........................................................................................................1791 Failure Code [DD13KA]..........................................................................................................1793 Failure Code [DD13KB]..........................................................................................................1795 Failure Code [DD14KA]..........................................................................................................1797 Failure Code [DD14KB]..........................................................................................................1799 Failure Code [DDDDKA]..........................................................................................................1801 Failure Code [DDDDKB]..........................................................................................................1803 Failure Code [DDDDKX]..........................................................................................................1805 Failure Code [DDDHKB]..........................................................................................................1806 Failure Code [DDDKKA]..........................................................................................................1808 Failure Code [DDDKKB]..........................................................................................................1810 Failure Code [DDDLKA]..........................................................................................................1812 Failure Code [DDDLKB]..........................................................................................................1814 Failure Code [DDE2KA]..........................................................................................................1816 Failure Code [DDKAKA]..........................................................................................................1817 Failure Code [DDKAKB]..........................................................................................................1819 Failure Code [DDKBKA]..........................................................................................................1821 Failure Code [DDKBKB]..........................................................................................................1823 Failure Code [DDKCL4]..........................................................................................................1825 Failure Code [DDKEL4]..........................................................................................................1827 Failure Code [DDKHKA]..........................................................................................................1829 Failure Code [DDKHKB]..........................................................................................................1831 Failure Code [DDKQKA]..........................................................................................................1833 Failure Code [DDKQKB]..........................................................................................................1835 Failure Code [DDKRKA]..........................................................................................................1837 Failure Code [DDKRKB]..........................................................................................................1839 Failure Code [DDKSKA]..........................................................................................................1841 Failure Code [DDKSKB]..........................................................................................................1843 Failure Code [DDN7L4]..........................................................................................................1845 Failure Code [DDN8L4]..........................................................................................................1847 Failure Code [DDNLKA]..........................................................................................................1849 Failure Code [DDNLKB]..........................................................................................................1851 Failure Code [DDTSL1]..........................................................................................................1853 Failure Code [DDTSLH]..........................................................................................................1855 Failure Code [DFA4KX]..........................................................................................................1857 Failure Code [DFA4KZ]..........................................................................................................1858 Failure Code [DFA4L8]..........................................................................................................1859 Failure Code [DFA5KA]..........................................................................................................1861 Failure Code [DFA5KY]..........................................................................................................1863 Failure Code [DFA6KA]..........................................................................................................1865 Failure Code [DFA6KY]..........................................................................................................1867 Failure Code [DFA7KX]..........................................................................................................1869 Failure Code [DFA7KZ]..........................................................................................................1870 Failure Code [DFA7L8]..........................................................................................................1871 Failure Code [DFA8KA]..........................................................................................................1873 Failure Code [DFA8KY]..........................................................................................................1875 Failure Code [DFA9KA]..........................................................................................................1877 Failure Code [DFA9KY]..........................................................................................................1879 Failure Code [DFAAKX]..........................................................................................................1881 Failure Code [DFAAKZ]..........................................................................................................1882 Failure Code [DFAAL8]..........................................................................................................1883 Failure Code [DFABKA]..........................................................................................................1885 Failure Code [DFABKY]..........................................................................................................1887 Failure Code [DFACKA]..........................................................................................................1889 Failure Code [DFACKY]..........................................................................................................1891 Failure Code [DGS1KA]..........................................................................................................1893 Failure Code [DGS1KX]..........................................................................................................1895 Failure Code [DGT1KA]..........................................................................................................1897 Failure Code [DGT1KX]..........................................................................................................1899 Failure Code [DGT4KA]..........................................................................................................1901 Failure Code [DGT4KY]..........................................................................................................1903 Failure Code [DH21KA]..........................................................................................................1905 Failure Code [DH21KY]..........................................................................................................1907 Failure Code [DHA4KA]..........................................................................................................1909 Failure Code [DHAAMA]..........................................................................................................1911 Failure Code [DHABMA]..........................................................................................................1912 Failure Code [DHACMA]..........................................................................................................1913 Failure Code [DHADMA]..........................................................................................................1914 Failure Code [DHT2L6]..........................................................................................................1915 Failure Code [DHT3KX]..........................................................................................................1916 Failure Code [DHT5KA]..........................................................................................................1917 Failure Code [DHT5KY]..........................................................................................................1919 Failure Code [DHT7KA]..........................................................................................................1921 Failure Code [DHT7KY]..........................................................................................................1923 Failure Code [DK10KA]..........................................................................................................1925 Failure Code [DK10KB]..........................................................................................................1927 Failure Code [DK30KA]..........................................................................................................1929 Failure Code [DK30KX]..........................................................................................................1931 Failure Code [DK30KY]..........................................................................................................1932 Failure Code [DK30KZ]..........................................................................................................1934 Failure Code [DK30L8]..........................................................................................................1935 Failure Code [DK31KA]..........................................................................................................1937 Failure Code [DK31KY]..........................................................................................................1939 Failure Code [DK40KA]..........................................................................................................1941 Failure Code [DK40KY]..........................................................................................................1943 Failure Code [DK55KX]..........................................................................................................1945 Failure Code [DK55KZ]..........................................................................................................1946 Failure Code [DK55L8]..........................................................................................................1947 Failure Code [DK56KA]..........................................................................................................1948 Failure Code [DK56KY]..........................................................................................................1950 Failure Code [DK57KA]..........................................................................................................1952 Failure Code [DK57KY]..........................................................................................................1954 Failure Code [DK60KA]..........................................................................................................1956 Failure Code [DK60KY]..........................................................................................................1958 Failure Code [DK80KR]..........................................................................................................1960 Failure Code [DK80KT]..........................................................................................................1963 Failure Code [DKH1KA]..........................................................................................................1964 Failure Code [DKH1KY]..........................................................................................................1966 Failure Code [DKSGL8]..........................................................................................................1968 Failure Code [DKSHKA]..........................................................................................................1970 Failure Code [DKSHKB]..........................................................................................................1973 Failure Code [DKSJKA]..........................................................................................................1975 Failure Code [DKSJKB]..........................................................................................................1978 Failure Code [DKSKKA]..........................................................................................................1980 Failure Code [DKSKKB]..........................................................................................................1983 Failure Code [DKSKMB]..........................................................................................................1985 Failure Code [DKSLL8]..........................................................................................................1987 Failure Code [DKSMKA]..........................................................................................................1989 Failure Code [DKSMKB]..........................................................................................................1992 Failure Code [DKSNKA]..........................................................................................................1994 Failure Code [DKSNKB]..........................................................................................................1997 Failure Code [DKSPKA]..........................................................................................................1999 Failure Code [DKSPKB]..........................................................................................................2002 Failure Code [DKSPMB]..........................................................................................................2004 Failure Code [DLM3KA]..........................................................................................................2006 Failure Code [DLM3MB]..........................................................................................................2007 Failure Code [DLT3KA]..........................................................................................................2008 Failure Code [DLT3KB]..........................................................................................................2010 Failure Code [DNDAMC]..........................................................................................................2012 Failure Code [DNDBKA]..........................................................................................................2014 Failure Code [DNDBKB]..........................................................................................................2016 Failure Code [DNDCKA]..........................................................................................................2018 Failure Code [DNDCKB]..........................................................................................................2020 Failure Code [DNDDKA]..........................................................................................................2022 Failure Code [DNDDKB]..........................................................................................................2024 Failure Code [DNDEKA]..........................................................................................................2026 Failure Code [DNDEKB]..........................................................................................................2028 Failure Code [DR21KX]..........................................................................................................2030 Failure Code [DR31KX]..........................................................................................................2031 Failure Code [DV20KB]..........................................................................................................2032 Failure Code [DW7BKA]..........................................................................................................2034 Failure Code [DW7BKB]..........................................................................................................2036 Failure Code [DWN3KA]..........................................................................................................2037 Failure Code [DWN3KB]..........................................................................................................2039 Failure Code [DWN3KY]..........................................................................................................2041 Failure Code [DWN5KA]..........................................................................................................2042 Failure Code [DWN5KB]..........................................................................................................2044 Failure Code [DWN5KY]..........................................................................................................2046 Failure Code [DWNCKA]..........................................................................................................2047 Failure Code [DWNCKB]..........................................................................................................2049 Failure Code [DWNCKY]..........................................................................................................2050 Failure Code [DWNVKA]..........................................................................................................2051 Failure Code [DWNVKB]..........................................................................................................2053 Failure Code [DWNWKA]..........................................................................................................2055 Failure Code [DWNWKB]..........................................................................................................2057 Failure Code [DWNXKA]..........................................................................................................2059 Failure Code [DWNXKB]..........................................................................................................2061 Failure Code [DWNYKA]..........................................................................................................2063 Failure Code [DWNYKB]..........................................................................................................2065 Failure Code [DXH1KA]..........................................................................................................2067 Failure Code [DXH1KB]..........................................................................................................2069 Failure Code [DXH1KY]..........................................................................................................2071 Failure Code [DXH4KA]..........................................................................................................2072 Failure Code [DXH4KB]..........................................................................................................2074 Failure Code [DXH4KY]..........................................................................................................2076 Failure Code [DXH5KA]..........................................................................................................2077 Failure Code [DXH5KB]..........................................................................................................2079 Failure Code [DXH5KY]..........................................................................................................2081 Failure Code [DXH6KA]..........................................................................................................2082 Failure Code [DXH6KB]..........................................................................................................2084 Failure Code [DXH6KY]..........................................................................................................2086 Failure Code [DXH7KA]..........................................................................................................2087 Failure Code [DXH7KB]..........................................................................................................2089 Failure Code [DXH7KY]..........................................................................................................2091 Failure Code [DXH8KA]..........................................................................................................2092 Failure Code [DXH8KB]..........................................................................................................2094 Failure Code [DXH8KY]..........................................................................................................2096 Failure Code [DXH9KA]..........................................................................................................2097 Failure Code [DXH9KB]..........................................................................................................2099 Failure Code [DXH9KY]..........................................................................................................2101 Failure Code [DXHAKA]..........................................................................................................2102 Failure Code [DXHAKB]..........................................................................................................2104 Failure Code [DXHAKY]..........................................................................................................2106 Failure Code [DXHBKA]..........................................................................................................2107 Failure Code [DXHBKB]..........................................................................................................2109 Failure Code [DXHBKY]..........................................................................................................2111 Failure Code [DXHCKA]..........................................................................................................2112 Failure Code [DXHCKB]..........................................................................................................2114 Failure Code [DXHCKY]..........................................................................................................2116 Failure Code [DXHRKA]..........................................................................................................2117 Failure Code [DXHRKB]..........................................................................................................2119 Failure Code [DXHRKY]..........................................................................................................2121 Failure Code [DXHSKA]..........................................................................................................2122 Failure Code [DXHSKB]..........................................................................................................2124 Failure Code [DXHSKY]..........................................................................................................2126 Failure Code [DXHTKA]..........................................................................................................2127 Failure Code [DXHTKB]..........................................................................................................2129 Failure Code [DXHTKY]..........................................................................................................2131 Failure Code [DXHUKA]..........................................................................................................2132 Failure Code [DXHUKB]..........................................................................................................2134 Failure Code [DXHUKY]..........................................................................................................2136 Failure Code [DXHWKA]..........................................................................................................2137 Failure Code [DXHWKB]..........................................................................................................2139 Failure Code [DXHWKY]..........................................................................................................2141 Failure Code [DXHXKA]..........................................................................................................2142 Failure Code [DXHXKB]..........................................................................................................2144 Failure Code [DXHXKY]..........................................................................................................2146 Failure Code [DXHYKA]..........................................................................................................2147 Failure Code [DXHYKB]..........................................................................................................2149 Failure Code [DXHYKY]..........................................................................................................2151 Failure Code [DXHZKA]..........................................................................................................2152 Failure Code [DXHZKB]..........................................................................................................2154 Failure Code [DXHZKY]..........................................................................................................2156 Failure Code [DXJ4KA]..........................................................................................................2157 Failure Code [DXJ4KB]..........................................................................................................2159 Failure Code [DXJ8KA]..........................................................................................................2160 Failure Code [DXJ8KB]..........................................................................................................2162 Failure Code [DXJ8KY]..........................................................................................................2164 Failure Code [DXJ9KA]..........................................................................................................2165 Failure Code [DXJ9KB]..........................................................................................................2167 Failure Code [DXJ9KY]..........................................................................................................2169 Failure Code [DXJBKA]..........................................................................................................2170 Failure Code [DXJBKB]..........................................................................................................2172 Failure Code [DXJBKY]..........................................................................................................2173 Failure Code [DY2HKA]..........................................................................................................2174 Failure Code [F7A0KT]..........................................................................................................2176 Failure Code [F7A1KK]..........................................................................................................2177 Failure Code [F7A8KB]..........................................................................................................2180 Failure Code [F7ALKA]..........................................................................................................2181 Failure Code [F7ALKB]..........................................................................................................2184 Failure Code [F7AQKR]..........................................................................................................2186 Failure Code [F7ARKR]..........................................................................................................2191 Failure Code [F7ASKA]..........................................................................................................2196 Failure Code [F7BSKR]..........................................................................................................2200 Failure Code [F7BTKR]..........................................................................................................2202 Failure Code [F7C0KR]..........................................................................................................2203 Failure Code [F7CRKT]..........................................................................................................2207 Failure Code [F9A0KT]..........................................................................................................2208 Failure Code [F9A0MC]..........................................................................................................2209 Failure Code [F9A1KK]..........................................................................................................2210 Failure Code [F9A2KK]..........................................................................................................2212 Failure Code [F9AQKR]..........................................................................................................2214 Failure Code [F9ARKR]..........................................................................................................2219 Failure Code [F9ATKA]..........................................................................................................2224 Failure Code [F9ATKB]..........................................................................................................2227 Failure Code [F9AUMC]..........................................................................................................2229 Failure Code [F@BYNR]..........................................................................................................2231 Failure Code [F@BYNS]..........................................................................................................2232 Troubleshooting of Electrical System (E-Mode)......................................................................................2233 E-1 Engine Does Not Start (Engine Does Not Crank)..............................................................................2233 E-2 Engine Does Not Start in Radio Control Mode (Engine Does Not Crank)........................................................2237 E-3 Engine Stops During Operation (Specifications of Radio Control)............................................................2240 E-4 Manual Preheating System Does Not Work.....................................................................................2245 E-5 Automatic Preheating System Does Not Work..................................................................................2248 E-6 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................2250 E-7 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................2252 E-8 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....2256 E-9 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................2258 E-10 Charge Level Monitor Comes On in Red While Engine Runs....................................................................2259 E-11 Engine Coolant Temperature Monitor Comes on in Red While Engine is in Operation...........................................2261 E-12 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation..................................................2262 E-13 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs.....................................................2263 E-14 Hydraulic Oil Temperature Monitor Comes on in Red While Engine Runs.......................................................2264 E-15 Engine Coolant Temperature Gauge Does Not Show Correct Temperature........................................................2265 E-16 Fuel Level Gauge Does Not Show Correct Level..............................................................................2266 E-17 Power Train Oil Temperature Gauge Does Not Show Correct Temperature.......................................................2268 E-18 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature.........................................................2270 E-19 Operation Mode Does Not Change............................................................................................2272 E-20 Gear Shift Mode Does Not Change...........................................................................................2273 E-21 Movement of Machine Does Not Align to Instructions in Radio Control Transmitter Operation.................................2274 E-22 Radio Control/on-Board Can Not be Changed.................................................................................2277 E-23 All Radio Control Can Not be Operated.....................................................................................2281 E-24 Operating Customize Switch Does Not Display Customize Screen..............................................................2284 E-25 Modifying Setting on Customize Screen Does Not Change Setting of Machine..................................................2285 E-26 Some Areas of Machine Monitor Screen are Not Shown........................................................................2286 E-27 Alarm Buzzer Does Not Sound or Cannot be Stopped..........................................................................2287 E-28 Service Meter is Not Shown, While Starting Switch is in OFF Position......................................................2288 E-29 Service Mode Cannot be Selected...........................................................................................2289 E-30 Horn Does Not Sound.......................................................................................................2290 E-31 Horn Does Not Stop........................................................................................................2292 E-32 Horn Does Not Sound or Does Not Stop (Specifications of Radio Control)....................................................2293 E-33 Backup Alarm Does Not Sound...............................................................................................2295 E-34 Backup Alarm Does Not Stop................................................................................................2296 E-35 Headlamp Does Not Come On.................................................................................................2297 E-36 Rear Lamp and Ripper Point Lamp Do Not Come On............................................................................2301 E-37 Working Lamp Does Not Come On or Go Out (Specifications of Radio Control).................................................2305 E-38 Red Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control)...........................................2308 E-39 Blue Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control)..........................................2311 E-40 Green Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control).........................................2314 E-41 No Wiper Operates.........................................................................................................2317 E-42 Front Wiper Does Not Operate..............................................................................................2322 E-43 Rear Wiper Does Not Operate...............................................................................................2326 E-44 Left Door Wiper Does Not Operate..........................................................................................2330 E-45 Right Door Wiper Does Not Operate.........................................................................................2334 E-46 Fuel Feed Pump Does Not Operate or Stop Automatically.....................................................................2338 E-47 Fan Does Not Rotate in Reverse............................................................................................2340 E-48 Gear Cannot be Shifted....................................................................................................2341 E-49 Front Washer Does Not Operate.............................................................................................2342 E-50 Rear Washer Does Not Operate..............................................................................................2344 E-51 Left Door Washer Does Not Operate.........................................................................................2346 E-52 Right Door Washer Does Not Operate........................................................................................2348 E-53 Ripper Pin Puller Does Not Work...........................................................................................2350 E-54 KOMTRAX Plus System Does Not Operate Normally.............................................................................2352 E-55 Cannot Download Data with Wireless LAN....................................................................................2353 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)......................................................................2354 Information Shown in Troubleshooting Table (H-Mode)............................................................................2354 H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull)..............................................................2355 H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed).........................................................................2358 H-3 Machine Does Not Move Off at All Gear Speeds...............................................................................2360 H-4 Machine Travels Only in One Direction, Forward or in Reverse...............................................................2362 H-5 Large Time Lag is in Gear Shifting or Directional Change...................................................................2363 H-6 Brake Does Not Work........................................................................................................2365 H-7 Power Train Oil Overheats..................................................................................................2366 H-8 Torque Converter Lockup Clutch Does Not Engage.............................................................................2367 H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)............................................................2368 H-10 Machine Can Turn (Steering) Only in One Direction.........................................................................2369 H-11 Machine Falls Over Too Much (Steering)....................................................................................2370 H-12 All Work Equipment Operate Slowly.........................................................................................2371 H-13 All Work Equipment Do Not Operate.........................................................................................2373 H-14 Blade Lift Speed or Power is Low..........................................................................................2375 H-15 Blade Tilt Speed or Power is Low..........................................................................................2377 H-16 Ripper Lift Speed or Power is Low.........................................................................................2379 H-17 Ripper Tilt Speed or Power is Low.........................................................................................2381 H-18 Hydraulic Drift of Blade Lift is Large....................................................................................2383 H-19 Hydraulic Drift of Tilted Blade is Large..................................................................................2384 H-20 Hydraulic Drift of Lifted Ripper is Large.................................................................................2385 H-21 Ripper Pin Puller Cylinder Does Not Operate...............................................................................2386 H-22 Blade Pitch Cylinder Does Not Operate.....................................................................................2387 H-23 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve...................................2388 H-24 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...............................................................2389 H-25 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock.......................................................2390 Troubleshooting of Engine (S-Mode).................................................................................................2391 Information Shown in Troubleshooting Table (S-Mode)............................................................................2391 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................................2392 S-2 Engine Cranks but No Exhaust Smoke Comes Out...............................................................................2393 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...................................2394 S-4 Engine Startability is Unsatisfactory......................................................................................2395 S-5 Engine Does Not Pick Up Smoothly...........................................................................................2397 S-6 Engine Stops During Operation..............................................................................................2399 S-7 Engine Runs Rough or is Not Stable.........................................................................................2401 S-8 Engine Lacks Power.........................................................................................................2402 S-9 KDPF Becomes Clogged in a Short Time.......................................................................................2404 S-10 Engine Oil Consumption is Excessive.......................................................................................2406 S-11 Oil Becomes Dirty Quickly.................................................................................................2407 S-12 Fuel Consumption is Excessive.............................................................................................2408 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant......................................................................2409 S-14 Oil Pressure Drops........................................................................................................2410 S-15 Fuel Mixes Into Engine Oil................................................................................................2412 S-16 Water Mixes Into Engine Oil (Milky).......................................................................................2413 S-17 Coolant Temperature Increases Too High (Overheating)......................................................................2414 S-18 Unusual Noise is Heard....................................................................................................2416 S-19 Vibration is Excessive....................................................................................................2417 S-20 Air Cannot be Bled from Fuel Circuit......................................................................................2418 S-21 Active Regeneration is Done Frequently....................................................................................2419 S-22 Active Regeneration Continues Long........................................................................................2420 S-23 White Smoke is Exhausted During Active Regeneration.......................................................................2421 50 Disassembly and Assembly............................................................................................................2423 Table of Contents..................................................................................................................2424 Precautions Before Work............................................................................................................2430 Related Information on Disassembly and Assembly....................................................................................2431 How to Read This Manual........................................................................................................2431 Coating Materials List.........................................................................................................2433 Special Tool List..............................................................................................................2438 Sketches of Special Tools......................................................................................................2463 Engine and Cooling System..........................................................................................................2489 Remove and Install Supply Pump Assembly........................................................................................2489 How to Remove Supply Pump Assembly.........................................................................................2489 How to Install Supply Pump Assembly........................................................................................2497 Remove and Install Injector Assembly...........................................................................................2508 How to Remove Injector Assembly............................................................................................2509 How to Install Injector Assembly...........................................................................................2517 Remove and Install Fuel Doser Assembly.........................................................................................2530 How to Remove Fuel Doser Assembly..........................................................................................2530 How to Install Fuel Doser Assembly.........................................................................................2532 Remove and Install Cylinder Head Assembly......................................................................................2535 How to Remove Cylinder Head Assembly.......................................................................................2536 How to Install Cylinder Head Assembly......................................................................................2558 Remove and Install Common Rail.................................................................................................2589 How to Remove Common Rail..................................................................................................2589 How to Install Common Rail.................................................................................................2595 Remove and Install EGR Valve Assembly..........................................................................................2602 How to Remove EGR Valve Assembly...........................................................................................2602 How to Install EGR Valve Assembly..........................................................................................2603 Remove and Install EGR Cooler Assembly.........................................................................................2604 How to Remove EGR Cooler Assembly..........................................................................................2604 How to Install EGR Cooler Assembly.........................................................................................2609 Remove and Install Starter Assembly............................................................................................2614 How to Remove Starting Motor Assembly......................................................................................2614 How to Install Starting Motor Assembly.....................................................................................2615 Remove and Install Radiator Guard Assembly.....................................................................................2617 How to Remove Radiator Guard Assembly......................................................................................2617 How to Install Radiator Guard Assembly.....................................................................................2623 Remove and Install Cooler Assembly.............................................................................................2630 How to Remove Cooling Assembly.............................................................................................2630 How to Install Cooling Assembly............................................................................................2635 Remove and Install Radiator Assembly...........................................................................................2639 How to Remove Radiator Assembly............................................................................................2639 How to Install Radiator Assembly...........................................................................................2641 Remove and Install Hydraulic Oil Cooler Assembly...............................................................................2643 How to Remove Hydraulic Oil Cooler Assembly................................................................................2643 How to Install Hydraulic Oil Cooler Assembly...............................................................................2645 Remove and Install Aftercooler Assembly........................................................................................2647 How to Remove Aftercooler Assembly.........................................................................................2647 How to Install Aftercooler Assembly........................................................................................2649 Open and Close Cooling Fan Drive Assembly......................................................................................2651 How to Open Cooling Fan Drive Assembly.....................................................................................2651 How to Close Cooling Fan Drive Assembly....................................................................................2654 Remove and Install Cooling Fan Drive Assembly..................................................................................2657 How to Remove Cooling Fan Drive Assembly...................................................................................2657 How to Install Cooling Fan Drive Assembly..................................................................................2661 Remove and Install Cooling Fan Motor Assembly..................................................................................2664 How to Remove Cooling Fan Motor Assembly...................................................................................2664 How to Install Cooling Fan Motor Assembly..................................................................................2666 Remove and Install Engine Assembly.............................................................................................2668 How to Remove Engine Assembly..............................................................................................2668 How to Install Engine Assembly.............................................................................................2681 Remove and Install Engine Front Oil Seal.......................................................................................2694 How to Remove Engine Front Oil Seal........................................................................................2694 How to Install Engine Front Oil Seal.......................................................................................2695 Remove and Install Engine Rear Oil Seal........................................................................................2697 How to Remove Engine Rear Oil Seal.........................................................................................2697 How to Install Engine Rear Oil Seal........................................................................................2698 Remove and Install Engine Hood Assembly........................................................................................2702 How to Remove Engine Hood Assembly.........................................................................................2702 How to Install Engine Hood Assembly........................................................................................2707 Remove and Install Fuel Tank Assembly..........................................................................................2714 How to Remove Fuel Tank Assembly...........................................................................................2714 How to Install Fuel Tank Assembly..........................................................................................2718 Remove and Install KDPF Assembly...............................................................................................2723 How to Remove KDPF Assembly................................................................................................2723 How to Install KDPF Assembly...............................................................................................2728 Disassemble and Assemble KDPF Assembly.........................................................................................2733 How to Disassemble KDPF Assembly...........................................................................................2734 How to Assemble KDPF Assembly..............................................................................................2739 Remove and Install KCCV Assembly...............................................................................................2746 How to Remove KCCV Assembly................................................................................................2746 How to Install KCCV Assembly...............................................................................................2748 Remove and Install VGT Assembly................................................................................................2752 How to Remove VGT Assembly.................................................................................................2752 How to Install VGT Assembly................................................................................................2760 Remove and Install Air Cleaner Bracket Assembly................................................................................2770 How to Remove Air Cleaner Bracket Assembly.................................................................................2770 How to Install Air Cleaner Bracket Assembly................................................................................2775 Remove and Install Air Cleaner Assembly........................................................................................2780 How to Remove Air Cleaner Assembly.........................................................................................2780 How to Install Air Cleaner Assembly........................................................................................2781 Remove and Install Air Conditioner Compressor Assembly.........................................................................2782 How to Remove Air Conditioner Compressor Assembly..........................................................................2782 How to Install Air Conditioner Compressor Assembly.........................................................................2785 Remove and Install Air Conditioner Condenser Assembly..........................................................................2788 How to Remove Air Conditioner Condenser Assembly...........................................................................2788 How to Install Air Conditioner Condenser Assembly..........................................................................2791 Power Train........................................................................................................................2794 Remove and Install Damper Assembly.............................................................................................2794 How to Remove Damper Assembly..............................................................................................2794 How to Install Damper Assembly.............................................................................................2802 Disassemble and Assemble Damper Assembly.......................................................................................2812 How to Disassemble Damper Assembly.........................................................................................2812 How to Assemble Damper Assembly............................................................................................2813 Remove and Install Power Train Unit Assembly...................................................................................2816 How to Remove Power Train Unit Assembly....................................................................................2816 How to Install Power Train Unit Assembly...................................................................................2829 Disconnect and Connect Power Train Unit Assembly...............................................................................2842 How to Disconnect Power Train Unit Assembly................................................................................2842 How to Connect Power Train Unit Assembly...................................................................................2851 Disassemble and Assemble PTO Assembly..........................................................................................2861 How to Disassemble PTO Assembly............................................................................................2861 How to Assemble PTO Assembly...............................................................................................2864 Disassemble and Assemble Torque Converter Assembly.............................................................................2869 How to Disassemble Torque Converter Assembly...............................................................................2869 How to Assemble Torque Converter Assembly..................................................................................2873 Disassemble and Assemble Transmission Assembly.................................................................................2880 How to Disassemble Transmission Assembly...................................................................................2881 How to Assemble Transmission Assembly......................................................................................2893 Disassemble and Assemble Steering Case Assembly................................................................................2911 How to Disassemble Steering Case Assembly..................................................................................2911 How to Assemble Steering Case Assembly.....................................................................................2918 Remove and Install Final Drive Assembly........................................................................................2928 How to Remove Final Drive Assembly.........................................................................................2928 How to Install Final Drive Assembly........................................................................................2929 Disassemble and Assemble Final Drive Assembly..................................................................................2931 How to Disassemble Final Drive Assembly....................................................................................2932 How to Assemble Final Drive Assembly.......................................................................................2938 Undercarriage and Frame............................................................................................................2948 Remove and Install Track Frame Assembly........................................................................................2948 How to Remove Track Frame Assembly.........................................................................................2948 How to Install Track Frame Assembly........................................................................................2952 Remove and Install Idler Assembly..............................................................................................2957 How to Remove Idler Assembly...............................................................................................2957 How to Install Idler Assembly..............................................................................................2958 Disassemble and Assemble Idler Assembly........................................................................................2959 How to Disassemble Idler Assembly..........................................................................................2959 How to Assemble Idler Assembly.............................................................................................2960 Remove and Install Recoil Spring Assembly......................................................................................2963 How to Remove Recoil Spring Assembly.......................................................................................2964 How to Install Recoil Spring Assembly......................................................................................2972 Disassemble and Assemble Recoil Spring Assembly................................................................................2977 How to Disassemble Recoil Spring Assembly..................................................................................2977 How to Assemble Recoil Spring Assembly.....................................................................................2978 Remove and Install Track Roller Assembly.......................................................................................2979 How to Remove Track Roller Assembly........................................................................................2979 How to Install Track Roller Assembly.......................................................................................2981 Disassemble and Assemble Track Roller Assembly.................................................................................2983 How to Disassemble Track Roller Assembly...................................................................................2983 How to Assemble Track Roller Assembly......................................................................................2984 Remove and Install No. 1 Bogie Assembly........................................................................................2986 How to Remove No.1 Bogie Assembly..........................................................................................2987 How to Install No. 1 Bogie Assembly........................................................................................2989 Remove and Install Bogie Assembly..............................................................................................2992 How to Remove Bogie Assembly...............................................................................................2993 How to Install Bogie Assembly..............................................................................................2996 Disassemble and Assemble Bogie Assembly........................................................................................2998 How to Disassemble Bogie Assembly..........................................................................................2998 How to Assemble Bogie Assembly.............................................................................................2999 Remove and Install Carrier Roller Assembly.....................................................................................3001 How to Remove Carrier Roller Assembly......................................................................................3001 How to Install Carrier Roller Assembly.....................................................................................3001 Disassemble and Assemble Carrier Roller Assembly...............................................................................3003 How to Disassemble Carrier Roller Assembly.................................................................................3003 How to Assemble Carrier Roller Assembly....................................................................................3004 Remove and Install Pivot Shaft Assembly........................................................................................3008 How to Remove Pivot Shaft Assembly.........................................................................................3008 How to Install Pivot Shaft Assembly........................................................................................3009 Separate and Connect Track Assembly............................................................................................3010 How to Separate Track Assembly.............................................................................................3010 How to Install Track Assembly..............................................................................................3012 Disassemble and Assemble Track Assembly Generally..............................................................................3014 How to Disassemble Full Track Shoes Assembly...............................................................................3014 How to Assemble Full Track Shoes Assembly..................................................................................3017 Disassemble and Assemble One Track Link Assembly in Field......................................................................3031 How to Disassemble One Track Link Assembly in Field........................................................................3032 How to Assemble One Track Link Assembly in Field...........................................................................3034 Disassemble and Assemble Master Link...........................................................................................3036 How to Disassemble Master Link.............................................................................................3038 How to Assemble Master Link................................................................................................3038 Remove and Install Equalizer Bar Assembly......................................................................................3041 How to Remove Equalizer Bar Assembly.......................................................................................3041 How to Install Equalizer Bar Assembly......................................................................................3046 Disassemble and Assemble Equalizer Bar Bushing.................................................................................3051 How to Disassemble Equalizer Bar Bushing...................................................................................3051 How to Assemble Equalizer Bar Bushing......................................................................................3052 Remove and Install Segment Teeth...............................................................................................3054 How to Remove Segment Teeth................................................................................................3054 How to Install Segment Teeth...............................................................................................3054 Remove and Install Power Ladder Assembly.......................................................................................3056 How to Remove Power Ladder Assembly........................................................................................3056 How to Install Power Ladder Assembly.......................................................................................3059 Open and Close Underguard Assembly.............................................................................................3062 How to Open Underguard Assembly............................................................................................3062 How to Close Underguard Assembly...........................................................................................3068 Remove and Install Under Guard Assembly........................................................................................3074 How to Remove Underguard Assembly..........................................................................................3074 How to Install Underguard Assembly.........................................................................................3081 Hydraulic System...................................................................................................................3087 Remove and Install Hydraulic Tank Assembly.....................................................................................3087 How to Remove Hydraulic Tank Assembly......................................................................................3087 How to Install Hydraulic Tank Assembly.....................................................................................3091 Remove and Install Work Equipment Pump Assembly................................................................................3096 How to Remove Work Equipment Pump Assembly.................................................................................3096 How to Install Work Equipment Pump Assembly................................................................................3100 Remove and Install Power Train Pump and Steering Lubrication Pump Assembly.....................................................3105 How to Remove Power Train Pump and Steering Lubrication Pump Assembly......................................................3105 How to Install Power Train Pump and Steering Lubrication Pump Assembly.....................................................3105 Remove and Install Cooling Fan Pump Assembly...................................................................................3107 How to Remove Cooling Fan Pump Assembly....................................................................................3107 How to Install Cooling Fan Pump Assembly...................................................................................3108 Remove and Install Scavenging Pump Assembly....................................................................................3110 How to Remove Scavenging Pump Assembly.....................................................................................3110 How to Install Scavenging Pump Assembly....................................................................................3110 Disassemble and Assemble Control Valve Assembly................................................................................3112 How to Assemble Control Valve Assembly.....................................................................................3112 Remove and Install Control Valve Assembly......................................................................................3115 How to Remove Control Valve Assembly.......................................................................................3115 How to Install Control Valve Assembly......................................................................................3121 Work Equipment.....................................................................................................................3128 Remove and Install Blade Assembly..............................................................................................3128 How to Remove Blade Assembly...............................................................................................3128 How to Install Blade Assembly..............................................................................................3131 Disassemble and Assemble Blade Assembly........................................................................................3135 How to Disassemble Blade Assembly..........................................................................................3135 How to Assemble Blade Assembly.............................................................................................3138 Disassemble and Assemble Giant Ripper Assembly.................................................................................3142 How to Disassemble Giant Ripper Assembly...................................................................................3142 How to Assemble Giant Ripper Assembly......................................................................................3144 Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly.......................................................3147 How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly........................................................3149 How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly.......................................................3154 Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly.................................................3159 How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly...................................................3160 How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly......................................................3166 Disassemble and Assemble Blade Tilt Cylinder Assembly..........................................................................3176 How to Disassemble Blade Tilt Cylinder Assembly............................................................................3176 How to Assemble Blade Tilt Cylinder Assembly...............................................................................3178 Disassemble and Assemble Ripper Pin Puller Cylinder Assembly...................................................................3181 How to Disassemble Ripper Pin Puller Cylinder Assembly.....................................................................3181 How to Assemble Ripper Pin Puller Cylinder Assembly........................................................................3182 CAB Related Parts..................................................................................................................3184 Remove and Install ROPS Guard..................................................................................................3184 How to Remove ROPS Guard...................................................................................................3184 How to Install ROPS Guard..................................................................................................3185 Remove and Install Operator Cab Assembly.......................................................................................3186 How to Remove Operator Cab Assembly........................................................................................3186 How to Install Operator Cab Assembly.......................................................................................3190 Remove and Install Operator Cab Glass (Adhered Glass)..........................................................................3194 How to Remove Operator Cab Glass (Adhered Glass)...........................................................................3195 How to Install Operator Cab Glass (Adhered Glass)..........................................................................3195 Remove and Install Air Conditioner Unit Assembly...............................................................................3199 How to Remove Air Conditioner Unit Assembly................................................................................3199 How to Install Air Conditioner Unit Assembly...............................................................................3205 Remove and Install Operator Seat...............................................................................................3211 How to Remove Operator Seat................................................................................................3211 How to Install Operator Seat...............................................................................................3212 How to Remove and Install Seat Belt............................................................................................3214 How to Remove Seat Belt....................................................................................................3214 How to Install Seatbelt....................................................................................................3215 Remove and Install FCCS........................................................................................................3216 How to Remove FCCS.........................................................................................................3216 How to Install FCCS........................................................................................................3217 Electrical System..................................................................................................................3219 Remove and Install Engine Controller Assembly..................................................................................3219 How to Remove Engine Controller Assembly...................................................................................3219 How to Install Engine Controller Assembly..................................................................................3223 Remove and Install Power Train Controller Assembly.............................................................................3228 How to Remove Power Train Controller Assembly..............................................................................3228 How to Install Power Train Controller Assembly.............................................................................3229 Remove and Install Work Equipment Controller Assembly..........................................................................3230 How to Remove Work Equipment Controller Assembly...........................................................................3230 How to Install Work Equipment Controller Assembly..........................................................................3231 Remove and Install Machine Monitor Assembly....................................................................................3232 How to Remove Machine Monitor Assembly.....................................................................................3232 How to Install Machine Monitor Assembly....................................................................................3233 Remove and Install Mass Air Flow and Temperature Sensor........................................................................3235 How to Remove Mass Air Flow and Temperature Sensor.........................................................................3235 How to Install Mass Air Flow and Temperature Sensor........................................................................3236 Remove and Install KCCV Crankcase Pressure Sensor..............................................................................3238 How to Remove KCCV Crankcase Pressure Sensor...............................................................................3238 How to Install KCCV Crankcase Pressure Sensor..............................................................................3239 Remove and Install KOMTRAX Terminal Assembly...................................................................................3240 How to Remove KOMTRAX Terminal Assembly....................................................................................3240 How to Install KOMTRAX Terminal Assembly...................................................................................3240 Remove And Install KOMTRAX Plus Controller Assembly............................................................................3242 How to Remove KOMTRAX Plus Controller Assembly.............................................................................3242 How to Install KOMTRAX Plus Controller Assembly............................................................................3243 Remove and Install Wireless LAN Unit Assembly..................................................................................3245 How to Remove Wireless LAN Unit Assembly...................................................................................3245 How to Install Wireless LAN Unit Assembly..................................................................................3246 Remove and Install Control Box.................................................................................................3248 How to Remove Control Box..................................................................................................3248 How to Install Control Box.................................................................................................3249 Remove and Install Option Controller Assembly..................................................................................3250 How to Remove Option Controller Assembly...................................................................................3250 How to Install Option Controller Assembly..................................................................................3253 Remove and Install Navigation Controller Assembly..............................................................................3258 How to Remove Navigation Controller Assembly...............................................................................3258 How to Install Navigation Controller Assembly..............................................................................3259 Remove and Install AUX BOX.....................................................................................................3261 How to Remove AUX BOX......................................................................................................3261 How to Install AUX BOX.....................................................................................................3263 Remove and Install IMU Sensor..................................................................................................3265 How to Remove IMU Sensor...................................................................................................3265 How to Install IMU Sensor..................................................................................................3266 Remove and Install Radio Control Receiver......................................................................................3269 How to Remove Radio Control Receiver.......................................................................................3269 How to Install Radio Control Receiver......................................................................................3270 60 Maintenance Standard................................................................................................................3273 Table of Contents..................................................................................................................3274 Engine and Cooling System..........................................................................................................3276 Maintenance Standard for Engine Mount..........................................................................................3276 Maintenance Standard for Damper................................................................................................3278 Maintenance Standard for Cooling System........................................................................................3280 Maintenance Standard for Cooling Fan Pump......................................................................................3282 Maintenance Standard for Servo Valve.......................................................................................3290 Maintenance Standard for Cooling Fan Motor.....................................................................................3292 Power Train........................................................................................................................3295 Maintenance Standard for Universal Joint.......................................................................................3295 Maintenance Standard for Power Train Mount.....................................................................................3296 Maintenance Standard for Torque Converter and PTO..............................................................................3298 Maintenance Standard for Torque Converter Control Valve........................................................................3303 Maintenance Standard for Lockup Clutch ECMV....................................................................................3305 Maintenance Standard for Stator Clutch ECMV....................................................................................3306 Maintenance Standard for Transmission..........................................................................................3307 Maintenance Standard for PTO, Transmission Lubrication Pump, and Power Train Pump..............................................3313 Maintenance Standard for Transmission ECMV.....................................................................................3315 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve...................................................3316 Maintenance Standard for Transmission Lubrication Relief Valve.................................................................3317 Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering..............................................................3318 Maintenance Standard for Brake Solenoid Valve..................................................................................3324 Maintenance Standard for Sudden Stop Prevention Valve..........................................................................3325 Maintenance Standard for Final Drive...........................................................................................3326 Maintenance Standard for Sprocket for Conventional Type Track Shoes............................................................3330 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes...........................3331 Undercarriage and Frame............................................................................................................3333 Maintenance Standard for Main Frame............................................................................................3333 Maintenance Standard for Suspension............................................................................................3336 Maintenance Standard for Track Frame and Idler Cushion.........................................................................3339 Maintenance Standard for Idler.................................................................................................3343 Maintenance Standard for Track Roller Bogie....................................................................................3345 Maintenance Standard for Track Roller for Conventional Type Track Shoes........................................................3346 Maintenance Standard for Carrier Roller for Conventional Type Track Shoes......................................................3349 Maintenance Standard for Conventional Type Track Shoes.........................................................................3350 Maintenance Standard for Single Shoes and Heavy Duty Shoes.....................................................................3352 Hydraulic System...................................................................................................................3353 Maintenance Standard for Hydraulic Tank........................................................................................3353 Maintenance Standard for Work Equipment Pump...................................................................................3354 Maintenance Standard for Scavenging Pump.......................................................................................3357 Maintenance Standard for Control Valve.........................................................................................3358 Maintenance Standard for Self-Pressure Reducing Valve..........................................................................3368 Maintenance Standard for Quick Drop Valve......................................................................................3371 Work Equipment.....................................................................................................................3372 Maintenance Standard for Cylinder Stay.........................................................................................3372 Maintenance Standard for Front Work Equipment..................................................................................3373 Maintenance Standard for Cutting Edge and End Bit..............................................................................3379 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder..........................................................3380 Maintenance Standard for Pin Puller Cylinder...................................................................................3381 Maintenance Standard for Blade Tilt Cylinder...................................................................................3382 Maintenance Standard for Variable Multi-Shank Ripper...........................................................................3384 Maintenance Standard for Variable Giant Ripper.................................................................................3386 Maintenance Standard for Ripper Lift Cylinder..................................................................................3388 Maintenance Standard for Ripper Tilt Cylinder..................................................................................3389 CAB Related Parts..................................................................................................................3390 Maintenance Standard for CAB Mount.............................................................................................3390 Maintenance Standard for ROPS..................................................................................................3391 80 Appendix............................................................................................................................3393 Table of Contents..................................................................................................................3394 Precautions Before Work............................................................................................................3396 Air Conditioner System.............................................................................................................3397 Precautions for Refrigerant....................................................................................................3397 Air Conditioner Component......................................................................................................3398 Specifications of Air Conditioner..............................................................................................3400 Structure and Function of Refrigeration Cycle..................................................................................3401 Outline of Refrigeration Cycle.................................................................................................3402 Component Parts of Air Conditioner System..........................................................................................3404 Air Conditioner Unit...........................................................................................................3404 Configuration Diagram of Air Conditioner Unit..............................................................................3404 Function of Air Conditioner Unit...........................................................................................3406 Component Parts of Air Conditioner Unit........................................................................................3408 Function of Evaporator as Air Conditioner Unit Component...................................................................3409 Function of Heater Core as Air Conditioner Unit Component..................................................................3409 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component................................................3409 Function of Servo Motor as Air Conditioner Unit Component..................................................................3409 Structure of Expansion Valve as Air Conditioner Unit Component.............................................................3410 Function of Expansion Valve as Air Conditioner Unit Component..............................................................3410 Operate Expansion Valve as Air Conditioner Unit Component..................................................................3410 Function of Triple Pressure Switch.........................................................................................3411 Air Conditioner Controller.....................................................................................................3412 Structure of Air Conditioner Controller....................................................................................3412 Compressor.....................................................................................................................3413 Structure of Compressor....................................................................................................3413 Specifications of Compressor...............................................................................................3413 Function of Compressor.....................................................................................................3413 Condenser......................................................................................................................3414 Structure of Condenser.....................................................................................................3414 Specifications of Condenser................................................................................................3414 Function of Condenser......................................................................................................3414 Receiver Drier.................................................................................................................3415 Structure of Receiver Dryer................................................................................................3415 Specifications of Receiver Dryer...........................................................................................3415 Function of Receiver Dryer.................................................................................................3415 Air Conditioner Related Sensors................................................................................................3416 Structure of Sunlight Sensor...............................................................................................3416 Function of Sunlight Sensor................................................................................................3416 Structure of Outside Temperature Sensor....................................................................................3416 Function of Outside Air Temperature Sensor.................................................................................3416 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner........................................................3418 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.............................................................3420 System Diagram of Air Conditioner..................................................................................................3422 Input and Output Signals of Air Conditioner Controller.........................................................................3423 Function of Air Conditioner Controller.....................................................................................3424 Locations of Air Conditioner Parts and Layout of Connectors........................................................................3425 Examine Air Leakage (Duct).........................................................................................................3434 How to Examine Air Leakage (Duct)..............................................................................................3434 Examine Air Conditioner with Self-Diagnosis Function...............................................................................3437 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor............................................3438 Examine Vent (Mode) Changeover.....................................................................................................3439 How to Examine Vent (Mode) Changeover..........................................................................................3439 Examine Fresh/Recirc Air Changeover................................................................................................3440 How to Examine Fresh/Recirc Air Changeover.....................................................................................3440 Examine Sunlight Sensor............................................................................................................3441 How to Examine Sunlight Sensor.................................................................................................3441 Examine Refrigerant (Triple) Pressure Switch.......................................................................................3442 How to Examine Refrigerant (Triple) Pressure Switch............................................................................3442 Examine Relay......................................................................................................................3443 How to Examine Relay...........................................................................................................3443 Air Conditioner Troubleshooting Chart 1............................................................................................3444 Air Conditioner Troubleshooting Chart 2............................................................................................3445 Information Shown in Troubleshooting Table.........................................................................................3448 Failure Code [879AKA]..............................................................................................................3449 Failure Code [879AKB]..............................................................................................................3450 Failure Code [879BKA]..............................................................................................................3451 Failure Code [879BKB]..............................................................................................................3453 Failure Code [879CKA]..............................................................................................................3455 Failure Code [879CKB]..............................................................................................................3456 Failure Code [879DKZ]..............................................................................................................3457 Failure Code [879EMC]..............................................................................................................3459 Failure Code [879FMC]..............................................................................................................3460 Failure Code [879GKX]..............................................................................................................3461 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).....................................................3463 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)......................................................3465 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal).............................................3469 A-4 Troubleshooting for Fresh/Recirc Air Changeover................................................................................3471 Troubleshooting by Gauge Pressure..................................................................................................3473 Connect Service Tool...............................................................................................................3476 How to Connect Service Tool....................................................................................................3476 Precautions for Disconnection and Connection of Air Conditioner Piping.............................................................3478 Handle Compressor Oil..............................................................................................................3480 90 Circuit Diagrams....................................................................................................................3483 Table of Contents..................................................................................................................3484 Hydraulic Circuit Diagram..........................................................................................................3485 Symbols Used in Hydraulic Circuit Diagram......................................................................................3485 Hydraulic Circuit Diagram......................................................................................................3489 Power Train Hydraulic Circuit Diagram..........................................................................................3491 Electrical Circuit Diagram.........................................................................................................3493 Symbols Used in Electric Circuit Diagram.......................................................................................3493 Electrical Circuit Diagram (1/12)..............................................................................................3497 Electrical Circuit Diagram (2/12)..............................................................................................3499 Electrical Circuit Diagram (3/12)..............................................................................................3501 Electrical Circuit Diagram (4/12)..............................................................................................3503 Electrical Circuit Diagram (5/12)..............................................................................................3505 Electrical Circuit Diagram (6/12)..............................................................................................3507 Electrical Circuit Diagram (7/12)..............................................................................................3509 Electrical Circuit Diagram (8/12)..............................................................................................3511 Electrical Circuit Diagram (9/12)..............................................................................................3513 Electrical Circuit Diagram (10/12).............................................................................................3515 Electrical Circuit Diagram (11/12).............................................................................................3517 Electrical Circuit Diagram (12/12).............................................................................................3519 Electrical Circuit Diagram of Inside of CAB (1/14).............................................................................3521 Electrical Circuit Diagram of Inside of CAB (2/14).............................................................................3523 Electrical Circuit Diagram of Inside of CAB (3/14).............................................................................3525 Electrical Circuit Diagram of Inside of CAB (4/14).............................................................................3527 Electrical Circuit Diagram of Inside of CAB (5/14).............................................................................3529 Electrical Circuit Diagram of Inside of CAB (6/14).............................................................................3531 Electrical Circuit Diagram of Inside of CAB (7/14).............................................................................3533 Electrical Circuit Diagram of Inside of CAB (8/14).............................................................................3535 Electrical Circuit Diagram of Inside of CAB (9/14).............................................................................3537 Electrical Circuit Diagram of Inside of CAB (10/14)............................................................................3539 Electrical Circuit Diagram of Inside of CAB (11/14)............................................................................3541 Electrical Circuit Diagram of Inside of CAB (12/14)............................................................................3543 Electrical Circuit Diagram of Inside of CAB (13/14)............................................................................3545 Electrical Circuit Diagram of Inside of CAB (14/14)............................................................................3547 Index...................................................................................................................................3549
DESCRIPTION:
KOMATSU D375Ai-8 BULLDOZER SHOP MANUAL SEN06714-07 – 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
