Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual PDF

Description

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06586-14 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06586-14 – PDF DOWNLOAD 

Language : English
Pages : 2776
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06586-14 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EX-85001 and up
D37PX-85001 and up
D39EX-95001 and up
D39PX-95001 and up

Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06586-14 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EX-85001 and up
D37PX-85001 and up
D39EX-95001 and up
D39PX-95001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF 42
General Character and Precautions for Handling 42
Precautions When You Add 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 54
Precautions When You Handle Fuel System Equipment 56
Precautions When You Handle Intake System Equipment 57
Practical Use of KOMTRAX 58
Disconnect and Connect Push-Pull Type Coupler 59
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 61
Precautions for Disconnection and Connection of Connectors 63
Disconnect and Connect Deutsch Connector 67
How to Disconnect and Connect Slide Lock Type Connector 68
Disconnect and Connect Connector with Lock to Pull 70
Disconnect and Connect Connector with Lock to Push 71
Disconnect and Connect Connector with Housing to Rotate 73
How to Read the Codes for Electric Cable 74
Explanation of Terms for Maintenance Standard 78
Standard Tightening Torque Table 81
Conversion Table 88
01 Specification 93
Table of Contents 94
Abbreviation List 95
Specifications 101
Specification Drawing 101
Specification Drawing: D37EX-24 101
Specification Drawing: D37PX-24 102
Specification Drawing: D39EX-24 104
Specification Drawing: D39PX-24 105
Specifications 107
Specification: D37EX-24 107
Specification: D37PX-24 111
Specification: D39EX-24 116
Specification: D39PX-24 121
Weight Table 126
Weight Table: D37EX-24 126
Weight Table: D37PX-24 128
Weight Table: D39EX-24 129
Weight Table: D39PX-24 131
Table of Fuel, Coolant, and Lubricants 133
10 Structure and Function 135
Table of Contents 136
Abbreviation List 139
Urea SCR System 145
Layout Drawing of Urea SCR System 145
Urea SCR System Diagram 147
Function of Urea SCR System 148
Function of DEF System 148
Inducement Strategy 150
Component Parts of Urea SCR System 164
DEF Mixing Tube 164
SCR Assembly 164
DEF Tank 167
DEF Pump 169
DEF Injector 170
DEF Hose 171
DEF Tank Heating Valve 172
Boot-up System 173
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 173
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 174
System Operating Lamp System 175
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 175
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 175
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 175
Function of System Operating Lamp System (Machine with Gateway Function Controller) 176
Battery Disconnect Switch 178
Function of Battery Disconnect Switch 178
Engine System 179
Layout Drawing of Engine System 179
Engine Control System 181
Layout of Engine Control System (Machine with KOMTRAX Terminal) 181
Layout of Engine Control System (Machine with Gateway Function Controller) 183
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 185
System Diagram of Engine Control System (Machine with Gateway Function Controller) 187
Function of Engine Control System (Machine with KOMTRAX Terminal) 189
Function of Engine Control System (Machine with Gateway Function Controller) 191
Automatic Idle Stop System 193
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 193
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 194
Function of Automatic Idle Stop System 194
Component Parts of Engine System 197
Damper 197
Variable Flow Turbocharger 198
EGR System 201
EGR Valve 203
EGR Cooler 204
KCCV System 206
KCCV Ventilator 208
Exhaust Throttle Valve 210
KDOC 211
Cooling System 214
Layout Drawing of Cooling System 214
Specifications of Cooling System 215
Cooling Fan Control System 216
System Diagram of Cooling Fan Control System 216
Function of Cooling Fan Control System 217
Component Parts of Cooling System 219
Cooling Fan Motor 219
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 224
Hydraulic Oil Cooler Bypass Valve 226
HST Charge Safety Valve 227
Control System 229
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 229
Layout Drawing of Control System (Machine with Gateway Function Controller) 230
Machine Monitor System 231
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 231
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 232
Function of Machine Monitor System 232
KOMTRAX System 233
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 233
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 233
Function of KOMTRAX System 234
Component Parts of Control System 235
Machine Monitor 235
KOMTRAX Terminal 250
Gateway Function Controller 252
Communication Terminal 255
HST Controller 257
Engine Controller 261
Fuel Control Dial 268
Decelerator and Brake Potentiometer 270
Hydraulic System 272
Layout Drawing of Hydraulic System 272
CLSS 273
Structure of CLSS 273
Function of CLSS 274
Component Parts of Hydraulic System 276
Hydraulic Tank 276
Work Equipment and Cooling Fan Pump 278
LS Valve 285
PC Valve 285
Control Valve 288
Power Train System 309
Layout Drawing of HST System 309
Operation of HST System 310
Steering and Brake Control System 312
Layout Drawing of Steering and Brake Control System 312
Function of Steering and Brake Control System 313
HST Control System 314
System Diagram of HST Control System 314
Gear Shift Control Function 315
Engine Low Speed Matching Control Function 319
HST Pump and Motor Sequence Control Function 320
Deceleration and Brake Control Function 322
Gear Shift Control Function by Load 324
Turn Control Function 325
Straight Travel Correction Control Function 326
Parking Brake Control System 327
System Diagram of Parking Brake Control System 327
Function of Parking Brake Control System 328
Operation of Parking Brake Control System 329
Component Parts of Power Train System 330
HST Pump 330
HST Charge Pump 347
HST Motor 348
Final Drive 360
Electric Steering Electric Lever 364
Work Equipment System 367
Work Equipment Control 367
Layout Drawing of Work Equipment Control 367
Function of Work Equipment Control 369
Layout Drawing of Front Work Equipment 371
Layout Drawing of Fixed Multi-Shank Ripper 372
Component Parts of Work Equipment System 373
Ripper PPC Valve 373
5-Spool EPC and Solenoid Valve 377
Pilot Circuit Accumulator 384
Angle Control EPC Valve 385
Piston Valve 388
Electric Blade Control Lever 389
Undercarriage and Frame 391
Main Frame 391
Structure of Main Frame 391
Track Frame and Idler Cushion 392
Structure of Track Frame and Idler Cushion 392
Function of Track Frame and Idler Cushion 394
Work Equipment 395
Structure of Front Work Equipment 395
Structure of Fixed Multi-Shank Ripper 396
CAB Related Parts 397
ROPS CAB 397
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 397
Structure of ROPS CAB (Machine with Gateway Function Controller) 398
Function of ROPS CAB 399
CAB Mount 400
Structure of CAB Mount 400
Function of CAB Mount 401
20 Standard Value Table 403
Table of Contents 404
Abbreviation List 405
Standard Value Table for Engine 411
Standard Value Table for Engine: D37EX-24 411
Standard Value Table for Engine: D37PX-24 414
Standard Value Table for Engine: D39EX-24 417
Standard Value Table for Engine: D39PX-24 420
Standard Value Table for Machine 423
Standard Value Table for Machine: D37EX-24 423
Standard Value Table for Machine: D37PX-24 439
Standard Value Table for Machine: D39EX-24 453
Standard Value Table for Machine: D39PX-24 469
Machine Posture and Procedures to Measure Performance 483
30 Testing and Adjusting 485
Table of Contents 486
Precautions Before Work 489
Abbreviation List 490
Related Information on Testing and Adjusting 496
Tools for Testing and Adjusting 496
Sketch of Tools for Testing and Adjusting 503
Engine and Cooling System 505
Examine Engine Speed 505
How to Examine Engine Speed 505
Examine Exhaust Gas Color 507
How to Examine Exhaust Gas Color with the Handy Smoke Checker 507
How to Examine Exhaust Gas Color with Smoke Meter 508
Examine the Clearance of Exhaust Throttle Valve 509
Measure Clearance of the Exhaust Throttle Valve 509
Examine and Adjust Valve Clearance 511
Check Valve Clearance 511
Adjust Valve Clearance 512
Examine Compression Pressure 513
How to Examine Compression Pressure 513
Examine Blowby Pressure 516
How to Examine Blowby Pressure 516
Examine Engine Oil Pressure 518
How to Examine Engine Oil Pressure 518
Visual Check Inside of EGR Valve 520
How to do the Visual Check Inside of EGR Valve 520
Clean Inside of EGR Valve 522
How to Clean Inside of EGR Valve 522
Examine Fuel Pressure 525
How to Examine Fuel Pressure 525
Examine Fuel Return Rate and Leakage 527
How to Examine Fuel Return Rate and Leakage 528
Bleed Air from Fuel System 532
How to Bleed Air from Fuel System 532
Examine Fuel Circuit for Leakage 534
How to Examine Fuel System for Leakage 534
Handle Cylinder Cut-out Mode Operation 536
Handle No-Injection Cranking Operation 537
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 538
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage 538
Examine Installed Condition of Cylinder Heads and Manifolds 539
How to Examine Installed Condition of Cylinder Heads and Manifolds 539
Examine Engine Piping for Damage and Looseness 540
How to Examine Engine Piping for Damage and Looseness 540
Examine Alternator Belt 541
How to Examine Alternator Belt 541
Examine Automatic Tensioner 542
How to Examine Automatic Tensioner 542
Write Injector Compensation Value to Engine Controller 544
Write Injector Compensation Value 544
Examine SCR Related Functions 551
Examine DEF Pump Raised Pressure 555
Examine Injection Volume from DEF Injector 558
Examine DEF Line Heater Relay 1 563
Examine DEF Line Heater Relay 2 566
Examine DEF Pump Heater Relay 569
Examine DEF Tank Heater Valve 573
Examine SCR Denitration Efficiency 576
Clean DEF Tank 579
How to Clean DEF Tank 579
Clean DEF Tank Mounting Part 584
How to Clean DEF Tank Mounting Part 584
Clean DEF Pump 585
How to Clean DEF Pump 585
Power Train 591
Examine and Adjust HST Oil Pressure 591
Examine HST Oil Pressure 591
Adjust HST Oil Pressure 594
Bleed Air from HST Pump 596
How to Bleed Air from HST Pump 596
Bleed Air from Servo Valve of HST Pump 596
Examine Outlet Pressure of Solenoid Valve 598
How to Examine Outlet Pressure of Solenoid Valve 598
Examine Travel Deviation 603
How to Examine Travel Deviation 603
Examine Brake Performance Simply 605
How to Examine Brake Performance Simply 605
Examine and Adjust Deceleration/Brake Pedal 606
How to Examine Deceleration/Brake Pedal 606
How to Adjust Deceleration/Brake Pedal 608
Adjust Parking Brake Lever 610
How to Adjust Parking Brake Lever 610
Move Machine When It Cannot Travel 612
Move Machine with Hydraulic Type Parking Brake Release System 612
Move Machine After You Remove Final Drive Shaft 614
Undercarriage and Frame 616
Adjust Idler Clearance 616
How to Adjust Idler Clearance 616
Examine Sprocket Wear 617
How to Examine Sprocket Wear 617
Examine and Adjust Track Tension 618
How to Examine Track Tension 618
How to Adjust Track Tension 618
Hydraulic System 620
Release Remained Pressure in Hydraulic Circuit 620
How to Release Remained Pressure in Hydraulic System 620
Examine and Adjust Work Equipment Circuit Oil Pressure 621
How to Examine Work Equipment Circuit Oil Pressure 621
Adjust Work Equipment Circuit Oil Pressure 622
Examine and Adjust Oil Pressure in Control Circuit 624
Examine Oil Pressure in Control Circuit 624
Adjust Oil Pressure in Control Circuit 625
Examine Outlet Pressure of EPC Solenoid Valve 626
How to Examine Outlet Pressure of EPC Solenoid Valve 626
Bleed Air from Work Equipment and Cooling Fan Pump 628
How to Bleed Air from Work Equipment and Cooling Fan Pump 628
Examine Cooling Fan Speed 629
How to Examine Cooling Fan Speed 629
Examine Cooling Fan Circuit Oil Pressure 630
How to Examine Cooling Fan Circuit Oil Pressure 630
Examine Parts Which Cause Hydraulic Drift of Work Equipment 632
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 632
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 632
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 633
Examine Oil Leakage from Work Equipment Cylinder 634
How to Examine Internal Oil Leakage of Work Equipment Cylinder 634
Bleed Air from Work Equipment Cylinders 636
Bleed Air from Work Equipment Cylinder 636
Work Equipment 637
Adjust Work Equipment Lock Lever 637
How to Adjust Work Equipment Lock Lever 637
Examine and Adjust Play of Blade Electric Lever 639
How to Examine Play of Blade Electric Lever 641
Adjust Play of Blade Electric Lever 641
Replace Universal Joint 642
Electrical System 649
Set and Operate Machine Monitor 649
Operator Mode 653
Function to Show Technician Identification Status Screen 653
Function to Show Operator Identification Input Screen 653
Examine Function by LCD (Liquid Crystal Display) 654
Examine Function of Service Meter 654
Usage Limitation and Change Maintenance Password 654
Service Mode 657
How to Operate Service Mode 657
How to See Pre-defined Monitoring Information 659
How to Examine Self-Define Monitor Information 665
Abnormality Record Menu 675
How to See Maintenance Record 679
Maintenance Mode Setting 680
Set Phone Number Entry 684
Default Menu 686
Diagnostic Tests Menu 693
Adjustment Menu 701
No-Injection Cranking Operation 756
KOMTRAX Settings Menu 759
Show Service Message 763
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 765
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 770
Start Up KOMTRAX System (Machine with Gateway Function Controller) 772
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 778
Adjust After Replacement of HST Controller 780
How to Adjust After Replacement of HST Controller 780
Adjust After Replacement of Electric and Hydraulic Equipment 786
Adjust Rearview Camera Angle 788
How to Adjust Rearview Camera Angle 788
Handle Voltage Circuit of Engine Controller 790
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 791
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 792
Examine Diodes 793
Examine Diodes by Digital Tester 793
How to Examine Diodes by Analog Tester 793
Pm Clinic 794
Pm Clinic Service 794
Pm Clinic Check Sheet: D37EX-24 796
Pm Clinic Check Sheet: D37PX-24 804
Pm Clinic Check Sheet: D39EX-24 812
Pm Clinic Check Sheet: D39PX-24 819
Pm Clinic Check Sheet for Undercarriage: D37EX-24 826
Pm Clinic Check Sheet for Undercarriage: D37PX-24 833
Pm Clinic Check Sheet for Undercarriage: D39EX-24 840
Pm Clinic Check Sheet for Undercarriage: D39PX-24 847
40 Troubleshooting 855
Table of Contents 856
Precautions Before Work 866
Abbreviation List 867
Related Information to Troubleshooting 873
General Troubleshooting Points 873
Troubleshooting Points for Urea SCR System 874
Sequence of Events in Troubleshooting 886
Checks Before Troubleshooting 888
Inspection Procedure Before Troubleshooting 890
Walk-Around Check 890
Test in Accordance with Testing Procedure 892
Examine Fuel Level and Type 892
Examine for Impure Ingredient in Fuel 892
Examine DEF Level and Type 893
Examine Fuel Prefilter 893
Examine Fuel Main Filter 895
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 897
Examine Coolant Level (Reservoir Tank) 898
Examine Air Cleaner Clogging 899
Clean Outer Element 899
Replace Element 901
Examine Hydraulic Oil Level 901
Examine Hydraulic Oil Strainer 902
Examine Oil Level in Final Drive Case 906
Bleed Air from Fuel System 906
Bleed Air from Hydraulic System 907
How to Examine Electric Equipment 907
Preparation for Troubleshooting of Electrical System 914
Procedure for Troubleshooting 921
Symptom and Troubleshooting Numbers 924
Information Shown in Troubleshooting Table 927
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 929
Connector List and Layout (Machine with KOMTRAX Terminal) 932
Connector List and Layout (Machine with Gateway Function Controller) 946
Connector Contact Connection Table 960
T-Branch Box and T-Branch Adapter Table 1000
Fuse Location Table (Machine with KOMTRAX Terminal) 1006
Fuse Location Table (Machine with Gateway Function Controller) 1010
Precautions When You Replace KDOC 1014
Failure Code Table 1015
Troubleshooting by Failure Code (Display of Code) 1035
Failure Code [6091NX] 1035
Failure Code [989L00] 1037
Failure Code [989M00] 1038
Failure Code [989N00] 1039
Failure Code [A1U0N3] 1040
Failure Code [A1U0N4] 1042
Failure Code [A900FR] 1044
Failure Code [A900N6] 1045
Failure Code [A900NY] 1046
Failure Code [AA10NX] 1047
Failure Code [AB00KE] 1049
Failure Code [AQ10MB] 1051
Failure Code [AQ10N3] 1053
Failure Code [AS00R2] 1054
Failure Code [AS00R3] 1055
Failure Code [AS00R4] 1056
Failure Code [AS00R5] 1057
Failure Code [AS00R6] 1058
Failure Code [AS00ZK] 1059
Failure Code [AS10KM] 1060
Failure Code [AS10NR] 1061
Failure Code [AS10NT] 1062
Failure Code [AU10QA] 1063
Failure Code [B@BAZG] 1064
Failure Code [B@BCNS] 1065
Failure Code [B@CRNS] 1066
Failure Code [B@CRZG] 1067
Failure Code [CA115] 1068
Failure Code [CA122] 1069
Failure Code [CA123] 1071
Failure Code [CA131] 1073
Failure Code [CA132] 1075
Failure Code [CA144] 1077
Failure Code [CA145] 1079
Failure Code [CA153] 1081
Failure Code [CA154] 1084
Failure Code [CA187] 1087
Failure Code [CA221] 1089
Failure Code [CA222] 1091
Failure Code [CA227] 1093
Failure Code [CA234] 1094
Failure Code [CA238] 1095
Failure Code [CA239] 1097
Failure Code [CA249] 1099
Failure Code [CA256] 1101
Failure Code [CA271] 1103
Failure Code [CA272] 1105
Failure Code [CA322] 1107
Failure Code [CA324] 1109
Failure Code [CA331] 1111
Failure Code [CA332] 1113
Failure Code [CA343] 1115
Failure Code [CA351] 1116
Failure Code [CA352] 1117
Failure Code [CA356] 1120
Failure Code [CA357] 1122
Failure Code [CA386] 1124
Failure Code [CA435] 1125
Failure Code [CA441] 1127
Failure Code [CA442] 1129
Failure Code [CA449] 1130
Failure Code [CA451] 1131
Failure Code [CA452] 1133
Failure Code [CA515] 1135
Failure Code [CA516] 1137
Failure Code [CA553] 1139
Failure Code [CA555] 1140
Failure Code [CA556] 1141
Failure Code [CA559] 1142
Failure Code [CA689] 1146
Failure Code [CA691] 1148
Failure Code [CA692] 1150
Failure Code [CA697] 1152
Failure Code [CA698] 1153
Failure Code [CA731] 1154
Failure Code [CA778] 1156
Failure Code [CA1117] 1161
Failure Code [CA1664] 1162
Failure Code [CA1669] 1164
Failure Code [CA1673] 1165
Failure Code [CA1677] 1166
Failure Code [CA1678] 1167
Failure Code [CA1682] 1168
Failure Code [CA1683] 1173
Failure Code [CA1684] 1175
Failure Code [CA1686] 1177
Failure Code [CA1691] 1178
Failure Code [CA1694] 1180
Failure Code [CA1695] 1182
Failure Code [CA1696] 1183
Failure Code [CA1712] 1185
Failure Code [CA1713] 1188
Failure Code [CA1714] 1190
Failure Code [CA1715] 1191
Failure Code [CA1776] 1192
Failure Code [CA1777] 1195
Failure Code [CA1843] 1198
Failure Code [CA1844] 1200
Failure Code [CA1885] 1203
Failure Code [CA1887] 1205
Failure Code [CA1896] 1207
Failure Code [CA1938] 1211
Failure Code [CA1942] 1213
Failure Code [CA1961] 1214
Failure Code [CA2185] 1215
Failure Code [CA2186] 1217
Failure Code [CA2249] 1219
Failure Code [CA2272] 1220
Failure Code [CA2311] 1223
Failure Code [CA2349] 1224
Failure Code [CA2353] 1226
Failure Code [CA2357] 1228
Failure Code [CA2555] 1229
Failure Code [CA2556] 1231
Failure Code [CA2636] 1233
Failure Code [CA2637] 1236
Failure Code [CA2765] 1238
Failure Code [CA2771] 1239
Failure Code [CA2976] 1245
Failure Code [CA3142] 1247
Failure Code [CA3143] 1248
Failure Code [CA3144] 1249
Failure Code [CA3146] 1251
Failure Code [CA3147] 1252
Failure Code [CA3148] 1253
Failure Code [CA3151] 1255
Failure Code [CA3165] 1261
Failure Code [CA3229] 1263
Failure Code [CA3231] 1265
Failure Code [CA3232] 1267
Failure Code [CA3235] 1271
Failure Code [CA3239] 1273
Failure Code [CA3241] 1276
Failure Code [CA3242] 1279
Failure Code [CA3251] 1282
Failure Code [CA3313] 1284
Failure Code [CA3314] 1285
Failure Code [CA3315] 1286
Failure Code [CA3419] 1288
Failure Code [CA3421] 1290
Failure Code [CA3497] 1292
Failure Code [CA3498] 1293
Failure Code [CA3543] 1294
Failure Code [CA3545] 1300
Failure Code [CA3547] 1302
Failure Code [CA3558] 1303
Failure Code [CA3559] 1305
Failure Code [CA3562] 1307
Failure Code [CA3563] 1309
Failure Code [CA3567] 1312
Failure Code [CA3568] 1315
Failure Code [CA3571] 1320
Failure Code [CA3572] 1322
Failure Code [CA3574] 1324
Failure Code [CA3575] 1327
Failure Code [CA3577] 1329
Failure Code [CA3578] 1331
Failure Code [CA3582] 1333
Failure Code [CA3583] 1341
Failure Code [CA3596] 1343
Failure Code [CA3649] 1347
Failure Code [CA3681] 1349
Failure Code [CA3682] 1354
Failure Code [CA3713] 1359
Failure Code [CA3717] 1362
Failure Code [CA3718] 1363
Failure Code [CA3724] 1364
Failure Code [CA3725] 1365
Failure Code [CA3748] 1368
Failure Code [CA3755] 1371
Failure Code [CA3866] 1373
Failure Code [CA3867] 1377
Failure Code [CA3868] 1380
Failure Code [CA3899] 1384
Failure Code [CA3911] 1386
Failure Code [CA3912] 1390
Failure Code [CA3918] 1392
Failure Code [CA3921] 1394
Failure Code [CA3928] 1395
Failure Code [CA3932] 1396
Failure Code [CA3933] 1398
Failure Code [CA3934] 1400
Failure Code [CA3935] 1403
Failure Code [CA3936] 1405
Failure Code [CA4152] 1407
Failure Code [CA4155] 1411
Failure Code [CA4156] 1414
Failure Code [CA4157] 1417
Failure Code [CA4159] 1419
Failure Code [CA4164] 1420
Failure Code [CA4165] 1422
Failure Code [CA4166] 1424
Failure Code [CA4168] 1425
Failure Code [CA4169] 1428
Failure Code [CA4171] 1430
Failure Code [CA4249] 1434
Failure Code [CA4251] 1436
Failure Code [CA4261] 1438
Failure Code [CA4277] 1441
Failure Code [CA4281] 1445
Failure Code [CA4459] 1449
Failure Code [CA4461] 1452
Failure Code [CA4533] 1455
Failure Code [CA4534] 1456
Failure Code [CA4731] 1457
Failure Code [CA4732] 1458
Failure Code [CA4739] 1459
Failure Code [CA4768] 1460
Failure Code [CA4769] 1462
Failure Code [CA4842] 1464
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1468
Failure Code [CA4952] (Machine with Gateway Function Controller) 1470
Failure Code [CA5115] 1472
Failure Code [CA5179] 1475
Failure Code [CA5181] 1477
Failure Code [CA5271] 1479
Failure Code [CA5272] 1481
Failure Code [CA5273] 1483
Failure Code [CA5274] 1485
Failure Code [CA5275] 1486
Failure Code [CA5276] 1488
Failure Code [CA5387] 1490
Failure Code [CA5388] 1492
Failure Code [CA5389] 1494
Failure Code [CA5391] 1496
Failure Code [CA5392] 1500
Failure Code [CA5393] 1501
Failure Code [CA5394] 1504
Failure Code [CA5395] 1507
Failure Code [CA5396] 1510
Failure Code [CA5631] 1511
Failure Code [CA5938] 1513
Failure Code [D130KA] 1515
Failure Code [D130KB] 1517
Failure Code [D130KY] 1519
Failure Code [D19JKZ] 1521
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1524
Failure Code [D811MC] (Machine with Gateway Function Controller) 1525
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1526
Failure Code [D862KA] (Machine with Gateway Function Controller) 1527
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1528
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1530
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1532
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1534
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1536
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1539
Failure Code [D8G1KT] 1542
Failure Code [D8G6KT] 1543
Failure Code [DAF0MB] 1544
Failure Code [DAF0MC] 1545
Failure Code [DAF8KB] 1546
Failure Code [DAF9KQ] 1548
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1549
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1550
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1551
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1553
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1555
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1557
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1559
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1563
Failure Code [DAJ000] 1567
Failure Code [DAJ0KQ] 1568
Failure Code [DAJ0KT] 1569
Failure Code [DAJ0MC] 1570
Failure Code [DAJ1KK] 1571
Failure Code [DAJ2KK] 1573
Failure Code [DAJ5KK] 1575
Failure Code [DAJ6KK] 1578
Failure Code [DAJLKA] (Machine with KOMTRAX Terminal) 1580
Failure Code [DAJLKA] (Machine with Gateway Function Controller) 1582
Failure Code [DAJLKB] (Machine with KOMTRAX Terminal) 1584
Failure Code [DAJLKB] (Machine with Gateway Function Controller) 1586
Failure Code [DAJPMA] 1588
Failure Code [DAJQKR] (Machine with KOMTRAX Terminal) 1589
Failure Code [DAJQKR] (Machine with Gateway Function Controller) 1593
Failure Code [DAJRKR] 1597
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1601
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1605
Failure Code [DB2RKR] 1609
Failure Code [DD12KA] 1613
Failure Code [DD12KB] 1615
Failure Code [DD13KA] 1617
Failure Code [DD13KB] 1619
Failure Code [DD14KA] 1621
Failure Code [DD14KB] 1623
Failure Code [DDKAKA] 1625
Failure Code [DDKAKB] 1627
Failure Code [DDKFL4] 1629
Failure Code [DDKGL4] 1631
Failure Code [DDKHKA] 1633
Failure Code [DDKHKB] 1635
Failure Code [DDNLKA] 1637
Failure Code [DDNLKB] 1639
Failure Code [DDP6KA] 1641
Failure Code [DDP6KB] 1643
Failure Code [DDP6MA] 1645
Failure Code [DDU1FS] 1647
Failure Code [DDU1KA] 1649
Failure Code [DDU1KY] 1651
Failure Code [DFA4KX] 1653
Failure Code [DFA4KZ] 1654
Failure Code [DFA4L8] 1655
Failure Code [DFA5KA] 1656
Failure Code [DFA5KB] 1658
Failure Code [DFA6KA] 1660
Failure Code [DFA6KB] 1662
Failure Code [DFA7KX] 1664
Failure Code [DFA7KZ] 1665
Failure Code [DFA7L8] 1666
Failure Code [DFA8KA] 1667
Failure Code [DFA8KB] 1669
Failure Code [DFA9KA] 1671
Failure Code [DFA9KB] 1673
Failure Code [DGS1KA] 1675
Failure Code [DGS1KX] 1677
Failure Code [DH21KA] 1679
Failure Code [DH21KB] 1681
Failure Code [DHA4KA] 1682
Failure Code [DHH7KA] 1684
Failure Code [DHH7KB] 1686
Failure Code [DHH8KA] 1688
Failure Code [DHH8KB] 1690
Failure Code [DHH9KA] 1692
Failure Code [DHH9KB] 1694
Failure Code [DHHAKA] 1696
Failure Code [DHHAKB] 1698
Failure Code [DK30KA] 1700
Failure Code [DK30KB] 1702
Failure Code [DK30KX] 1704
Failure Code [DK30KZ] 1705
Failure Code [DK30L8] 1706
Failure Code [DK31KA] 1709
Failure Code [DK31KB] 1711
Failure Code [DK40KA] 1713
Failure Code [DK40KB] 1715
Failure Code [DK55KX] 1717
Failure Code [DK55KZ] 1718
Failure Code [DK55L8] 1719
Failure Code [DK56KA] 1721
Failure Code [DK56KB] 1723
Failure Code [DK57KA] 1725
Failure Code [DK57KB] 1727
Failure Code [DLM0KX] 1729
Failure Code [DLM0MA] 1730
Failure Code [DLM1KA] 1731
Failure Code [DLM1KB] 1733
Failure Code [DLM1MA] 1735
Failure Code [DLM2KA] 1736
Failure Code [DLM2KB] 1738
Failure Code [DLM2MA] 1740
Failure Code [DLM3KA] 1741
Failure Code [DLM3KB] 1743
Failure Code [DLM3MB] 1745
Failure Code [DN21FS] 1746
Failure Code [DR21KX] 1748
Failure Code [DR31KX] 1749
Failure Code [DV20KB] 1750
Failure Code [DW4BKA] 1752
Failure Code [DW4BKB] 1754
Failure Code [DW4BKY] 1756
Failure Code [DW7BKA] 1757
Failure Code [DW7BKB] 1759
Failure Code [DW7EKA] 1760
Failure Code [DW7EKB] 1763
Failure Code [DW7EKY] 1766
Failure Code [DWN5KA] 1768
Failure Code [DWN5KB] 1770
Failure Code [DWN5KY] 1771
Failure Code [DXA4KA] 1772
Failure Code [DXA4KB] 1774
Failure Code [DXA4KY] 1776
Failure Code [DXA5KA] 1777
Failure Code [DXA5KB] 1779
Failure Code [DXA5KY] 1781
Failure Code [DXA6KA] 1782
Failure Code [DXA6KB] 1784
Failure Code [DXA6KY] 1786
Failure Code [DXA7KA] 1787
Failure Code [DXA7KB] 1789
Failure Code [DXA7KY] 1791
Failure Code [DXHRKA] 1792
Failure Code [DXHRKB] 1794
Failure Code [DXHRKY] 1795
Failure Code [DXHSKA] 1796
Failure Code [DXHSKB] 1798
Failure Code [DXHSKY] 1799
Failure Code [DXHTKA] 1800
Failure Code [DXHTKB] 1802
Failure Code [DXHTKY] 1803
Failure Code [DXHUKA] 1804
Failure Code [DXHUKB] 1806
Failure Code [DXHUKY] 1807
Failure Code [DXJ4KA] 1808
Failure Code [DXJ4KB] 1810
Failure Code [DXJCKA] 1812
Failure Code [DXJCKB] 1814
Failure Code [DXJCKY] 1815
Failure Code [DXJDKA] 1816
Failure Code [DXJDKB] 1818
Failure Code [DXJDKY] 1819
Failure Code [DXK1KA] 1820
Failure Code [DXK1KB] 1822
Failure Code [DXK1KY] 1823
Failure Code [DXK2KA] 1824
Failure Code [DXK2KB] 1826
Failure Code [DXK2KY] 1827
Failure Code [F313KA] 1828
Failure Code [F313KB] 1829
Failure Code [F318KB] 1830
Failure Code [F318KY] 1831
Troubleshooting of Electrical System (E-Mode) 1832
Engine Does Not Start (Engine Does Not Crank) 1832
Manual Preheating System Does Not Operate 1839
Automatic Preheating System Does Not Operate 1842
While Preheating is in Operation, Preheating Monitor Does Not Come On 1844
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1846
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 1849
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1850
Charge Level Monitor Comes On in Red While Engine is in Operation 1851
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1852
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1853
HST Charge Pressure Monitor Comes On in Red While Engine Runs 1854
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1855
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 1856
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1857
DEF Level is Not Shown Correctly 1858
Fuel Gauge Does Not Show Normally 1861
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1864
Operation Mode Does Not Change 1865
When You Operate Customize Switch Does Not Show Customize Screen 1866
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1867
Service Meter is Not Shown While Starting Switch is in OFF Position 1868
Service Mode Cannot be Selected 1869
Work Equipment Does Not Operate 1870
Foot Heater Does Not Operate 1872
Horn Does Not Sound 1878
Horn Does Not Stop 1880
Backup Alarm Does Not Sound 1881
Backup Alarm Does Not Stop Operation 1882
Headlamp Does Not Come On 1883
Rear Lamp Does Not Come On 1887
No Wiper Operates 1890
Front Wiper Does Not Operate 1892
Rear Wiper Does Not Operate 1894
Left Door Wiper Does Not Operate 1896
Right Door Wiper Does Not Operate 1900
Front Washer Does Not Operate 1904
Rear Washer Does Not Operate 1906
Left Door Washer Does Not Operate 1908
Right Door Washer Does Not Operate 1910
KOMTRAX System Does Not Operate Correctly 1912
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1913
Information Shown in Troubleshooting Table (H-Mode) 1913
Failure Mode and Cause Table 1914
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 1920
R H or L H Track Cannot Travel FORWARD and Reverse (One of R H or L H Travel Systems Cannot Operate) 1922
R H or L H Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction) 1924
Travel Speed or Power is Low 1926
Speed Range Does Not Change 1928
Shock is Large When Machine Moves Off or Stops 1929
Travel Deviation is Large 1930
Machine Drift on a Slope is Large 1933
Engine Speed Drops Largely or Engine Stops 1935
Unusual Noise is Heard from Around HST Pump or Motor 1937
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 1939
All Work Equipment Do Not Operate 1941
All Work Equipment Speed or Power is Low 1943
Blade Lift Speed or Power is Low 1944
Blade Tilt Speed or Power is Low 1946
Blade Angle Speed or Power is Low 1947
Time Lag of Blade Lift is Large 1948
Hydraulic Drift of Blade Lift is Large 1949
Hydraulic Drift of Tilted Blade is Large 1950
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 1951
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1952
Unusual Noise is Heard from Around Fan 1954
Troubleshooting of Engine (S-Mode) 1955
Information Shown in Troubleshooting Table (S-Mode) 1955
Engine Does Not Crank When Starting Switch is Turned to Start Position 1956
Engine Cranks but No Exhaust Smoke Comes Out 1957
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1958
Engine Startability is Unsatisfactory 1959
Engine Does Not Pick Up Smoothly 1961
Engine Stops During Operation 1963
Engine Does Not Rotate Smoothly 1965
Engine Lacks Output (or Lacks Power) 1966
Exhaust Smoke is Black 1968
Engine Oil Consumption is Excessive 1970
Engine Oil Becomes Dirty Quickly 1971
Fuel Consumption is Excessive 1972
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1973
Engine Oil Pressure Drops 1974
Fuel Mixes Into Engine Oil 1975
Water Mixes Into Engine Oil (Milky) 1976
Coolant Temperature Increases Too High (Overheat) 1977
Unusual Noise is Heard 1978
Vibration is Excessive 1980
Air Cannot be Bled from Fuel Circuit 1981
Active Regeneration is Done Frequently 1982
Active Regeneration Continues Long 1983
White Smoke is Exhausted During Active Regeneration 1984
DEF Consumption is Excessive 1985
There is an Unusual Smell (Irritating Odor) 1987
Foreign Materials Enter DEF (DEF Increases) 1988
50 Disassembly and Assembly 1989
Table of Contents 1990
Precautions Before Work 1995
Abbreviation List 1996
Related Information on Disassembly and Assembly 2002
How to Read This Manual 2002
Coating Materials List 2003
Special Tool List 2008
Sketches of Special Tools 2025
Engine and Cooling System 2040
Remove and Install Supply Pump Assembly 2040
Remove Supply Pump Assembly 2040
Install Supply Pump Assembly 2044
Remove and Install Injector Assembly 2048
How to Remove Injector Assembly 2048
How to Install Injector Assembly 2051
Remove and Install Cylinder Head Assembly 2057
How to Remove Cylinder Head Assembly 2057
How to Install Cylinder Head Assembly 2071
Remove and Install EGR Valve Assembly 2092
Remove EGR Valve Assembly 2092
Install EGR Valve Assembly 2093
Remove and Install EGR Cooler Assembly 2095
How to Remove EGR Cooler Assembly 2095
How to Install EGR Cooler Assembly 2097
Remove and Install Starter Assembly 2100
Remove Starting Motor Assembly 2100
Install Starting Motor Assembly 2101
Remove and Install Alternator Belt 2103
Remove Alternator Belt 2103
Install Alternator Belt 2104
Remove and Install Automatic Tensioner 2106
Remove Automatic Tensioner 2106
Install Automatic Tensioner 2106
Remove and Install Radiator Assembly 2107
How to Remove Radiator Assembly 2107
How to Install Radiator Assembly 2110
Remove and Install Hydraulic Oil Cooler Assembly 2114
How to Remove Hydraulic Oil Cooler Assembly 2114
How to Install Hydraulic Oil Cooler Assembly 2116
Remove and Install Aftercooler Assembly 2120
Remove Aftercooler Assembly 2120
Install Aftercooler Assembly 2122
Remove and Install Cooling Fan Drive Assembly 2126
Remove Cooling Fan Drive Assembly 2126
Install Cooling Fan Drive Assembly 2128
Remove and Install Cooling Fan Motor Assembly 2130
Remove Cooling Fan Motor Assembly 2130
Install Cooling Fan Motor Assembly 2131
Remove and Install Engine and HST Pump Assembly 2133
Remove Engine and HST Pump Assembly 2133
Install Engine and HST Pump Assembly 2139
Remove and Install Engine Front Oil Seal 2147
How to Remove Engine Front Oil Seal 2147
How to Install Engine Front Oil Seal 2148
Remove and Install Engine Rear Oil Seal 2150
How to Remove Engine Rear Oil Seal 2150
How to Install Engine Rear Oil Seal 2151
Remove and Install Engine Hood Assembly 2154
How to Remove Engine Hood Assembly 2154
How to Install Engine Hood Assembly 2156
Remove and Install KDOC Assembly 2160
How to Remove KDOC Assembly 2160
How to Install KDOC Assembly 2164
Remove and Install KDOC and SCR Assembly 2171
Remove KDOC and SCR Assembly 2172
Install KDOC and SCR Assembly 2181
Remove and Install Bellows Pipe Assembly 2191
Remove Bellows Pipe Assembly 2191
Install Bellows Pipe Assembly 2193
Remove and Install Fuel Tank Assembly 2198
Remove Fuel Tank Assembly 2198
Install Fuel Tank Assembly 2201
Remove and Install DEF Tank Assembly 2205
How to Remove DEF Tank Assembly 2205
How to Install DEF Tank Assembly 2211
Remove and Install DEF Tank Sensor Flange Assembly 2217
How to Remove DEF Tank Sensor Flange Assembly 2217
How to Install DEF Tank Sensor Flange Assembly 2218
Remove and Install DEF Tank Sensor 2222
Remove DEF Tank Sensor 2222
Install DEF Tank Sensor 2223
Remove and Install DEF Tank Strainer 2230
Remove DEF Tank Strainer 2230
Install DEF Tank Strainer 2231
Remove and Install SCR Assembly 2232
How to Remove SCR Assembly 2232
How to Install SCR Assembly 2236
Remove and Install KCCV Assembly 2240
Remove KCCV Assembly 2240
Install KCCV Assembly 2241
Remove and Install Turbo Charger Assembly 2242
How to Remove Turbo Charger Assembly 2242
How to Install Turbo Charger Assembly 2246
Remove and Install Exhaust Throttle Valve 2252
Remove Exhaust Throttle Valve 2252
Install Exhaust Throttle Valve 2256
Remove and Install DEF Mixing Tube 2262
Remove DEF Mixing Tube 2263
Install DEF Mixing Tube 2267
Remove and Install DEF Injector 2275
Remove DEF Injector 2275
Install DEF Injector 2278
Remove and Install DEF Pump 2282
Remove DEF Pump 2282
Install DEF Pump 2285
Remove and Install DEF Hose 2288
Remove DEF Hose 2288
Install DEF Hose 2296
Remove and Install Air Cleaner Assembly 2307
Remove Air Cleaner Assembly 2307
Install Air Cleaner Assembly 2308
Remove and Install Air Conditioner Compressor Assembly 2310
Remove Air Conditioner Compressor Assembly 2310
How to Install Air Conditioner Compressor Assembly 2311
Power Train 2313
Remove and Install Damper Assembly 2313
How to Remove Damper Assembly 2313
How to Install Damper Assembly 2314
Remove and Install HST Pump Assembly 2315
Remove HST Pump Assembly 2315
Install HST Pump Assembly 2318
Remove and Install HST Motor and Final Drive Assembly 2321
Remove HST Motor and Final Drive Assembly 2321
Install HST Motor and Final Drive Assembly 2323
Disassemble and Assemble Final Drive Assembly 2325
Disassemble Final Drive Assembly 2325
Assemble Final Drive Assembly 2331
Undercarriage and Frame 2340
Remove and Install Idler and Recoil Spring Assembly 2340
How to Remove Idler and Recoil Spring Assembly 2340
How to Install Idler and Recoil Spring Assembly 2340
Disassemble and Assemble Idler Assembly 2342
Disassemble Idler Assembly 2342
Assemble Idler Assembly 2344
Disassemble and Assemble Recoil Spring Assembly 2348
Disassemble Recoil Spring Assembly 2349
Assemble Recoil Spring Assembly 2350
Disassemble and Assemble Track Roller Assembly 2352
Disassemble Track Roller Assembly 2352
Assemble Track Roller Assembly 2354
Disassemble and Assemble Carrier Roller Assembly 2358
Disassemble Carrier Roller Assembly 2358
Assemble Carrier Roller Assembly 2359
Separate and Connect Track Assembly 2362
Separate Track Assembly (Standard) 2362
Install Track Assembly 2363
Separate and Connect PLUS Type Track Assembly 2366
Separate PLUS Type Track Assembly Generally 2366
Install PLUS Type Track Assembly 2366
Disassemble and Assemble Track Assembly Generally 2368
How to Disassemble Full Track Shoes Assembly 2369
How to Assemble Full Track Shoes Assembly 2371
Disassemble and Assemble PLUS Type Track Assembly Generally 2384
Disassemble PLUS Type Track Assembly Generally 2385
How to Assemble PLUS Type Track Shoes Assembly Generally 2386
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2402
Disassemble One Track Link Assembly in Field (Track Assembly) 2404
Assemble One Track Link Assembly in Field (Track Assembly) 2405
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2413
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2414
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2416
Hydraulic System 2420
Remove and Install Hydraulic Tank Assembly 2420
Remove Hydraulic Tank Assembly 2420
How to Install Hydraulic Tank Assembly 2425
Remove and Install Control Valve Assembly 2430
How to Remove Control Valve Assembly 2430
How to Install Control Valve Assembly 2432
Work Equipment 2435
Remove and Install Blade Assembly (Power Angle Power Tilt Dozer) 2435
How to Remove Blade Assembly (Power Angle Power Tilt Dozer) 2435
How to Install Blade Assembly (Power Angle Power Tilt Dozer) 2437
Remove and Install Work Equipment Assembly (Power Angle Power Tilt Dozer) 2440
How to Remove Work Equipment Assembly (Power Angle Power Tilt Dozer) 2440
How to Install Work Equipment Assembly (Power Angle Power Tilt Dozer) 2441
Disassemble and Assemble Work Equipment Cylinder Assembly 2443
How to Disassemble Work Equipment Cylinder Assembly 2444
How to Assemble Work Equipment Cylinder Assembly 2445
Remove and Install U-Frame Assembly 2449
Remove U-Frame Assembly 2449
Install U-Frame Assembly 2450
CAB Related Parts 2453
Remove and Install Operator Cab Assembly 2453
How to Remove Operator Cab Assembly 2453
Install Operator CAB Assembly 2458
Remove and Install Wiper Arm 2464
How to Remove Wiper Arm 2464
How to Install Wiper Arm 2465
Remove and Install Operator Cab Glass (Adhered Glass) 2467
Remove Operator CAB Glass (Adhered Glass) 2469
Install Operator CAB Glass (Adhered Glass) 2469
Remove and Install Air Conditioner Unit Assembly 2475
Remove Air Conditioner Unit Assembly 2475
Install Air Conditioner Unit Assembly 2481
Remove and Install Operator Seat 2489
Remove Operator’s Seat 2489
Install Operator’s Seat 2490
How to Remove and Install Seat Belt 2491
How to Remove Seat Belt 2491
How to Install Seatbelt 2491
Remove and Install Foot Heater Assembly 2493
Remove Foot Heater Assembly 2493
Install Foot Heater Assembly 2495
Disassemble and Assemble Foot Heater Assembly 2497
Disassemble Foot Heater Assembly 2497
Assemble Foot Heater Assembly 2498
Electrical System 2499
Remove and Install Engine Controller Assembly 2499
Remove Engine Controller Assembly 2499
Install Engine Controller Assembly 2502
Remove and Install HST Controller Assembly 2505
Remove HST Controller Assembly 2505
How to Install HST Controller Assembly 2506
Remove and Install Machine Monitor Assembly 2507
Remove Machine Monitor Assembly 2507
Install Machine Monitor Assembly 2508
Remove and Install Mass Air Flow and Temperature Sensor 2510
How to Remove Mass Air Flow and Temperature Sensor 2510
How to Install Mass Air Flow and Temperature Sensor 2512
Remove and Install KCCV Crankcase Pressure Sensor 2513
How to Remove KCCV Crankcase Pressure Sensor 2513
How to Install KCCV Crankcase Pressure Sensor 2514
Remove and Install SCR Temperature Sensor 2516
Remove SCR Temperature Sensor 2516
Install SCR Temperature Sensor 2518
Remove and Install KOMTRAX Terminal Assembly 2521
Remove KOMTRAX Terminal Assembly 2521
Install KOMTRAX Terminal Assembly 2522
Remove and Install Gateway Function Controller Assembly 2523
How to Remove Gateway Function Controller Assembly 2523
How to Install Gateway Function Controller Assembly 2524
Remove and Install Communication Terminal 2525
How to Remove Communication Terminal 2525
How to Install Communication Terminal 2528
60 Maintenance Standard 2531
Table of Contents 2532
Abbreviation List 2534
Engine and Cooling System 2540
Maintenance Standard for Engine Mount 2540
Maintenance Standard for Damper 2541
Maintenance Standard for Cooling System 2542
Maintenance Standard for Cooling Fan Motor 2544
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 2546
Power Train 2547
Maintenance Standard for HST Pump 2547
Maintenance Standard for EPC Valve of HST Pump 2548
Maintenance Standard for Tow Receiving Valve of HST Pump 2549
Maintenance Standard for HST Charge Pump 2550
Maintenance Standard for HST Motor 2552
Maintenance Standard for Final Drive 2553
Maintenance Standard for Sprocket for Conventional Type Track Shoes: D37EX-24, D37PX-24 2555
Maintenance Standard for Sprocket for Conventional Type Track Shoes: D39EX-24, D39PX-24 2556
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes: D37EX-24, D37PX-24 2557
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes: D39EX-24, D39PX-24 2558
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D37EX-24, D37PX-24 2559
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D39EX-24, D39PX-24 2561
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D37EX-24, D37PX-24 2563
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D39EX-24, D39PX-24 2564
Undercarriage and Frame 2565
Maintenance Standard for Track Frame and Idler Cushion 2565
Maintenance Standard for Track Shoe for Conventional Type Track Shoes: D37EX-24, D37PX-24 2568
Maintenance Standard for Track Shoe for Conventional Type Track Shoes: D39EX-24, D39PX-24 2570
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D37EX-24, D37PX-24 2572
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D39EX-24, D39PX-24 2574
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2576
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2578
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2580
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2582
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2584
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2586
Maintenance Standard for Conventional Type Track Shoes 2588
Maintenance Standard for PLUS Type Track Shoes 2592
Maintenance Standard for Single Shoes 2596
Hydraulic System 2597
Maintenance Standard for Hydraulic Tank 2597
Maintenance Standard for Work Equipment and Cooling Fan Pump 2598
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump 2599
Maintenance Standard for Control Valve 2601
Maintenance Standard for Ripper PPC Valve 2608
Maintenance Standard for 5-Spool EPC and Solenoid Valve 2610
Maintenance Standard for EPC Valve 2611
Maintenance Standard for Angle Control EPC Valve 2612
Work Equipment 2613
Maintenance Standard for Front Work Equipment 2613
Maintenance Standard for Cutting Edge and End Bit 2616
Maintenance Standard for Blade Lift Cylinder 2617
Maintenance Standard for Blade Tilt Cylinder 2618
Maintenance Standard for Blade Angle Cylinder 2619
Maintenance Standard for Fixed Multi-Shank Ripper 2620
Maintenance Standard for Ripper Lift Cylinder 2622
CAB Related Parts 2623
Maintenance Standard for CAB Mount 2623
Electrical System 2624
Maintenance Standard for Steering Electric Lever 2624
80 Appendix 2625
Table of Contents 2626
Precautions Before Work 2627
Abbreviation List 2628
Air Conditioner System 2634
Precautions for Refrigerant 2634
Air Conditioner Component 2635
Specifications of Air Conditioner 2638
Structure and Function of Refrigeration Cycle 2639
Outline of Refrigeration Cycle 2640
Component Parts of Air Conditioner System 2642
Air Conditioner Unit 2642
Configuration Diagram of Air Conditioner Unit 2642
Function of Air Conditioner Unit 2643
Component Parts of Air Conditioner Unit 2644
Function of Evaporator as Air Conditioner Unit Component 2644
Function of Heater Core as Air Conditioner Unit Component 2644
Function of Thermostat as Air Conditioner Unit Component 2644
Structure of Expansion Valve as Air Conditioner Unit Component 2645
Function of Expansion Valve as Air Conditioner Unit Component 2645
Operate Expansion Valve as Air Conditioner Unit Component 2645
Function of Dual Pressure Switch 2646
Function of Pressure Switch 2646
Compressor 2647
Structure of Compressor 2647
Specifications of Compressor 2647
Function of Compressor 2647
Condenser 2648
Structure of Condenser 2648
Specifications of Condenser 2648
Function of Condenser 2649
Receiver Drier 2650
Structure of Receiver Dryer 2650
Specifications of Receiver Dryer 2650
Function of Receiver Dryer 2650
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2652
Circuit Diagram of Air Conditioner 2655
System Diagram of Air Conditioner 2656
Control Function of Air Conditioner 2657
Locations of Air Conditioner Parts and Layout of Connectors 2658
Examine Relay 2662
How to Examine Relay 2662
Air Conditioner Troubleshooting Chart 1 2664
Air Conditioner Troubleshooting Chart 2 2665
Information Shown in Troubleshooting Table 2668
Troubleshooting for Condenser Fan 2669
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2672
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2676
Troubleshooting for Temperature Control Function 2679
Troubleshooting by Gauge Pressure 2683
Connect Service Tool 2685
How to Connect Service Tool 2685
Precautions for Disconnection and Connection of Air Conditioner Piping 2686
Handle Compressor Oil 2688
90 Circuit Diagrams 2691
Table of Contents 2692
Abbreviation List 2693
Hydraulic Circuit Diagram 2699
Symbols Used in Hydraulic Circuit Diagram 2699
Hydraulic Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) 2703
Electrical Circuit Diagram 2705
Symbols Used in Electric Circuit Diagram 2705
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (1/11) 2709
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (2/11) 2711
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (3/11) 2713
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (4/11) 2715
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (5/11) 2717
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (6/11) 2719
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (7/11) 2721
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (8/11) 2723
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (9/11) 2725
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (10/11) 2727
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24,D39PX-24) (Machine with KOMTRAX Terminal) (11/11) 2729
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (1/13) 2731
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (2/13) 2733
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (3/13) 2735
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (4/13) 2737
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (5/13) 2739
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (6/13) 2741
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (7/13) 2743
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (8/13) 2745
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (9/13) 2747
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (10/13) 2749
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (11/13) 2751
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (12/13) 2753
Electrical Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) (Machine with Gateway Function Controller) (13/13) 2755
INDEX 2757

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24