Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – PDF DOWNLOAD
$33.95
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – PDF DOWNLOAD
Language : English
Pages : 2622
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – PDF DOWNLOAD
COVER................................................................................................................................................. 1 00 INDEX AND FOREWORD................................................................................................................................ 3 INDEX............................................................................................................................................ 4 ABBREVIATION LIST................................................................................................................................ 20 FOREWORD, SAFETY, BASIC INFORMATION.............................................................................................................. 26 HOW TO READ THE SHOP MANUAL.................................................................................................................. 26 SAFETY NOTICE FOR OPERATION.................................................................................................................. 28 PRECAUTIONS TO PREVENT FIRE.................................................................................................................. 36 ACTIONS IF FIRE OCCURS....................................................................................................................... 38 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................................................................................................. 39 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................................ 40 PRECAUTIONS FOR DEF.......................................................................................................................... 41 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING........................................................................................... 41 PRECAUTIONS FOR ADDING................................................................................................................... 41 PRECAUTIONS FOR STORING.................................................................................................................. 41 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE.................................................................................................. 41 THE OTHER PRECAUTIONS.................................................................................................................... 41 STORE AdBlue/DEF............................................................................................................................. 42 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................................................................................................. 43 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...................................................................................... 46 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................................ 53 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT............................................................................................... 55 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT............................................................................................. 56 PRACTICAL USE OF KOMTRAX..................................................................................................................... 57 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................................ 58 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER.................................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER.................................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER.................................................................... 60 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS................................................................................... 62 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR.................................................................................... 66 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................................ 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.......................................................................... 69 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.......................................................................... 70 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE..................................................................... 72 HOW TO READ ELECTRICAL WIRE CODE............................................................................................................. 73 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................................ 77 STANDARD TIGHTENING TORQUE TABLE............................................................................................................. 80 CONVERSION TABLE............................................................................................................................. 87 01 SPECIFICATIONS.................................................................................................................................... 93 CONTENTS......................................................................................................................................... 94 ABBREVIATION LIST................................................................................................................................ 95 SPECIFICATIONS................................................................................................................................... 101 SPECIFICATION DRAWING........................................................................................................................ 101 SPECIFICATION DRAWING: D37EX-24.......................................................................................................... 101 SPECIFICATION DRAWING: D37PX-24.......................................................................................................... 103 SPECIFICATION DRAWING: D39EX-24.......................................................................................................... 105 SPECIFICATION DRAWING: D39PX-24.......................................................................................................... 107 SPECIFICATIONS............................................................................................................................... 109 SPECIFICATIONS: D37EX-24................................................................................................................. 109 SPECIFICATIONS: D37PX-24................................................................................................................. 114 SPECIFICATIONS: D39EX-24................................................................................................................. 119 SPECIFICATIONS: D39PX-24................................................................................................................. 124 WEIGHT TABLE................................................................................................................................. 129 WEIGHT TABLE: D37EX-24................................................................................................................... 129 WEIGHT TABLE: D37PX-24................................................................................................................... 131 WEIGHT TABLE: D39EX-24................................................................................................................... 133 WEIGHT TABLE: D39PX-24................................................................................................................... 135 TABLE OF FUEL, COOLANT, AND LUBRICANTS....................................................................................................... 137 10 STRUCTURE AND FUNCTION............................................................................................................................ 139 CONTENTS......................................................................................................................................... 140 ABBREVIATION LIST................................................................................................................................ 143 UREA SCR SYSTEM.................................................................................................................................. 149 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................................ 149 UREA SCR SYSTEM DIAGRAM...................................................................................................................... 151 FUNCTION OF UREA SCR SYSTEM.................................................................................................................. 152 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................................ 152 INDUCEMENT STRATEGY...................................................................................................................... 155 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................................................... 169 AdBlue/DEF MIXING TUBE................................................................................................................... 169 SCR ASSEMBLY............................................................................................................................. 170 AdBlue/DEF TANK.......................................................................................................................... 172 AdBlue/DEF PUMP.......................................................................................................................... 174 AdBlue/DEF INJECTOR...................................................................................................................... 175 AdBlue/DEF HOSE.......................................................................................................................... 176 AdBlue/DEF TANK HEATING VALVE............................................................................................................ 177 BOOT-UP SYSTEM................................................................................................................................... 178 LAYOUT DRAWING OF BOOT-UP SYSTEM............................................................................................................. 178 SYSTEM OPERATING LAMP SYSTEM................................................................................................................. 179 SYSTEM OPERATING LAMP SYSTEM DIAGRAM..................................................................................................... 179 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM................................................................................................. 180 BATTERY DISCONNECT SWITCH.................................................................................................................... 181 FUNCTION OF BATTERY DISCONNECT SWITCH.................................................................................................... 181 ENGINE SYSTEM.................................................................................................................................... 182 LAYOUT DRAWING OF ENGINE SYSTEM.............................................................................................................. 182 ENGINE CONTROL SYSTEM........................................................................................................................ 184 LAYOUT OF ENGINE CONTROL SYSTEM.......................................................................................................... 184 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................................ 186 FUNCTION OF ENGINE CONTROL SYSTEM........................................................................................................ 188 AUTOMATIC IDLE STOP SYSTEM................................................................................................................... 190 AUTOMATIC IDLE STOP SYSTEM DIAGRAM....................................................................................................... 190 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM................................................................................................... 191 COMPONENT PARTS OF ENGINE SYSTEM............................................................................................................. 193 DAMPER................................................................................................................................... 193 VARIABLE FLOW TURBOCHARGER............................................................................................................... 194 EGR SYSTEM............................................................................................................................... 197 EGR VALVE................................................................................................................................ 200 EGR COOLER............................................................................................................................... 202 KCCV SYSTEM.............................................................................................................................. 204 KCCV VENTILATOR.......................................................................................................................... 207 EXHAUST THROTTLE VALVE................................................................................................................... 209 KDOC..................................................................................................................................... 210 COOLING SYSTEM................................................................................................................................... 213 LAYOUT DRAWING OF COOLING SYSTEM............................................................................................................. 213 SPECIFICATIONS OF COOLING SYSTEM......................................................................................................... 214 COOLING FAN CONTROL SYSTEM................................................................................................................... 215 COOLING FAN CONTROL SYSTEM DIAGRAM....................................................................................................... 215 FUNCTION OF COOLING FAN CONTROL SYSTEM................................................................................................... 216 COMPONENT PARTS OF COOLING SYSTEM............................................................................................................ 218 COOLING FAN MOTOR........................................................................................................................ 218 HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE.................................................................................. 223 HYDRAULIC OIL COOLER BYPASS VALVE........................................................................................................ 225 HST CHARGE SAFETY VALVE.................................................................................................................. 226 CONTROL SYSTEM................................................................................................................................... 228 LAYOUT DRAWING OF CONTROL SYSTEM............................................................................................................. 228 MACHINE MONITOR SYSTEM....................................................................................................................... 229 MACHINE MONITOR SYSTEM DIAGRAM........................................................................................................... 229 FUNCTION OF MACHINE MONITOR SYSTEM....................................................................................................... 230 KOMTRAX SYSTEM............................................................................................................................... 231 KOMTRAX SYSTEM DIAGRAM................................................................................................................... 231 FUNCTION OF KOMTRAX SYSTEM............................................................................................................... 232 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................................ 233 MACHINE MONITOR.......................................................................................................................... 233 KOMTRAX TERMINAL......................................................................................................................... 248 HST CONTROLLER........................................................................................................................... 250 ENGINE CONTROLLER........................................................................................................................ 254 FUEL CONTROL DIAL........................................................................................................................ 261 DECELERATOR AND BRAKE POTENTIOMETER...................................................................................................... 263 HYDRAULIC SYSTEM................................................................................................................................. 265 LAYOUT DRAWING OF HYDRAULIC SYSTEM........................................................................................................... 265 CLSS......................................................................................................................................... 266 STRUCTURE OF CLSS........................................................................................................................ 266 FUNCTION OF CLSS......................................................................................................................... 267 COMPONENT PARTS OF HYDRAULIC SYSTEM.......................................................................................................... 269 HYDRAULIC TANK........................................................................................................................... 269 WORK EQUIPMENT AND COOLING FAN PUMP...................................................................................................... 271 LS VALVE................................................................................................................................. 278 PC VALVE................................................................................................................................. 279 CONTROL VALVE............................................................................................................................ 282 POWER TRAIN SYSTEM............................................................................................................................... 303 LAYOUT DRAWING OF HST SYSTEM................................................................................................................. 303 OPERATION OF HST SYSTEM...................................................................................................................... 304 STEERING AND BRAKE CONTROL SYSTEM............................................................................................................ 306 LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM...................................................................................... 306 FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM............................................................................................ 307 HST CONTROL SYSTEM........................................................................................................................... 308 HST CONTROL SYSTEM DIAGRAM............................................................................................................... 308 GEAR SHIFT CONTROL FUNCTION.............................................................................................................. 309 ENGINE LOW SPEED MATCHING CONTROL FUNCTION............................................................................................... 313 HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION............................................................................................. 314 DECELERATION AND BRAKE CONTROL FUNCTION.................................................................................................. 316 GEAR SHIFT CONTROL FUNCTION BY LOAD...................................................................................................... 318 TURN CONTROL FUNCTION.................................................................................................................... 319 STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION.............................................................................................. 320 PARKING BRAKE CONTROL SYSTEM................................................................................................................. 321 PARKING BRAKE CONTROL SYSTEM DIAGRAM..................................................................................................... 321 FUNCTION OF PARKING BRAKE CONTROL SYSTEM................................................................................................. 322 OPERATION OF PARKING BRAKE CONTROL SYSTEM................................................................................................ 323 COMPONENT PARTS OF POWER TRAIN SYSTEM........................................................................................................ 324 HST PUMP................................................................................................................................. 324 HST CHARGE PUMP.......................................................................................................................... 341 HST MOTOR................................................................................................................................ 342 FINAL DRIVE.............................................................................................................................. 354 ELECTRIC STEERING CONTROL LEVER.......................................................................................................... 358 WORK EQUIPMENT SYSTEM............................................................................................................................ 360 WORK EQUIPMENT CONTROL....................................................................................................................... 360 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM.................................................................................................... 360 FUNCTION OF WORK EQUIPMENT CONTROL....................................................................................................... 362 LAYOUT DRAWING OF FRONT WORK EQUIPMENT....................................................................................................... 364 LAYOUT OF FIXED MULTI-SHANK RIPPER........................................................................................................... 365 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM..................................................................................................... 366 RIPPER PPC VALVE......................................................................................................................... 366 5-PORT VALVE OF EPC AND SOLENOID......................................................................................................... 370 PILOT CIRCUIT ACCUMULATOR................................................................................................................ 377 ANGLE CONTROL EPC VALVE.................................................................................................................. 378 PISTON VALVE............................................................................................................................. 381 ELECTRIC BLADE CONTROL LEVER............................................................................................................. 382 UNDERCARRIAGE AND FRAME.......................................................................................................................... 384 MAIN FRAME................................................................................................................................... 384 STRUCTURE OF MAIN FRAME.................................................................................................................. 384 TRACK FRAME AND IDLER CUSHION................................................................................................................ 385 STRUCTURE OF TRACK FRAME AND IDLER CUSHION............................................................................................... 385 FUNCTION OF TRACK FRAME AND IDLER CUSHION................................................................................................ 387 WORK EQUIPMENT................................................................................................................................... 388 STRUCTURE OF FRONT WORK EQUIPMENT............................................................................................................ 388 STRUCTURE OF FIXED MULTI-SHANK RIPPER........................................................................................................ 389 CAB AND ITS ATTACHMENTS.......................................................................................................................... 390 ROPS CAB..................................................................................................................................... 390 STRUCTURE OF ROPS CAB.................................................................................................................... 390 FUNCTION OF ROPS CAB..................................................................................................................... 391 CAB MOUNT.................................................................................................................................... 392 STRUCTURE OF CAB MOUNT................................................................................................................... 392 FUNCTION OF CAB MOUNT.................................................................................................................... 393 20 STANDARD VALUE TABLE.............................................................................................................................. 395 CONTENTS......................................................................................................................................... 396 ABBREVIATION LIST................................................................................................................................ 397 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................. 403 STANDARD VALUE TABLE FOR ENGINE: D37EX-24.................................................................................................... 403 STANDARD VALUE TABLE FOR ENGINE: D37PX-24.................................................................................................... 406 STANDARD VALUE TABLE FOR ENGINE: D39EX-24.................................................................................................... 409 STANDARD VALUE TABLE FOR ENGINE: D39PX-24.................................................................................................... 412 STANDARD VALUE TABLE FOR MACHINE................................................................................................................. 415 STANDARD VALUE TABLE FOR MACHINE: D37EX-24................................................................................................... 415 STANDARD VALUE TABLE FOR MACHINE: D37PX-24................................................................................................... 431 STANDARD VALUE TABLE FOR MACHINE: D39EX-24................................................................................................... 445 STANDARD VALUE TABLE FOR MACHINE: D39PX-24................................................................................................... 461 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...................................................................................... 475 30 TESTING AND ADJUSTING............................................................................................................................. 477 CONTENTS......................................................................................................................................... 478 ABBREVIATION LIST................................................................................................................................ 481 RELATED INFORMATION ON TESTING AND ADJUSTING..................................................................................................... 487 TOOLS FOR TESTING AND ADJUSTING.............................................................................................................. 487 SKETCH OF TOOLS FOR TESTING AND ADJUSTING.................................................................................................... 493 ENGINE AND COOLING SYSTEM........................................................................................................................ 494 TEST ENGINE SPEED............................................................................................................................ 494 METHOD FOR TESTING ENGINE SPEED.......................................................................................................... 494 TEST EXHAUST GAS COLOR....................................................................................................................... 496 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER.............................................................................. 496 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...................................................................................... 497 TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE............................................................................................. 498 METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE......................................................................... 498 TEST AND ADJUST VALVE CLEARANCE.............................................................................................................. 500 METHOD FOR TESTING VALVE CLEARANCE....................................................................................................... 500 METHOD FOR ADJUSTING VALVE CLEARANCE..................................................................................................... 501 TEST COMPRESSION PRESSURE.................................................................................................................... 502 METHOD FOR TESTING COMPRESSION PRESSURE.................................................................................................. 502 TEST BLOWBY PRESSURE......................................................................................................................... 505 METHOD FOR TESTING BLOWBY PRESSURE....................................................................................................... 505 TEST ENGINE OIL PRESSURE..................................................................................................................... 507 METHOD FOR TESTING ENGINE OIL PRESSURE................................................................................................... 507 TEST FUEL PRESSURE........................................................................................................................... 509 METHOD FOR TESTING FUEL PRESSURE......................................................................................................... 509 TEST FUEL RETURN RATE AND LEAKAGE............................................................................................................ 511 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE.......................................................................................... 512 BLEEDING AIR FROM FUEL SYSTEM................................................................................................................ 516 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM................................................................................................. 516 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................................ 518 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE.............................................................................................. 518 HANDLE CYLINDER CUT-OUT MODE OPERATION....................................................................................................... 520 HANDLE NO-INJECTION CRANKING OPERATION....................................................................................................... 521 TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.................................................................................... 522 METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.................................................................. 522 TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS..................................................................................... 523 METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS................................................................... 523 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS.................................................................................................. 524 METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS................................................................................ 524 TEST ALTERNATOR BELT......................................................................................................................... 525 METHOD FOR TESTING ALTERNATOR BELT....................................................................................................... 525 TEST AUTOMATIC TENSIONER..................................................................................................................... 526 METHOD FOR TESTING AUTOMATIC TENSIONER................................................................................................... 526 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER....................................................................................... 528 METHOD FOR WRITING INJECTOR COMPENSATION VALUE........................................................................................... 528 TEST SCR RELATED FUNCTIONS................................................................................................................... 534 TEST AdBlue/DEF PUMP RAISED PRESSURE..................................................................................................... 538 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR........................................................................................... 541 TEST AdBlue/DEF LINE HEATER RELAY 1...................................................................................................... 546 TEST AdBlue/DEF LINE HEATER RELAY 2...................................................................................................... 549 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................................ 552 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................................ 556 TEST DENITRATION EFFICIENCY OF SCR....................................................................................................... 560 CLEAN AdBlue/DEF TANK........................................................................................................................ 563 METHOD FOR CLEANING AdBlue/DEF TANK...................................................................................................... 563 CLEAN AdBlue/DEF TANK MOUNTING PORTION....................................................................................................... 568 METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION..................................................................................... 568 POWER TRAIN...................................................................................................................................... 569 TEST AND ADJUST HST OIL PRESSURE............................................................................................................. 569 METHOD FOR TESTING HST OIL PRESSURE...................................................................................................... 569 METHOD FOR ADJUSTING HST OIL PRESSURE.................................................................................................... 572 BLEED AIR FROM HST PUMP...................................................................................................................... 574 METHOD FOR BLEEDING AIR FROM HST PUMP.................................................................................................... 574 METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP..................................................................................... 574 TEST OUTLET PRESSURE OF SOLENOID VALVE....................................................................................................... 576 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE..................................................................................... 576 TEST TRAVEL DEVIATION........................................................................................................................ 581 METHOD FOR TESTING TRAVEL DEVIATION...................................................................................................... 581 TEST BRAKE PERFORMANCE SIMPLY................................................................................................................ 583 METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY.............................................................................................. 583 TEST AND ADJUST DECELERATION/BRAKE PEDAL..................................................................................................... 584 METHOD FOR TESTING DECELERATION/BRAKE PEDAL.............................................................................................. 584 METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL............................................................................................ 586 ADJUST PARKING BRAKE LEVER................................................................................................................... 588 METHOD FOR ADJUSTING PARKING BRAKE LEVER................................................................................................. 588 MOVE MACHINE WHEN IT CANNOT TRAVEL........................................................................................................... 590 METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM............................................................... 590 METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT......................................................................... 592 UNDERCARRIAGE AND FRAME.......................................................................................................................... 594 ADJUST IDLER CLEARANCE....................................................................................................................... 594 METHOD FOR ADJUSTING IDLER CLEARANCE..................................................................................................... 594 TESTING SPROCKET WEAR........................................................................................................................ 595 METHOD FOR TESTING SPROCKET WEAR......................................................................................................... 595 TEST AND ADJUST TRACK TENSION................................................................................................................ 596 METHOD FOR TESTING TRACK TENSION......................................................................................................... 596 METHOD FOR ADJUSTING TRACK TENSION....................................................................................................... 596 HYDRAULIC SYSTEM................................................................................................................................. 598 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................................................................. 598 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT........................................................................... 598 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES................................................................................................. 599 METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES.......................................................................................... 599 METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES........................................................................................ 600 TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT.............................................................................................. 602 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT....................................................................................... 602 METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT..................................................................................... 603 TEST OUTLET PRESSURE OF EPC SOLENOID VALVE................................................................................................... 604 METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE................................................................................. 604 BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP........................................................................................... 606 METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP......................................................................... 606 TEST COOLING FAN SPEED....................................................................................................................... 607 METHOD FOR TESTING COOLING FAN SPEED..................................................................................................... 607 TEST COOLING FAN CIRCUIT OIL PRESSURE........................................................................................................ 608 METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...................................................................................... 608 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT..................................................................................... 610 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER.............................................................. 610 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER.............................................................. 610 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER............................................................. 611 TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER......................................................................................... 612 METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER....................................................................... 612 BLEED AIR FROM WORK EQUIPMENT CYLINDERS...................................................................................................... 614 METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS.................................................................................... 614 WORK EQUIPMENT................................................................................................................................... 615 ADJUST WORK EQUIPMENT LOCK LEVER............................................................................................................. 615 METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER........................................................................................... 615 ELECTRICAL SYSTEM................................................................................................................................ 617 SET AND OPERATE MACHINE MONITOR.............................................................................................................. 617 OPERATOR MODE............................................................................................................................ 621 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN.............................................................................. 621 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN................................................................................. 621 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................................ 622 CHECKING FUNCTION OF SERVICE METER....................................................................................................... 622 METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD.................................................................... 622 SERVICE MODE............................................................................................................................. 625 METHOD FOR OPERATING SERVICE MODE........................................................................................................ 625 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION................................................................................... 627 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION................................................................................... 633 ABNORMALITY RECORD MENU.................................................................................................................. 643 METHOD FOR CONFIRMING MAINTENANCE RECORD................................................................................................. 647 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................................ 648 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING.......................................................................................... 652 DEFAULT MENU............................................................................................................................. 653 DIAGNOSTIC TESTS MENU.................................................................................................................... 660 ADJUSTMENT MENU.......................................................................................................................... 668 METHOD FOR PERFORMING NO-INJECTION CRANKING.............................................................................................. 723 KOMTRAX SETTINGS MENU.................................................................................................................... 726 METHOD FOR DISPLAYING SERVICE MESSAGE.................................................................................................... 728 METHOD FOR STARTING UP KOMTRAX TERMINAL...................................................................................................... 730 ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED............................................................................................. 735 ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED.................................................................................. 735 ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED............................................................................... 741 ADJUST REARVIEW CAMERA ANGLE................................................................................................................. 743 METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE............................................................................................... 743 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................................................................. 744 HANDLE BATTERY DISCONNECT SWITCH............................................................................................................. 745 TEST DIODES.................................................................................................................................. 746 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................................ 746 METHOD FOR TESTING DIODE USING ANALOG TESTER............................................................................................. 746 Pm CLINIC........................................................................................................................................ 747 Pm CLINIC SERVICE............................................................................................................................ 747 Pm CLINIC CHECK SHEET: D37EX-24.......................................................................................................... 749 Pm CLINIC CHECK SHEET: D37PX-24.......................................................................................................... 757 Pm CLINIC CHECK SHEET: D39EX-24.......................................................................................................... 765 Pm CLINIC CHECK SHEET: D39PX-24.......................................................................................................... 772 Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37EX-24........................................................................................ 779 Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37PX-24........................................................................................ 786 Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39EX-24........................................................................................ 793 Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39PX-24........................................................................................ 800 40 TROUBLESHOOTING................................................................................................................................... 807 CONTENTS......................................................................................................................................... 808 ABBREVIATION LIST................................................................................................................................ 818 RELATED INFORMATION ON TROUBLESHOOTING........................................................................................................... 824 GENERAL TROUBLESHOOTING POINTS............................................................................................................... 824 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................................................... 825 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................ 837 CHECKS BEFORE TROUBLESHOOTING................................................................................................................ 839 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.................................................................................................. 841 WALK-AROUND CHECK........................................................................................................................ 841 TESTING IN ACCORDANCE WITH TESTING PROCEDURE................................................................................................. 843 CHECK FUEL LEVEL AND TYPE................................................................................................................ 843 CHECK IMPURE INGREDIENT IN FUEL.......................................................................................................... 843 CHECK AdBule/DEF LEVEL AND TYPE.......................................................................................................... 844 CHECK FUEL PREFILTER..................................................................................................................... 844 CHECK MAIN FILTER........................................................................................................................ 846 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE.................................................................................. 848 CHECK COOLANT LEVEL (RESERVOIR TANK)..................................................................................................... 849 CHECK CLOGGING OF AIR CLEANER............................................................................................................ 849 CLEAN OUTER ELEMENT...................................................................................................................... 850 REPLACE ELEMENT.......................................................................................................................... 851 CHECK HYDRAULIC OIL LEVEL................................................................................................................ 852 CHECK HYDRAULIC OIL STRAINER............................................................................................................. 853 CHECK OIL LEVEL IN FINAL DRIVE CASE...................................................................................................... 857 BLEED AIR FROM FUEL SYSTEM............................................................................................................... 857 BLEED AIR FROM HYDRAULIC SYSTEM.......................................................................................................... 857 METHOD FOR CHECKING ELECTRIC EQUIPMENT................................................................................................... 857 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM......................................................................................... 864 PROCEDURE FOR TROUBLESHOOTING................................................................................................................ 871 SYMPTOM AND TROUBLESHOOTING NUMBERS.......................................................................................................... 874 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE............................................................................................... 877 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM.......................................................... 879 CONNECTORS LIST AND LAYOUT................................................................................................................... 882 CONNECTOR CONTACT IDENTIFICATION............................................................................................................. 896 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...................................................................................................... 936 FUSE LOCATION TABLE.......................................................................................................................... 942 PRECAUTIONS FOR REPLACING KDOC............................................................................................................... 946 FAILURE CODES TABLE.......................................................................................................................... 947 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................................ 965 FAILURE CODE [6091NX]........................................................................................................................ 965 FAILURE CODE [989L00]........................................................................................................................ 967 FAILURE CODE [989M00]........................................................................................................................ 968 FAILURE CODE [989N00]........................................................................................................................ 969 FAILURE CODE [A1U0N3]........................................................................................................................ 970 FAILURE CODE [A1U0N4]........................................................................................................................ 972 FAILURE CODE [A900FR]........................................................................................................................ 974 FAILURE CODE [A900N6]........................................................................................................................ 975 FAILURE CODE [A900NY]........................................................................................................................ 976 FAILURE CODE [AA10NX]........................................................................................................................ 977 FAILURE CODE [AB00KE]........................................................................................................................ 979 FAILURE CODE [AQ10MB]........................................................................................................................ 981 FAILURE CODE [AQ10N3]........................................................................................................................ 983 FAILURE CODE [AS00R2]........................................................................................................................ 984 FAILURE CODE [AS00R3]........................................................................................................................ 985 FAILURE CODE [AS00R4]........................................................................................................................ 986 FAILURE CODE [AS00R5]........................................................................................................................ 987 FAILURE CODE [AS00R6]........................................................................................................................ 988 FAILURE CODE [AS00ZK]........................................................................................................................ 989 FAILURE CODE [AS10KM]........................................................................................................................ 990 FAILURE CODE [AS10NR]........................................................................................................................ 991 FAILURE CODE [AS10NT]........................................................................................................................ 992 FAILURE CODE [AU10QA]........................................................................................................................ 993 FAILURE CODE [B@BAZG]........................................................................................................................ 994 FAILURE CODE [B@BCNS]........................................................................................................................ 995 FAILURE CODE [B@CRNS]........................................................................................................................ 996 FAILURE CODE [B@CRZG]........................................................................................................................ 997 FAILURE CODE [CA115]......................................................................................................................... 998 FAILURE CODE [CA122]......................................................................................................................... 999 FAILURE CODE [CA123].........................................................................................................................1001 FAILURE CODE [CA131].........................................................................................................................1003 FAILURE CODE [CA132].........................................................................................................................1005 FAILURE CODE [CA144].........................................................................................................................1007 FAILURE CODE [CA145].........................................................................................................................1009 FAILURE CODE [CA153].........................................................................................................................1011 FAILURE CODE [CA154].........................................................................................................................1014 FAILURE CODE [CA187].........................................................................................................................1017 FAILURE CODE [CA221].........................................................................................................................1019 FAILURE CODE [CA222].........................................................................................................................1021 FAILURE CODE [CA227].........................................................................................................................1023 FAILURE CODE [CA234].........................................................................................................................1024 FAILURE CODE [CA238].........................................................................................................................1025 FAILURE CODE [CA239].........................................................................................................................1027 FAILURE CODE [CA249].........................................................................................................................1029 FAILURE CODE [CA256].........................................................................................................................1031 FAILURE CODE [CA271].........................................................................................................................1033 FAILURE CODE [CA272].........................................................................................................................1035 FAILURE CODE [CA322].........................................................................................................................1037 FAILURE CODE [CA324].........................................................................................................................1039 FAILURE CODE [CA331].........................................................................................................................1041 FAILURE CODE [CA332].........................................................................................................................1043 FAILURE CODE [CA343].........................................................................................................................1045 FAILURE CODE [CA351].........................................................................................................................1046 FAILURE CODE [CA352].........................................................................................................................1047 FAILURE CODE [CA356].........................................................................................................................1050 FAILURE CODE [CA357].........................................................................................................................1052 FAILURE CODE [CA386].........................................................................................................................1054 FAILURE CODE [CA435].........................................................................................................................1055 FAILURE CODE [CA441].........................................................................................................................1057 FAILURE CODE [CA442].........................................................................................................................1059 FAILURE CODE [CA449].........................................................................................................................1060 FAILURE CODE [CA451].........................................................................................................................1061 FAILURE CODE [CA452].........................................................................................................................1063 FAILURE CODE [CA515].........................................................................................................................1065 FAILURE CODE [CA516].........................................................................................................................1067 FAILURE CODE [CA553].........................................................................................................................1069 FAILURE CODE [CA555].........................................................................................................................1070 FAILURE CODE [CA556].........................................................................................................................1071 FAILURE CODE [CA559].........................................................................................................................1072 FAILURE CODE [CA689].........................................................................................................................1076 FAILURE CODE [CA691].........................................................................................................................1078 FAILURE CODE [CA692].........................................................................................................................1080 FAILURE CODE [CA697].........................................................................................................................1082 FAILURE CODE [CA698].........................................................................................................................1083 FAILURE CODE [CA731].........................................................................................................................1084 FAILURE CODE [CA778].........................................................................................................................1086 FAILURE CODE [CA1117]........................................................................................................................1091 FAILURE CODE [CA1664]........................................................................................................................1092 FAILURE CODE [CA1669]........................................................................................................................1094 FAILURE CODE [CA1673]........................................................................................................................1095 FAILURE CODE [CA1677]........................................................................................................................1096 FAILURE CODE [CA1678]........................................................................................................................1097 FAILURE CODE [CA1682]........................................................................................................................1098 FAILURE CODE [CA1683]........................................................................................................................1103 FAILURE CODE [CA1684]........................................................................................................................1105 FAILURE CODE [CA1686]........................................................................................................................1107 FAILURE CODE [CA1691]........................................................................................................................1108 FAILURE CODE [CA1694]........................................................................................................................1110 FAILURE CODE [CA1695]........................................................................................................................1112 FAILURE CODE [CA1696]........................................................................................................................1113 FAILURE CODE [CA1712]........................................................................................................................1115 FAILURE CODE [CA1713]........................................................................................................................1118 FAILURE CODE [CA1714]........................................................................................................................1120 FAILURE CODE [CA1715]........................................................................................................................1121 FAILURE CODE [CA1776]........................................................................................................................1122 FAILURE CODE [CA1777]........................................................................................................................1125 FAILURE CODE [CA1843]........................................................................................................................1128 FAILURE CODE [CA1844]........................................................................................................................1130 FAILURE CODE [CA1885]........................................................................................................................1133 FAILURE CODE [CA1887]........................................................................................................................1135 FAILURE CODE [CA1896]........................................................................................................................1137 FAILURE CODE [CA1938]........................................................................................................................1138 FAILURE CODE [CA1942]........................................................................................................................1140 FAILURE CODE [CA1961]........................................................................................................................1141 FAILURE CODE [CA2185]........................................................................................................................1142 FAILURE CODE [CA2186]........................................................................................................................1144 FAILURE CODE [CA2249]........................................................................................................................1146 FAILURE CODE [CA2272]........................................................................................................................1147 FAILURE CODE [CA2311]........................................................................................................................1150 FAILURE CODE [CA2349]........................................................................................................................1151 FAILURE CODE [CA2353]........................................................................................................................1153 FAILURE CODE [CA2357]........................................................................................................................1155 FAILURE CODE [CA2555]........................................................................................................................1156 FAILURE CODE [CA2556]........................................................................................................................1158 FAILURE CODE [CA2636]........................................................................................................................1160 FAILURE CODE [CA2637]........................................................................................................................1163 FAILURE CODE [CA2765]........................................................................................................................1165 FAILURE CODE [CA2771]........................................................................................................................1166 FAILURE CODE [CA2976]........................................................................................................................1172 FAILURE CODE [CA3142]........................................................................................................................1174 FAILURE CODE [CA3143]........................................................................................................................1175 FAILURE CODE [CA3144]........................................................................................................................1176 FAILURE CODE [CA3146]........................................................................................................................1178 FAILURE CODE [CA3147]........................................................................................................................1179 FAILURE CODE [CA3148]........................................................................................................................1180 FAILURE CODE [CA3151]........................................................................................................................1182 FAILURE CODE [CA3165]........................................................................................................................1188 FAILURE CODE [CA3229]........................................................................................................................1190 FAILURE CODE [CA3231]........................................................................................................................1192 FAILURE CODE [CA3232]........................................................................................................................1194 FAILURE CODE [CA3235]........................................................................................................................1198 FAILURE CODE [CA3239]........................................................................................................................1200 FAILURE CODE [CA3241]........................................................................................................................1203 FAILURE CODE [CA3242]........................................................................................................................1206 FAILURE CODE [CA3251]........................................................................................................................1209 FAILURE CODE [CA3313]........................................................................................................................1211 FAILURE CODE [CA3314]........................................................................................................................1212 FAILURE CODE [CA3315]........................................................................................................................1213 FAILURE CODE [CA3419]........................................................................................................................1215 FAILURE CODE [CA3421]........................................................................................................................1217 FAILURE CODE [CA3497]........................................................................................................................1219 FAILURE CODE [CA3498]........................................................................................................................1220 FAILURE CODE [CA3543]........................................................................................................................1221 FAILURE CODE [CA3545]........................................................................................................................1227 FAILURE CODE [CA3547]........................................................................................................................1229 FAILURE CODE [CA3558]........................................................................................................................1230 FAILURE CODE [CA3559]........................................................................................................................1232 FAILURE CODE [CA3562]........................................................................................................................1234 FAILURE CODE [CA3563]........................................................................................................................1236 FAILURE CODE [CA3567]........................................................................................................................1239 FAILURE CODE [CA3568]........................................................................................................................1242 FAILURE CODE [CA3571]........................................................................................................................1247 FAILURE CODE [CA3572]........................................................................................................................1249 FAILURE CODE [CA3574]........................................................................................................................1251 FAILURE CODE [CA3575]........................................................................................................................1253 FAILURE CODE [CA3577]........................................................................................................................1255 FAILURE CODE [CA3578]........................................................................................................................1257 FAILURE CODE [CA3582]........................................................................................................................1259 FAILURE CODE [CA3583]........................................................................................................................1266 FAILURE CODE [CA3596]........................................................................................................................1268 FAILURE CODE [CA3649]........................................................................................................................1271 FAILURE CODE [CA3681]........................................................................................................................1273 FAILURE CODE [CA3682]........................................................................................................................1278 FAILURE CODE [CA3713]........................................................................................................................1283 FAILURE CODE [CA3717]........................................................................................................................1286 FAILURE CODE [CA3718]........................................................................................................................1287 FAILURE CODE [CA3724]........................................................................................................................1288 FAILURE CODE [CA3725]........................................................................................................................1289 FAILURE CODE [CA3748]........................................................................................................................1292 FAILURE CODE [CA3755]........................................................................................................................1295 FAILURE CODE [CA3866]........................................................................................................................1297 FAILURE CODE [CA3867]........................................................................................................................1301 FAILURE CODE [CA3868]........................................................................................................................1304 FAILURE CODE [CA3899]........................................................................................................................1308 FAILURE CODE [CA3911]........................................................................................................................1310 FAILURE CODE [CA3912]........................................................................................................................1314 FAILURE CODE [CA3918]........................................................................................................................1316 FAILURE CODE [CA3921]........................................................................................................................1318 FAILURE CODE [CA3928]........................................................................................................................1319 FAILURE CODE [CA3932]........................................................................................................................1320 FAILURE CODE [CA3933]........................................................................................................................1322 FAILURE CODE [CA3934]........................................................................................................................1324 FAILURE CODE [CA3935]........................................................................................................................1327 FAILURE CODE [CA3936]........................................................................................................................1329 FAILURE CODE [CA4152]........................................................................................................................1331 FAILURE CODE [CA4155]........................................................................................................................1335 FAILURE CODE [CA4156]........................................................................................................................1338 FAILURE CODE [CA4157]........................................................................................................................1341 FAILURE CODE [CA4159]........................................................................................................................1343 FAILURE CODE [CA4164]........................................................................................................................1344 FAILURE CODE [CA4165]........................................................................................................................1346 FAILURE CODE [CA4166]........................................................................................................................1348 FAILURE CODE [CA4168]........................................................................................................................1349 FAILURE CODE [CA4169]........................................................................................................................1352 FAILURE CODE [CA4171]........................................................................................................................1354 FAILURE CODE [CA4249]........................................................................................................................1358 FAILURE CODE [CA4251]........................................................................................................................1360 FAILURE CODE [CA4261]........................................................................................................................1362 FAILURE CODE [CA4277]........................................................................................................................1365 FAILURE CODE [CA4281]........................................................................................................................1369 FAILURE CODE [CA4459]........................................................................................................................1373 FAILURE CODE [CA4461]........................................................................................................................1376 FAILURE CODE [CA4533]........................................................................................................................1379 FAILURE CODE [CA4534]........................................................................................................................1380 FAILURE CODE [CA4731]........................................................................................................................1381 FAILURE CODE [CA4732]........................................................................................................................1382 FAILURE CODE [CA4739]........................................................................................................................1383 FAILURE CODE [CA4768]........................................................................................................................1384 FAILURE CODE [CA4769]........................................................................................................................1386 FAILURE CODE [CA4842]........................................................................................................................1389 FAILURE CODE [CA4952]........................................................................................................................1393 FAILURE CODE [CA5115]........................................................................................................................1395 FAILURE CODE [CA5179]........................................................................................................................1398 FAILURE CODE [CA5181]........................................................................................................................1400 FAILURE CODE [CA5271]........................................................................................................................1402 FAILURE CODE [CA5272]........................................................................................................................1404 FAILURE CODE [CA5273]........................................................................................................................1406 FAILURE CODE [CA5274]........................................................................................................................1408 FAILURE CODE [CA5275]........................................................................................................................1409 FAILURE CODE [CA5276]........................................................................................................................1411 FAILURE CODE [CA5277]........................................................................................................................1413 FAILURE CODE [CA5387]........................................................................................................................1414 FAILURE CODE [CA5388]........................................................................................................................1416 FAILURE CODE [CA5389]........................................................................................................................1418 FAILURE CODE [CA5391]........................................................................................................................1420 FAILURE CODE [CA5392]........................................................................................................................1424 FAILURE CODE [CA5393]........................................................................................................................1425 FAILURE CODE [CA5394]........................................................................................................................1428 FAILURE CODE [CA5395]........................................................................................................................1431 FAILURE CODE [CA5396]........................................................................................................................1434 FAILURE CODE [CA5631]........................................................................................................................1435 FAILURE CODE [CA5938]........................................................................................................................1437 FAILURE CODE [D130KA]........................................................................................................................1439 FAILURE CODE [D130KB]........................................................................................................................1441 FAILURE CODE [D130KY]........................................................................................................................1443 FAILURE CODE [D19JKZ]........................................................................................................................1445 FAILURE CODE [D811MC]........................................................................................................................1448 FAILURE CODE [D862KA]........................................................................................................................1449 FAILURE CODE [D8ALKA]........................................................................................................................1450 FAILURE CODE [D8ALKB]........................................................................................................................1452 FAILURE CODE [D8AQKR]........................................................................................................................1454 FAILURE CODE [DAF0MB]........................................................................................................................1457 FAILURE CODE [DAF0MC]........................................................................................................................1458 FAILURE CODE [DAF8KB]........................................................................................................................1459 FAILURE CODE [DAF9KQ]........................................................................................................................1461 FAILURE CODE [DAFGMC]........................................................................................................................1462 FAILURE CODE [DAFLKA]........................................................................................................................1463 FAILURE CODE [DAFLKB]........................................................................................................................1465 FAILURE CODE [DAFQKR]........................................................................................................................1467 FAILURE CODE [DAJ000]........................................................................................................................1471 FAILURE CODE [DAJ0KQ]........................................................................................................................1472 FAILURE CODE [DAJ0KT]........................................................................................................................1473 FAILURE CODE [DAJ0MC]........................................................................................................................1474 FAILURE CODE [DAJ1KK]........................................................................................................................1475 FAILURE CODE [DAJ2KK]........................................................................................................................1477 FAILURE CODE [DAJ5KK]........................................................................................................................1479 FAILURE CODE [DAJ6KK]........................................................................................................................1482 FAILURE CODE [DAJLKA]........................................................................................................................1484 FAILURE CODE [DAJLKB]........................................................................................................................1486 FAILURE CODE [DAJPMA]........................................................................................................................1488 FAILURE CODE [DAJQKR]........................................................................................................................1489 FAILURE CODE [DAJRKR]........................................................................................................................1493 FAILURE CODE [DB2QKR]........................................................................................................................1497 FAILURE CODE [DB2RKR]........................................................................................................................1501 FAILURE CODE [DD12KA]........................................................................................................................1505 FAILURE CODE [DD12KB]........................................................................................................................1507 FAILURE CODE [DD13KA]........................................................................................................................1509 FAILURE CODE [DD13KB]........................................................................................................................1511 FAILURE CODE [DD14KA]........................................................................................................................1513 FAILURE CODE [DD14KB]........................................................................................................................1515 FAILURE CODE [DDKAKA]........................................................................................................................1517 FAILURE CODE [DDKAKB]........................................................................................................................1519 FAILURE CODE [DDKFL4]........................................................................................................................1521 FAILURE CODE [DDKGL4]........................................................................................................................1523 FAILURE CODE [DDKHKA]........................................................................................................................1525 FAILURE CODE [DDKHKB]........................................................................................................................1527 FAILURE CODE [DDNLKA]........................................................................................................................1529 FAILURE CODE [DDNLKB]........................................................................................................................1531 FAILURE CODE [DDP6KA]........................................................................................................................1533 FAILURE CODE [DDP6KB]........................................................................................................................1535 FAILURE CODE [DDP6MA]........................................................................................................................1537 FAILURE CODE [DDU1FS]........................................................................................................................1539 FAILURE CODE [DDU1KA]........................................................................................................................1541 FAILURE CODE [DDU1KY]........................................................................................................................1543 FAILURE CODE [DFA4KX]........................................................................................................................1545 FAILURE CODE [DFA4KZ]........................................................................................................................1546 FAILURE CODE [DFA4L8]........................................................................................................................1547 FAILURE CODE [DFA5KA]........................................................................................................................1548 FAILURE CODE [DFA5KB]........................................................................................................................1550 FAILURE CODE [DFA6KA]........................................................................................................................1552 FAILURE CODE [DFA6KB]........................................................................................................................1554 FAILURE CODE [DFA7KX]........................................................................................................................1556 FAILURE CODE [DFA7KZ]........................................................................................................................1557 FAILURE CODE [DFA7L8]........................................................................................................................1558 FAILURE CODE [DFA8KA]........................................................................................................................1559 FAILURE CODE [DFA8KB]........................................................................................................................1561 FAILURE CODE [DFA9KA]........................................................................................................................1563 FAILURE CODE [DFA9KB]........................................................................................................................1565 FAILURE CODE [DGS1KA]........................................................................................................................1567 FAILURE CODE [DGS1KX]........................................................................................................................1569 FAILURE CODE [DH21KA]........................................................................................................................1571 FAILURE CODE [DH21KB]........................................................................................................................1573 FAILURE CODE [DHA4KA]........................................................................................................................1574 FAILURE CODE [DHH7KA]........................................................................................................................1576 FAILURE CODE [DHH7KB]........................................................................................................................1578 FAILURE CODE [DHH8KA]........................................................................................................................1580 FAILURE CODE [DHH8KB]........................................................................................................................1582 FAILURE CODE [DHH9KA]........................................................................................................................1584 FAILURE CODE [DHH9KB]........................................................................................................................1586 FAILURE CODE [DHHAKA]........................................................................................................................1588 FAILURE CODE [DHHAKB]........................................................................................................................1590 FAILURE CODE [DK30KA]........................................................................................................................1592 FAILURE CODE [DK30KB]........................................................................................................................1594 FAILURE CODE [DK30KX]........................................................................................................................1596 FAILURE CODE [DK30KZ]........................................................................................................................1597 FAILURE CODE [DK30L8]........................................................................................................................1598 FAILURE CODE [DK31KA]........................................................................................................................1601 FAILURE CODE [DK31KB]........................................................................................................................1603 FAILURE CODE [DK40KA]........................................................................................................................1605 FAILURE CODE [DK40KB]........................................................................................................................1607 FAILURE CODE [DK55KX]........................................................................................................................1609 FAILURE CODE [DK55KZ]........................................................................................................................1610 FAILURE CODE [DK55L8]........................................................................................................................1611 FAILURE CODE [DK56KA]........................................................................................................................1613 FAILURE CODE [DK56KB]........................................................................................................................1615 FAILURE CODE [DK57KA]........................................................................................................................1617 FAILURE CODE [DK57KB]........................................................................................................................1619 FAILURE CODE [DLM0KX]........................................................................................................................1621 FAILURE CODE [DLM0MA]........................................................................................................................1622 FAILURE CODE [DLM1KA]........................................................................................................................1623 FAILURE CODE [DLM1KB]........................................................................................................................1625 FAILURE CODE [DLM1MA]........................................................................................................................1627 FAILURE CODE [DLM2KA]........................................................................................................................1628 FAILURE CODE [DLM2KB]........................................................................................................................1630 FAILURE CODE [DLM2MA]........................................................................................................................1632 FAILURE CODE [DLM3KA]........................................................................................................................1633 FAILURE CODE [DLM3KB]........................................................................................................................1635 FAILURE CODE [DLM3MB]........................................................................................................................1637 FAILURE CODE [DN21FS]........................................................................................................................1638 FAILURE CODE [DR21KX]........................................................................................................................1640 FAILURE CODE [DR31KX]........................................................................................................................1641 FAILURE CODE [DV20KB]........................................................................................................................1642 FAILURE CODE [DW4BKA]........................................................................................................................1644 FAILURE CODE [DW4BKB]........................................................................................................................1646 FAILURE CODE [DW4BKY]........................................................................................................................1648 FAILURE CODE [DW7BKA]........................................................................................................................1649 FAILURE CODE [DW7BKB]........................................................................................................................1651 FAILURE CODE [DW7EKA]........................................................................................................................1652 FAILURE CODE [DW7EKB]........................................................................................................................1655 FAILURE CODE [DW7EKY]........................................................................................................................1658 FAILURE CODE [DWN5KA]........................................................................................................................1660 FAILURE CODE [DWN5KB]........................................................................................................................1662 FAILURE CODE [DWN5KY]........................................................................................................................1663 FAILURE CODE [DXA4KA]........................................................................................................................1664 FAILURE CODE [DXA4KB]........................................................................................................................1666 FAILURE CODE [DXA4KY]........................................................................................................................1668 FAILURE CODE [DXA5KA]........................................................................................................................1669 FAILURE CODE [DXA5KB]........................................................................................................................1671 FAILURE CODE [DXA5KY]........................................................................................................................1673 FAILURE CODE [DXA6KA]........................................................................................................................1674 FAILURE CODE [DXA6KB]........................................................................................................................1676 FAILURE CODE [DXA6KY]........................................................................................................................1678 FAILURE CODE [DXA7KA]........................................................................................................................1679 FAILURE CODE [DXA7KB]........................................................................................................................1681 FAILURE CODE [DXA7KY]........................................................................................................................1683 FAILURE CODE [DXHRKA]........................................................................................................................1684 FAILURE CODE [DXHRKB]........................................................................................................................1686 FAILURE CODE [DXHRKY]........................................................................................................................1687 FAILURE CODE [DXHSKA]........................................................................................................................1688 FAILURE CODE [DXHSKB]........................................................................................................................1690 FAILURE CODE [DXHSKY]........................................................................................................................1691 FAILURE CODE [DXHTKA]........................................................................................................................1692 FAILURE CODE [DXHTKB]........................................................................................................................1694 FAILURE CODE [DXHTKY]........................................................................................................................1695 FAILURE CODE [DXHUKA]........................................................................................................................1696 FAILURE CODE [DXHUKB]........................................................................................................................1698 FAILURE CODE [DXHUKY]........................................................................................................................1699 FAILURE CODE [DXJ4KA]........................................................................................................................1700 FAILURE CODE [DXJ4KB]........................................................................................................................1702 FAILURE CODE [DXJCKA]........................................................................................................................1704 FAILURE CODE [DXJCKB]........................................................................................................................1706 FAILURE CODE [DXJCKY]........................................................................................................................1707 FAILURE CODE [DXJDKA]........................................................................................................................1708 FAILURE CODE [DXJDKB]........................................................................................................................1710 FAILURE CODE [DXJDKY]........................................................................................................................1711 FAILURE CODE [DXK1KA]........................................................................................................................1712 FAILURE CODE [DXK1KB]........................................................................................................................1714 FAILURE CODE [DXK1KY]........................................................................................................................1715 FAILURE CODE [DXK2KA]........................................................................................................................1716 FAILURE CODE [DXK2KB]........................................................................................................................1718 FAILURE CODE [DXK2KY]........................................................................................................................1719 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................................................1720 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)............................................................................................1720 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...................................................................................................1727 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK................................................................................................1730 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP........................................................................1732 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING..........................................................1734 E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP.......................................1737 E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.................................................................1738 E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................................................1739 E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1740 E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................................1741 E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................................1742 E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1743 E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1744 E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..................................................................1745 E-15 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY..............................................................................................1746 E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL........................................................................................1749 E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE...................................................................1752 E-18 OPERATION MODE DOES NOT CHANGE..........................................................................................................1753 E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN............................................................................1754 E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE................................................................1755 E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION................................................................1756 E-22 SERVICE MODE CANNOT BE SELECTED.........................................................................................................1757 E-23 WORK EQUIPMENT DOES NOT OPERATE.........................................................................................................1758 E-24 FOOT HEATER DOES NOT OPERATE............................................................................................................1760 E-25 HORN DOES NOT SOUND.....................................................................................................................1766 E-26 HORN DOES NOT STOP SOUNDING.............................................................................................................1768 E-27 BACKUP ALARM DOES NOT SOUND.............................................................................................................1769 E-28 BACKUP ALARM DOES NOT STOP SOUNDING.....................................................................................................1770 E-29 HEADLAMP DOES NOT LIGHT UP..............................................................................................................1771 E-30 REAR LAMP DOES NOT LIGHT UP.............................................................................................................1775 E-31 ALL WIPERS DO NOT OPERATE...............................................................................................................1778 E-32 FRONT WIPER DOES NOT OPERATE............................................................................................................1780 E-33 REAR WIPER DOES NOT OPERATE.............................................................................................................1782 E-34 LEFT DOOR WIPER DOES NOT OPERATE........................................................................................................1784 E-35 RIGHT DOOR WIPER DOES NOT OPERATE.......................................................................................................1788 E-36 FRONT WASHER DOES NOT OPERATE...........................................................................................................1792 E-37 REAR WASHER DOES NOT OPERATE............................................................................................................1794 E-38 LEFT DOOR WASHER DOES NOT OPERATE.......................................................................................................1796 E-39 RIGHT DOOR WASHER DOES NOT OPERATE......................................................................................................1798 E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY................................................................................................1800 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....................................................................................1801 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)......................................................................................1801 FAILURE MODE AND CAUSE TABLE.................................................................................................................1802 H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE).......................................1808 H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)..................1810 H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)....1812 H-4 TRAVEL SPEED OR POWER IS LOW.............................................................................................................1814 H-5 SPEED RANGE DOES NOT CHANGE..............................................................................................................1816 H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS...........................................................................................1817 H-7 MACHINE DEVIATES LARGELY.................................................................................................................1818 H-8 MACHINE DRIFT ON A SLOPE IS LARGE........................................................................................................1821 H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...............................................................................................1823 H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR....................................................................................1825 H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH..........................................................................1827 H-12 ALL WORK EQUIPMENT DO NOT OPERATE.......................................................................................................1829 H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW...............................................................................................1831 H-14 BLADE LIFT SPEED OR POWER IS LOW........................................................................................................1832 H-15 BLADE TILT SPEED OR POWER IS LOW........................................................................................................1834 H-16 BLADE ANGLE SPEED OR POWER IS LOW.......................................................................................................1835 H-17 TIME LAG OF BLADE LIFT IS LARGE.........................................................................................................1836 H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE................................................................................................1837 H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE................................................................................................1838 H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE.................................................1839 H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)..................................................................................1840 H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN..................................................................................................1842 TROUBLESHOOTING OF ENGINE (S-MODE)...............................................................................................................1843 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)......................................................................................1843 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...................................................................1844 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...............................................................................................1845 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...........................................1846 S-4 ENGINE STARTABILITY IS POOR..............................................................................................................1847 S-5 ENGINE DOES NOT PICK UP SMOOTHLY.........................................................................................................1849 S-6 ENGINE STOPS DURING OPERATION............................................................................................................1851 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE.........................................................................................................1853 S-8 ENGINE LACKS POWER.......................................................................................................................1854 S-9 EXHAUST SMOKE IS BLACK...................................................................................................................1856 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE.....................................................................................................1858 S-11 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................1859 S-12 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................1860 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...................................................................1861 S-14 OIL PRESSURE DROPS......................................................................................................................1862 S-15 FUEL MIXES INTO ENGINE OIL..............................................................................................................1863 S-16 WATER MIXES INTO ENGINE OIL (MILKY).....................................................................................................1864 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)........................................................................................1865 S-18 UNUSUAL NOISE IS HEARD..................................................................................................................1866 S-19 VIBRATION IS EXCESSIVE..................................................................................................................1868 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT....................................................................................................1869 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY..............................................................................................1870 S-22 ACTIVE REGENERATION TAKES TIME..........................................................................................................1871 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.....................................................................................1872 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE.....................................................................................................1873 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)................................................................................................1875 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...............................................................................1876 50 DISASSEMBLY AND ASSEMBLY..........................................................................................................................1877 CONTENTS.........................................................................................................................................1878 ABBREVIATION LIST................................................................................................................................1883 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY..................................................................................................1889 HOW TO READ THIS MANUAL......................................................................................................................1889 COATING MATERIALS LIST.......................................................................................................................1891 SPECIAL TOOLS LIST...........................................................................................................................1895 SKETCHES OF SPECIAL TOOLS....................................................................................................................1912 ENGINE AND COOLING SYSTEM........................................................................................................................1927 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY......................................................................................................1927 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY.................................................................................................1927 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...............................................................................................1931 REMOVE AND INSTALL INJECTOR ASSEMBLY.........................................................................................................1935 METHOD FOR REMOVING INJECTOR ASSEMBLY....................................................................................................1935 METHOD FOR INSTALLING INJECTOR ASSEMBLY..................................................................................................1938 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY....................................................................................................1944 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...............................................................................................1944 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY.............................................................................................1958 REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................................................1978 METHOD FOR REMOVING EGR VALVE ASSEMBLY...................................................................................................1978 METHOD FOR INSTALLING EGR VALVE ASSEMBLY.................................................................................................1979 REMOVE AND INSTALL EGR COOLER ASSEMBLY.......................................................................................................1981 METHOD FOR REMOVING EGR COOLER ASSEMBLY..................................................................................................1981 METHOD FOR INSTALLING EGR COOLER ASSEMBLY................................................................................................1982 REMOVE AND INSTALL STARTER ASSEMBLY..........................................................................................................1985 METHOD FOR REMOVING STARTER ASSEMBLY.....................................................................................................1985 METHOD FOR INSTALLING STARTER ASSEMBLY...................................................................................................1986 REMOVE AND INSTALL ALTERNATOR BELT...........................................................................................................1988 METHOD FOR REMOVING ALTERNATOR BELT......................................................................................................1988 METHOD FOR INSTALLING ALTERNATOR BELT....................................................................................................1989 REMOVE AND INSTALL AUTOMATIC TENSIONER.......................................................................................................1991 METHOD FOR REMOVING AUTOMATIC TENSIONER..................................................................................................1991 METHOD FOR INSTALLING AUTOMATIC TENSIONER................................................................................................1991 REMOVE AND INSTALL RADIATOR ASSEMBLY.........................................................................................................1992 METHOD FOR REMOVING RADIATOR ASSEMBLY....................................................................................................1992 METHOD FOR INSTALLING RADIATOR ASSEMBLY..................................................................................................1995 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.............................................................................................1999 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY........................................................................................1999 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY......................................................................................2001 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY......................................................................................................2004 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY.................................................................................................2004 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...............................................................................................2006 REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY................................................................................................2010 METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY...........................................................................................2010 METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY.........................................................................................2012 REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY................................................................................................2014 METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY...........................................................................................2014 METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY.........................................................................................2015 REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY.................................................................................................2017 METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY............................................................................................2017 METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY..........................................................................................2023 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.....................................................................................................2031 METHOD FOR REMOVING ENGINE FRONT OIL SEAL................................................................................................2031 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL..............................................................................................2032 REMOVE AND INSTALL ENGINE REAR OIL SEAL......................................................................................................2034 METHOD FOR REMOVING ENGINE REAR OIL SEAL.................................................................................................2034 METHOD FOR INSTALLING ENGINE REAR OIL SEAL...............................................................................................2035 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY......................................................................................................2038 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY.................................................................................................2038 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...............................................................................................2040 REMOVE AND INSTALL KDOC ASSEMBLY.............................................................................................................2044 METHOD FOR REMOVING KDOC ASSEMBLY........................................................................................................2044 METHOD FOR INSTALLING KDOC ASSEMBLY......................................................................................................2048 REMOVE AND INSTALL KDOC AND SCR ASSEMBLY.....................................................................................................2055 METHOD FOR REMOVING KDOC AND SCR ASSEMBLY................................................................................................2056 METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY..............................................................................................2065 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY.....................................................................................................2075 METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY................................................................................................2075 METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY..............................................................................................2077 REMOVE AND INSTALL FUEL TANK ASSEMBLY........................................................................................................2082 METHOD FOR REMOVING FUEL TANK ASSEMBLY...................................................................................................2082 METHOD FOR INSTALLING FUEL TANK ASSEMBLY.................................................................................................2085 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY..................................................................................................2089 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY.............................................................................................2089 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...........................................................................................2095 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....................................................................................2101 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...............................................................................2101 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.............................................................................2102 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR....................................................................................................2105 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...............................................................................................2105 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR.............................................................................................2106 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER..................................................................................................2113 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER.............................................................................................2113 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...........................................................................................2114 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER........................................................................................2115 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER...................................................................................2115 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER.................................................................................2116 REMOVE AND INSTALL SCR ASSEMBLY..............................................................................................................2119 METHOD FOR REMOVING SCR ASSEMBLY.........................................................................................................2119 METHOD FOR INSTALLING SCR ASSEMBLY.......................................................................................................2123 REMOVE AND INSTALL KCCV ASSEMBLY.............................................................................................................2127 METHOD FOR REMOVING KCCV ASSEMBLY........................................................................................................2127 METHOD FOR INSTALLING KCCV ASSEMBLY......................................................................................................2128 REMOVE AND INSTALL TURBO CHARGER ASSEMBLY....................................................................................................2129 METHOD FOR REMOVING TURBO CHARGER ASSEMBLY...............................................................................................2129 METHOD FOR INSTALLING TURBO CHARGER ASSEMBLY.............................................................................................2133 REMOVE AND INSTALL EXHAUST THROTTLE VALVE....................................................................................................2138 METHOD FOR REMOVING EXHAUST THROTTLE VALVE...............................................................................................2138 METHOD FOR INSTALLING EXHAUST THROTTLE VALVE.............................................................................................2142 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE....................................................................................................2148 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...............................................................................................2149 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE.............................................................................................2153 REMOVE AND INSTALL AdBlue/DEF INJECTOR.......................................................................................................2161 METHOD FOR REMOVING AdBlue/DEF INJECTOR..................................................................................................2161 METHOD FOR INSTALLING AdBlue/DEF INJECTOR................................................................................................2164 REMOVE AND INSTALL AdBlue/DEF PUMP...........................................................................................................2168 METHOD FOR REMOVING AdBlue/DEF PUMP......................................................................................................2168 METHOD FOR INSTALLING AdBlue/DEF PUMP....................................................................................................2171 REMOVE AND INSTALL AdBlue/DEF HOSE...........................................................................................................2174 METHOD FOR REMOVING AdBlue/DEF HOSE......................................................................................................2174 METHOD FOR INSTALLING AdBlue/DEF HOSE....................................................................................................2182 REMOVE AND INSTALL AIR CLEANER ASSEMBLY......................................................................................................2192 METHOD FOR REMOVING AIR CLEANER ASSEMBLY.................................................................................................2192 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...............................................................................................2193 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.......................................................................................2195 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................2195 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY................................................................................2196 POWER TRAIN......................................................................................................................................2198 REMOVE AND INSTALL DAMPER ASSEMBLY...........................................................................................................2198 METHOD FOR REMOVING DAMPER ASSEMBLY......................................................................................................2198 METHOD FOR INSTALLING DAMPER ASSEMBLY....................................................................................................2199 REMOVE AND INSTALL HST PUMP ASSEMBLY.........................................................................................................2200 METHOD FOR REMOVING HST PUMP ASSEMBLY....................................................................................................2200 METHOD FOR INSTALLING HST PUMP ASSEMBLY..................................................................................................2203 REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY........................................................................................2206 METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY...................................................................................2206 METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY.................................................................................2208 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY................................................................................................2210 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY............................................................................................2210 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................................2215 UNDERCARRIAGE AND FRAME..........................................................................................................................2225 REMOVE AND INSTALL IDLER AND RECOIL SPRING ASSEMBLY..........................................................................................2225 METHOD FOR REMOVING IDLER AND RECOIL SPRING ASSEMBLY.....................................................................................2225 METHOD FOR INSTALLING IDLER AND RECOIL SPRING ASSEMBLY...................................................................................2225 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY......................................................................................................2227 METHOD FOR DISASSEMBLING IDLER ASSEMBLY..................................................................................................2227 METHOD FOR ASSEMBLING IDLER ASSEMBLY.....................................................................................................2229 DISASSEMBLE AND ASSEMBLE RECOIL SPRING.......................................................................................................2233 METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING....................................................................................2234 METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY.............................................................................................2235 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...............................................................................................2237 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...........................................................................................2237 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................................2239 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY..............................................................................................2243 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY.........................................................................................2243 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................................2244 SEPARATE AND CONNECT TRACK ASSEMBLY..........................................................................................................2247 METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)............................................................................................2247 METHOD FOR CONNECTING TRACK ASSEMBLY.....................................................................................................2248 SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY................................................................................................2250 METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY...........................................................................................2250 METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY...........................................................................................2250 DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY............................................................................................2252 METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY........................................................................................2253 METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY...........................................................................................2255 DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY..................................................................................2268 METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY..............................................................................2269 METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY.................................................................................2270 DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD........................................................................2285 METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD....................................................................2287 METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD.......................................................................2288 DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD..............................................................2296 METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD..........................................................2297 METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD.............................................................2299 HYDRAULIC SYSTEM.................................................................................................................................2303 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...................................................................................................2303 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY..............................................................................................2303 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY............................................................................................2308 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY....................................................................................................2313 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...............................................................................................2313 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY.............................................................................................2315 WORK EQUIPMENT...................................................................................................................................2318 REMOVE AND INSTALL BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER).............................................................................2318 METHOD FOR REMOVING BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)........................................................................2318 METHOD FOR INSTALLING BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)......................................................................2320 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY (POWER ANGLE POWER TILT DOZER)....................................................................2323 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY (POWER ANGLE POWER TILT DOZER)...............................................................2323 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY (POWER ANGLE POWER TILT DOZER).............................................................2324 METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.....................................................................2326 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY................................................................................2327 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................................2328 REMOVE AND INSTALL U-FRAME ASSEMBLY..........................................................................................................2332 METHOD FOR REMOVING U-FRAME ASSEMBLY.....................................................................................................2332 METHOD FOR INSTALLING U-FRAME ASSEMBLY...................................................................................................2333 CAB AND ITS ATTACHMENTS..........................................................................................................................2336 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...................................................................................................2336 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY..............................................................................................2336 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY............................................................................................2341 REMOVE AND INSTALL WIPER ARM.................................................................................................................2347 METHOD FOR REMOVING WIPER ARM............................................................................................................2347 METHOD FOR INSTALLING WIPER ARM..........................................................................................................2348 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)......................................................................................2350 METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS).................................................................................2352 METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...............................................................................2352 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.............................................................................................2358 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY........................................................................................2358 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY......................................................................................2364 REMOVE AND INSTALL OPERATOR'S SEAT...........................................................................................................2372 METHOD FOR REMOVING OPERATOR'S SEAT......................................................................................................2372 METHOD FOR INSTALLING OPERATOR'S SEAT....................................................................................................2373 REMOVE AND INSTALL SEAT BELT.................................................................................................................2374 METHOD FOR REMOVING SEAT BELT............................................................................................................2374 METHOD FOR INSTALLING SEAT BELT..........................................................................................................2374 REMOVE AND INSTALL FOOT HEATER ASSEMBLY......................................................................................................2376 METHOD FOR REMOVING FOOT HEATER ASSEMBLY.................................................................................................2376 METHOD FOR INSTALLING FOOT HEATER ASSEMBLY...............................................................................................2378 DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY................................................................................................2380 METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY............................................................................................2380 METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY...............................................................................................2381 ELECTRICAL SYSTEM................................................................................................................................2382 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY................................................................................................2382 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...........................................................................................2382 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.........................................................................................2384 REMOVE AND INSTALL HST CONTROLLER ASSEMBLY...................................................................................................2388 METHOD FOR REMOVING HST CONTROLLER ASSEMBLY..............................................................................................2388 METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY............................................................................................2389 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY..................................................................................................2390 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.............................................................................................2390 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...........................................................................................2391 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR......................................................................................2393 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR.................................................................................2393 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...............................................................................2395 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR............................................................................................2396 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR.......................................................................................2396 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR.....................................................................................2397 REMOVE AND INSTALL SCR TEMPERATURE SENSOR....................................................................................................2399 METHOD FOR REMOVING SCR TEMPERATURE SENSOR...............................................................................................2399 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR.............................................................................................2401 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................................................................2403 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY............................................................................................2403 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY..........................................................................................2404 60 MAINTENANCE STANDARD..............................................................................................................................2405 CONTENTS.........................................................................................................................................2406 ABBREVIATION LIST................................................................................................................................2408 ENGINE AND COOLING SYSTEM........................................................................................................................2414 MAINTENANCE STANDARD OF ENGINE MOUNT.........................................................................................................2414 MAINTENANCE STANDARD OF DAMPER...............................................................................................................2415 MAINTENANCE STANDARD OF COOLING SYSTEM.......................................................................................................2416 MAINTENANCE STANDARD OF COOLING FAN MOTOR....................................................................................................2418 MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP..................................................................................2420 POWER TRAIN......................................................................................................................................2421 MAINTENANCE STANDARD OF HST PUMP.............................................................................................................2421 MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP............................................................................................2422 MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP..................................................................................2423 MAINTENANCE STANDARD OF HST CHARGE PUMP......................................................................................................2424 MAINTENANCE STANDARD OF HST MOTOR............................................................................................................2426 MAINTENANCE STANDARD OF FINAL DRIVE..........................................................................................................2427 MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE: D37EX-24,D37PX-24.........................................................2429 MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE: D39EX-24,D39PX-24.........................................................2430 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE: D37EX-24,D37PX-24........................2431 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE: D39EX-24,D39PX-24........................2432 MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D37EX-24,D37PX-24.................................................................2433 MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D39EX-24,D39PX-24.................................................................2435 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D37EX-24,D37PX-24................................2437 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D39EX-24,D39PX-24................................2438 UNDERCARRIAGE AND FRAME..........................................................................................................................2439 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION........................................................................................2439 MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL TYPE TRACK SHOES:D37EX-24,D37PX-24.......................................................2442 MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL TYPE TRACK SHOES:D39EX-24,D39PX-24.......................................................2444 MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D37EX-24,D37PX-24..................................................2446 MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D39EX-24,D39PX-24..................................................2448 MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE)..................................................2450 MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE)..................................................2452 MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)..........................................................2454 MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)..........................................................2456 MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE......................................................................2458 MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE..............................................................................2460 MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE.........................................................................................2462 MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE.................................................................................................2466 MAINTENANCE STANDARD OF SINGLE SHOE..........................................................................................................2470 HYDRAULIC SYSTEM.................................................................................................................................2471 MAINTENANCE STANDARD OF HYDRAULIC TANK.......................................................................................................2471 MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP..................................................................................2472 MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP...............................................................2473 MAINTENANCE STANDARD OF CONTROL VALVE........................................................................................................2475 MAINTENANCE STANDARD OF RIPPER PPC VALVE.....................................................................................................2482 MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID.....................................................................................2484 MAINTENANCE STANDARD OF EPC VALVE........................................................................................................2485 MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE............................................................................................2486 WORK EQUIPMENT...................................................................................................................................2487 MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT.................................................................................................2487 MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT.............................................................................................2490 MAINTENANCE STANDARD OF BLADE LIFT CYLINDER..................................................................................................2491 MAINTENANCE STANDARD OF BLADE TILT CYLINDER..................................................................................................2492 MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER.................................................................................................2493 MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER.............................................................................................2494 MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER.................................................................................................2496 CAB AND ITS ATTACHMENTS..........................................................................................................................2497 MAINTENANCE STANDARD OF CAB MOUNT............................................................................................................2497 ELECTRICAL SYSTEM................................................................................................................................2498 MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER......................................................................................2498 80 APPENDIX..........................................................................................................................................2499 CONTENTS.........................................................................................................................................2500 ABBREVIATION LIST................................................................................................................................2501 AIR CONDITIONER SYSTEM...........................................................................................................................2507 PRECAUTIONS FOR REFRIGERANT..................................................................................................................2507 AIR CONDITIONER COMPONENT....................................................................................................................2508 SPECIFICATIONS OF AIR CONDITIONER............................................................................................................2511 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE............................................................................................2512 OUTLINE OF REFRIGERATION CYCLE...............................................................................................................2513 COMPONENT PARTS OF AIR CONDITIONER SYSTEM........................................................................................................2515 AIR CONDITIONER UNIT.........................................................................................................................2515 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT............................................................................................2515 FUNCTION OF AIR CONDITIONER UNIT.........................................................................................................2516 COMPONENT PARTS OF AIR CONDITIONER UNIT......................................................................................................2517 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT.................................................................................2517 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT................................................................................2517 FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT.................................................................................2517 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...........................................................................2518 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT............................................................................2518 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT................................................................................2518 FUNCTION OF DUAL PRESSURE SWITCH.........................................................................................................2519 FUNCTION OF PRESSURE SWITCH..............................................................................................................2519 COMPRESSOR...................................................................................................................................2520 STRUCTURE OF COMPRESSOR..................................................................................................................2520 SPECIFICATIONS OF COMPRESSOR.............................................................................................................2520 FUNCTION OF COMPRESSOR...................................................................................................................2520 CONDENSER....................................................................................................................................2521 STRUCTURE OF CONDENSER...................................................................................................................2521 SPECIFICATIONS OF CONDENSER..............................................................................................................2521 FUNCTION OF CONDENSER....................................................................................................................2522 RECEIVER DRIER...............................................................................................................................2523 STRUCTURE OF RECEIVER DRIER..............................................................................................................2523 SPECIFICATIONS OF RECEIVER DRIER.........................................................................................................2523 FUNCTION OF RECEIVER DRIER...............................................................................................................2523 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......................................................................2525 CIRCUIT DIAGRAM OF AIR CONDITIONER...............................................................................................................2528 AIR CONDITIONER SYSTEM DIAGRAM...................................................................................................................2529 CONTROL FUNCTION OF AIR CONDITIONER..............................................................................................................2530 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS....................................................................2531 TEST RELAYS......................................................................................................................................2535 METHOD FOR TESTING RELAYS....................................................................................................................2535 AIR CONDITIONER TROUBLESHOOTING CHART 1..........................................................................................................2537 AIR CONDITIONER TROUBLESHOOTING CHART 2..........................................................................................................2538 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...................................................................................................2541 A-1 TROUBLESHOOTING FOR CONDENSER FAN............................................................................................................2543 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)....................................................................2546 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...........................................................2550 A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION.............................................................................................2553 TROUBLESHOOTING USING GAUGE PRESSURE.............................................................................................................2557 CONNECTION OF SERVICE TOOL.......................................................................................................................2559 METHOD FOR CONNECTING SERVICE TOOL...........................................................................................................2559 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS..........................................................2560 HANDLE COMPRESSOR OIL............................................................................................................................2562 90 CIRCUIT DIAGRAMS..................................................................................................................................2565 CONTENTS.........................................................................................................................................2566 ABBREVIATION LIST................................................................................................................................2567 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................2573 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM....................................................................................................2573 HYDRAULIC CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24)..............................................................................2577 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................2579 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...................................................................................................2579 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (1/11)......................................................................2583 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (2/11)......................................................................2585 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (3/11)......................................................................2587 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (4/11)......................................................................2589 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (5/11)......................................................................2591 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (6/11)......................................................................2593 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (7/11)......................................................................2595 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (8/11)......................................................................2597 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (9/11)......................................................................2599 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (10/11).....................................................................2601 ELECTRICAL CIRCUIT DIAGRAM (D37EX-24,D37PX-24,D39EX-24,D39PX-24) (11/11).....................................................................2603 INDEX.................................................................................................................................................2605
DESCRIPTION:
KOMATSU D37EX-24 D37PX-24 D39EX-24 D39PX-24 BULLDOZER SHOP MANUAL SEN06586-06 – 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 SPECIFICATIONS
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 THE OTHER INFORMATION
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 27/12/24
