Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06868-08 PDF

Description

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06868-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06868-08 – PDF DOWNLOAD

Language : English
Pages : 2696
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06868-08 – PDF DOWNLOAD

SERIAL NUMBERS
D37EX- 90001 and up
D37PX- 90001 and up
D39EX-100001 and up
D39PX-100001 and up

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

TABLE OF CONTENTS:

Komatsu D37EX-24 D37PX-24 D39EX-24 D39PX-24 Bulldozer Shop Manual SEN06868-08 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EX- 90001 and up
D37PX- 90001 and up
D39EX-100001 and up
D39PX-100001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 20
How to Read the Shop Manual 20
Safety Notice for Operation 22
Precautions to Prevent Fire 30
Procedures If Fire Occurs 32
Precautions When You Discard Waste Materials 33
Procedures for Exhaust Gas Regulations 34
Precautions for DEF 35
General Character and Precautions for Handling 35
Precautions When You Add 35
Precautions for Storage 35
Precautions for Fire Hazard and Leakage 35
Other Precautions 35
Store DEF 36
Precautions When You Handle Hydraulic Equipment 37
Precautions When You Disconnect and Connect Pipings 40
Precautions When You Handle Electrical Equipment 47
Precautions When You Handle Fuel System Equipment 49
Precautions When You Handle Intake System Equipment 50
Practical Use of KOMTRAX 51
Disconnect and Connect Push-Pull Type Coupler 52
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 52
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 53
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 54
Precautions for Disconnection and Connection of Connectors 56
Disconnect and Connect Deutsch Connector 60
How to Disconnect and Connect Slide Lock Type Connector 61
Disconnect and Connect Connector with Lock to Pull 63
Disconnect and Connect Connector with Lock to Push 64
Disconnect and Connect Connector with Housing to Rotate 66
How to Read the Codes for Electric Cable 67
Explanation of Terms for Maintenance Standard 71
Standard Tightening Torque Table 74
Conversion Table 81
Abbreviation List 86
01 Specification 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: D37EX-24 91
Specification Drawing: D37PX-24 93
Specification Drawing: D39EX-24 95
Specification Drawing: D39PX-24 97
Specifications 99
Specification: D37EX-24 99
Specification: D37PX-24 104
Specification: D39EX-24 109
Specification: D39PX-24 114
Weight Table 119
Weight Table: D37EX-24 119
Weight Table: D37PX-24 121
Weight Table: D39EX-24 123
Weight Table: D39PX-24 125
Table of Fuel, Coolant, and Lubricants 127
10 Structure and Function 129
Table of Contents 130
Urea SCR System 133
Layout Drawing of Urea SCR System 133
Urea SCR System Diagram 135
Function of Urea SCR System 136
Function of DEF System 136
Inducement Strategy 139
Component Parts of Urea SCR System 153
DEF Mixing Tube 153
SCR Assembly 154
DEF Tank 156
DEF Pump 158
DEF Injector 159
DEF Hose 160
DEF Tank Heating Valve 161
Boot-up System 162
Layout Drawing of Boot-up System 162
System Operating Lamp System 163
System Diagram of System Operating Lamp System 163
Function of Operation Lamp System 163
Battery Disconnect Switch 165
Function of Battery Disconnect Switch 165
Engine System 166
Layout Drawing of Engine System 166
Engine Control System 168
Layout Drawing of Engine Control System 168
System Diagram of Engine Control 170
Function of Engine Control System 172
Automatic Idle Stop System 174
System Diagram of Automatic Idle Stop System 174
Function of Automatic Idle Stop System 174
Component Parts of Engine System 177
Damper 177
Variable Flow Turbocharger 178
EGR System 182
EGR Valve 185
EGR Cooler 187
KCCV System 189
KCCV Ventilator 192
Exhaust Throttle Valve 194
KDOC 195
Cooling System 198
Layout Drawing of Cooling System 198
Specifications of Cooling System 199
Cooling Fan Control System 200
System Diagram of Cooling Fan Control System 200
Function of Cooling Fan Control System 201
Component Parts of Cooling System 203
Cooling Fan Motor 203
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 208
Hydraulic Oil Cooler Bypass Valve 210
HST Charge Safety Valve 211
Control System 213
Layout Drawing of Control System 213
Machine Monitor System 214
System Diagram of Machine Monitor System 214
Function of Machine Monitor System 215
KOMTRAX System 216
System Diagram of KOMTRAX System 216
Function of KOMTRAX System 217
Component Parts of Control System 218
Machine Monitor 218
Gateway Function Controller 233
Communication Terminal 236
HST Controller 238
Engine Controller 242
Fuel Control Dial 249
Decelerator and Brake Potentiometer 251
Hydraulic System 253
Layout Drawing of Hydraulic System 253
CLSS 254
Structure of CLSS 254
Function of CLSS 255
Component Parts of Hydraulic System 257
Hydraulic Tank 257
Work Equipment and Cooling Fan Pump 259
LS Valve 266
PC Valve 267
Control Valve 270
Power Train System 291
Layout Drawing of HST System 291
Operation of HST System 292
Steering and Brake Control System 294
Layout Drawing of Steering and Brake Control System 294
Function of Steering and Brake Control System 295
HST Control System 296
System Diagram of HST Control System 296
Gear Shift Control Function 297
Engine Low Speed Matching Control Function 301
HST Pump and Motor Sequence Control Function 302
Deceleration and Brake Control Function 303
Gear Shift Control Function by Load 305
Turn Control Function 306
Straight Travel Correction Control Function 307
Parking Brake Control System 308
System Diagram of Parking Brake Control System 308
Function of Parking Brake Control System 309
Operation of Parking Brake Control System 310
Component Parts of Power Train System 311
HST Pump 311
HST Charge Pump 328
HST Motor 329
Final Drive 341
Electric Steering Electric Lever 345
Work Equipment System 348
Work Equipment Control 348
Layout Drawing of Work Equipment Control 348
Function of Work Equipment Control 349
Layout Drawing of Front Work Equipment 351
Layout Drawing of Fixed Multi-Shank Ripper 352
Component Parts of Work Equipment System 353
Ripper PPC Valve 353
5-Spool EPC and Solenoid Valve 357
Pilot Circuit Accumulator 364
Angle Control EPC Valve 365
Piston Valve 368
Electric Blade Control Lever 369
Undercarriage and Frame 371
Main Frame 371
Structure of Main Frame 371
Track Frame and Idler Cushion 372
Structure of Track Frame and Idler Cushion 372
Function of Track Frame and Idler Cushion 374
Work Equipment 375
Structure of Front Work Equipment 375
Structure of Fixed Multi-Shank Ripper 376
CAB Related Parts 377
ROPS CAB 377
Structure of ROPS CAB 377
Function of ROPS CAB 378
CAB Mount 379
Structure of CAB Mount 379
Function of CAB Mount 380
20 Standard Value Table 381
Table of Contents 382
Standard Value Table for Engine 383
Standard Value Table for Engine: D37EX-24 383
Standard Value Table for Engine: D37PX-24 386
Standard Value Table for Engine: D39EX-24 389
Standard Value Table for Engine: D39PX-24 392
Standard Value Table for Machine 395
Standard Value Table for Machine: D37EX-24 395
Standard Value Table for Machine: D37PX-24 411
Standard Value Table for Machine: D39EX-24 425
Standard Value Table for Machine: D39PX-24 441
Machine Posture and Procedures to Measure Performance 455
30 Testing and Adjusting 457
Table of Contents 458
Precautions Before Work 461
Related Information on Testing and Adjusting 462
Tools for Testing and Adjusting 462
Sketch of Tools for Testing and Adjusting 469
Engine and Cooling System 471
Examine Engine Speed 471
How to Examine Engine Speed 471
Examine Exhaust Gas Color 473
How to Examine Exhaust Gas Color with the Handy Smoke Checker 473
How to Examine Exhaust Gas Color with Smoke Meter 474
Examine the Clearance of Exhaust Throttle Valve 475
Measure Clearance of the Exhaust Throttle Valve 475
Examine and Adjust Valve Clearance 477
Check Valve Clearance 477
Adjust Valve Clearance 478
Examine Compression Pressure 479
How to Examine Compression Pressure 479
Examine Blowby Pressure 482
How to Examine Blowby Pressure 482
Examine Engine Oil Pressure 484
How to Examine Engine Oil Pressure 484
Visual Check Inside of EGR Valve 486
How to do the Visual Check Inside of EGR Valve 486
Clean Inside of EGR Valve 488
How to Clean Inside of EGR Valve 488
Examine Fuel Pressure 491
How to Examine Fuel Pressure 491
Examine Fuel Return Rate and Leakage 493
How to Examine Fuel Return Rate and Leakage 494
Bleed Air from Fuel System 498
How to Bleed Air from Fuel System 498
Examine Fuel Circuit for Leakage 500
How to Examine Fuel System for Leakage 500
Handle Cylinder Cut-out Mode Operation 502
Handle No-Injection Cranking Operation 503
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 504
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage 504
Examine Installed Condition of Cylinder Heads and Manifolds 505
How to Examine Installed Condition of Cylinder Heads and Manifolds 505
Examine Engine Piping for Damage and Looseness 506
How to Examine Engine Piping for Damage and Looseness 506
Examine Alternator Belt 507
How to Examine Alternator Belt 507
Examine Automatic Tensioner 508
How to Examine Automatic Tensioner 508
Write Injector Compensation Value to Engine Controller 510
Write Injector Compensation Value 510
Examine SCR Related Functions 517
Examine DEF Pump Raised Pressure 521
Examine Injection Volume from DEF Injector 524
Examine DEF Line Heater Relay 1 529
Examine DEF Line Heater Relay 2 532
Examine DEF Pump Heater Relay 535
Examine DEF Tank Heater Valve 539
Examine SCR Denitration Efficiency 542
Clean DEF Tank 545
How to Clean DEF Tank 545
Clean DEF Tank Mounting Part 550
How to Clean DEF Tank Mounting Part 550
Clean DEF Pump 551
How to Clean DEF Pump 551
Power Train 557
Examine and Adjust HST Oil Pressure 557
Examine HST Oil Pressure 557
Adjust HST Oil Pressure 560
Bleed Air from HST Pump 562
How to Bleed Air from HST Pump 562
Bleed Air from Servo Valve of HST Pump 562
Examine Outlet Pressure of Solenoid Valve 564
How to Examine Outlet Pressure of Solenoid Valve 564
Examine Travel Deviation 569
How to Examine Travel Deviation 569
Examine Brake Performance Simply 571
How to Examine Brake Performance Simply 571
Examine and Adjust Deceleration/Brake Pedal 572
How to Examine Deceleration/Brake Pedal 572
How to Adjust Deceleration/Brake Pedal 574
Adjust Parking Brake Lever 576
How to Adjust Parking Brake Lever 576
Move Machine When It Cannot Travel 578
Move Machine with Hydraulic Type Parking Brake Release System 578
Move Machine After You Remove Final Drive Shaft 580
Undercarriage and Frame 582
Adjust Idler Clearance 582
How to Adjust Idler Clearance 582
Examine Sprocket Wear 583
How to Examine Sprocket Wear 583
Examine and Adjust Track Tension 584
How to Examine Track Tension 584
How to Adjust Track Tension 584
Hydraulic System 586
Release Remained Pressure in Hydraulic Circuit 586
How to Release Remained Pressure in Hydraulic System 586
Examine and Adjust Work Equipment Circuit Oil Pressure 587
How to Examine Work Equipment Circuit Oil Pressure 587
Adjust Work Equipment Circuit Oil Pressure 588
Examine and Adjust Oil Pressure in Control Circuit 590
Examine Oil Pressure in Control Circuit 590
Adjust Oil Pressure in Control Circuit 591
Examine Outlet Pressure of EPC Solenoid Valve 592
How to Examine Outlet Pressure of EPC Solenoid Valve 592
Bleed Air from Work Equipment and Cooling Fan Pump 594
How to Bleed Air from Work Equipment and Cooling Fan Pump 594
Examine Cooling Fan Speed 595
How to Examine Cooling Fan Speed 595
Examine Cooling Fan Circuit Oil Pressure 596
How to Examine Cooling Fan Circuit Oil Pressure 596
Examine Parts Which Cause Hydraulic Drift of Work Equipment 598
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 598
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 598
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 599
Examine Oil Leakage from Work Equipment Cylinder 600
How to Examine Internal Oil Leakage of Work Equipment Cylinder 600
Bleed Air from Work Equipment Cylinders 602
Bleed Air from Work Equipment Cylinder 602
Work Equipment 603
Adjust Work Equipment Lock Lever 603
How to Adjust Work Equipment Lock Lever 603
Examine and Adjust Play of Blade Electric Lever 605
How to Examine Play of Blade Electric Lever 607
Adjust Play of Blade Electric Lever 607
Replace Universal Joint 608
Electrical System 615
Set and Operate Machine Monitor 615
Operator Mode 619
Function to Show Technician Identification Status Screen 619
Function to Show Operator Identification Input Screen 619
Examine Function by LCD (Liquid Crystal Display) 620
Examine Function of Service Meter 620
Usage Limitation and Change Maintenance Password 620
Service Mode 623
How to Operate Service Mode 623
How to See Pre-defined Monitoring Information 624
How to Examine Self-Define Monitor Information 631
Abnormality Record Menu 641
How to See Maintenance Record 645
Maintenance Mode Setting 646
Set Phone Number Entry 650
Default Menu 652
Diagnostic Tests Menu 661
Adjustment Menu 668
No-Injection Cranking Operation 723
KOMTRAX Settings Menu 726
Show Service Message 728
Start Up KOMTRAX System 730
How to Stop Use of KOMTRAX System 736
Adjust After Replacement of HST Controller 738
How to Adjust After Replacement of HST Controller 738
Adjust After Replacement of Electric and Hydraulic Equipment 744
Adjust Rearview Camera Angle 746
How to Adjust Rearview Camera Angle 746
Set Region of Bluetooth(R) Compatible Radio 748
Set Region of Bluetooth(R) Compatible Radio 748
Handle Voltage Circuit of Engine Controller 750
Handle Battery Disconnect Switch 751
Examine Diodes 752
Examine Diodes by Digital Tester 752
How to Examine Diodes by Analog Tester 752
Pm Clinic 753
Pm Clinic Service 753
Pm Clinic Check Sheet: D37EX-24 755
Pm Clinic Check Sheet: D37PX-24 763
Pm Clinic Check Sheet: D39EX-24 771
Pm Clinic Check Sheet: D39PX-24 778
Pm Clinic Check Sheet for Undercarriage: D37EX-24 785
Pm Clinic Check Sheet for Undercarriage: D37PX-24 792
Pm Clinic Check Sheet for Undercarriage: D39EX-24 799
Pm Clinic Check Sheet for Undercarriage: D39PX-24 806
40 Troubleshooting 813
Table of Contents 814
Precautions Before Work 824
Related Information to Troubleshooting 825
General Troubleshooting Points 825
Troubleshooting Points for Urea SCR System 826
Sequence of Events in Troubleshooting 838
Checks Before Troubleshooting 840
Inspection Procedure Before Troubleshooting 842
Walk-Around Check 842
Test in Accordance with Testing Procedure 844
Examine Fuel Level and Type 844
Examine for Impure Ingredient in Fuel 844
Examine DEF Level and Type 845
Examine Fuel Prefilter 845
Examine Fuel Main Filter 847
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 849
Examine Coolant Level (Reservoir Tank) 850
Examine Air Cleaner Clogging 851
Clean Outer Element 851
Replace Element 853
Examine Hydraulic Oil Level 853
Examine Hydraulic Oil Strainer 854
Examine Oil Level in Final Drive Case 858
Bleed Air from Fuel System 858
Bleed Air from Hydraulic System 859
How to Examine Electric Equipment 859
Preparation for Troubleshooting of Electrical System 866
Procedure for Troubleshooting 873
Symptom and Troubleshooting Numbers 876
Information Shown in Troubleshooting Table 879
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 881
Connector List and Layout 884
Connector Contact Connection Table 906
T-Branch Box and T-Branch Adapter Table 946
Fuse Location Table 952
Precautions When You Replace KDOC 956
Failure Code Table 957
Troubleshooting by Failure Code (Display of Code) 976
Failure Code [6091NX] 976
Failure Code [989L00] 978
Failure Code [989M00] 979
Failure Code [989N00] 980
Failure Code [A1U0N3] 981
Failure Code [A1U0N4] 983
Failure Code [A900FR] 985
Failure Code [A900N6] 986
Failure Code [A900NY] 987
Failure Code [AA10NX] 988
Failure Code [AB00KE] 990
Failure Code [AQ10MB] 992
Failure Code [AQ10N3] 994
Failure Code [AS00R2] 995
Failure Code [AS00R3] 996
Failure Code [AS00R4] 997
Failure Code [AS00R5] 998
Failure Code [AS00R6] 999
Failure Code [AS00ZK] 1000
Failure Code [AS10KM] 1001
Failure Code [AS10NR] 1002
Failure Code [AS10NT] 1003
Failure Code [AU10QA] 1004
Failure Code [B@BAZG] 1005
Failure Code [B@BCNS] 1006
Failure Code [B@BCQA] 1007
Failure Code [B@BCZK] 1009
Failure Code [B@CRNS] 1011
Failure Code [B@CRZG] 1012
Failure Code [CA115] 1013
Failure Code [CA122] 1014
Failure Code [CA123] 1016
Failure Code [CA131] 1018
Failure Code [CA132] 1020
Failure Code [CA144] 1022
Failure Code [CA145] 1024
Failure Code [CA153] 1026
Failure Code [CA154] 1029
Failure Code [CA187] 1032
Failure Code [CA221] 1034
Failure Code [CA222] 1036
Failure Code [CA227] 1038
Failure Code [CA234] 1039
Failure Code [CA238] 1040
Failure Code [CA239] 1042
Failure Code [CA249] 1044
Failure Code [CA256] 1046
Failure Code [CA271] 1048
Failure Code [CA272] 1050
Failure Code [CA322] 1052
Failure Code [CA324] 1054
Failure Code [CA331] 1056
Failure Code [CA332] 1058
Failure Code [CA343] 1060
Failure Code [CA351] 1061
Failure Code [CA352] 1062
Failure Code [CA356] 1065
Failure Code [CA357] 1067
Failure Code [CA386] 1069
Failure Code [CA435] 1070
Failure Code [CA441] 1072
Failure Code [CA442] 1074
Failure Code [CA449] 1075
Failure Code [CA451] 1076
Failure Code [CA452] 1078
Failure Code [CA515] 1080
Failure Code [CA516] 1082
Failure Code [CA553] 1084
Failure Code [CA555] 1085
Failure Code [CA556] 1086
Failure Code [CA559] 1087
Failure Code [CA689] 1091
Failure Code [CA691] 1093
Failure Code [CA692] 1095
Failure Code [CA697] 1097
Failure Code [CA698] 1098
Failure Code [CA731] 1099
Failure Code [CA778] 1101
Failure Code [CA1117] 1106
Failure Code [CA1664] 1107
Failure Code [CA1669] 1109
Failure Code [CA1673] 1110
Failure Code [CA1677] 1111
Failure Code [CA1678] 1112
Failure Code [CA1682] 1113
Failure Code [CA1683] 1118
Failure Code [CA1684] 1120
Failure Code [CA1686] 1122
Failure Code [CA1691] 1123
Failure Code [CA1694] 1125
Failure Code [CA1695] 1127
Failure Code [CA1696] 1128
Failure Code [CA1712] 1130
Failure Code [CA1713] 1133
Failure Code [CA1714] 1135
Failure Code [CA1715] 1136
Failure Code [CA1776] 1137
Failure Code [CA1777] 1140
Failure Code [CA1843] 1143
Failure Code [CA1844] 1145
Failure Code [CA1885] 1148
Failure Code [CA1887] 1150
Failure Code [CA1896] 1152
Failure Code [CA1938] 1156
Failure Code [CA1942] 1158
Failure Code [CA1961] 1159
Failure Code [CA2185] 1160
Failure Code [CA2186] 1162
Failure Code [CA2249] 1164
Failure Code [CA2272] 1165
Failure Code [CA2311] 1168
Failure Code [CA2349] 1169
Failure Code [CA2353] 1171
Failure Code [CA2357] 1173
Failure Code [CA2555] 1174
Failure Code [CA2556] 1176
Failure Code [CA2636] 1178
Failure Code [CA2637] 1181
Failure Code [CA2765] 1183
Failure Code [CA2771] 1184
Failure Code [CA2976] 1190
Failure Code [CA3142] 1192
Failure Code [CA3143] 1193
Failure Code [CA3144] 1194
Failure Code [CA3146] 1196
Failure Code [CA3147] 1197
Failure Code [CA3148] 1198
Failure Code [CA3151] 1200
Failure Code [CA3165] 1206
Failure Code [CA3229] 1208
Failure Code [CA3231] 1210
Failure Code [CA3232] 1212
Failure Code [CA3235] 1216
Failure Code [CA3239] 1218
Failure Code [CA3241] 1221
Failure Code [CA3242] 1224
Failure Code [CA3251] 1227
Failure Code [CA3313] 1229
Failure Code [CA3314] 1230
Failure Code [CA3315] 1231
Failure Code [CA3419] 1233
Failure Code [CA3421] 1235
Failure Code [CA3497] 1237
Failure Code [CA3498] 1238
Failure Code [CA3543] 1239
Failure Code [CA3545] 1245
Failure Code [CA3547] 1247
Failure Code [CA3558] 1248
Failure Code [CA3559] 1250
Failure Code [CA3562] 1252
Failure Code [CA3563] 1254
Failure Code [CA3567] 1257
Failure Code [CA3568] 1260
Failure Code [CA3571] 1265
Failure Code [CA3572] 1267
Failure Code [CA3574] 1269
Failure Code [CA3575] 1272
Failure Code [CA3577] 1274
Failure Code [CA3578] 1276
Failure Code [CA3582] 1278
Failure Code [CA3583] 1286
Failure Code [CA3596] 1288
Failure Code [CA3649] 1292
Failure Code [CA3681] 1294
Failure Code [CA3682] 1299
Failure Code [CA3713] 1304
Failure Code [CA3717] 1307
Failure Code [CA3718] 1308
Failure Code [CA3724] 1309
Failure Code [CA3725] 1310
Failure Code [CA3748] 1313
Failure Code [CA3755] 1316
Failure Code [CA3866] 1318
Failure Code [CA3867] 1322
Failure Code [CA3868] 1325
Failure Code [CA3899] 1329
Failure Code [CA3911] 1331
Failure Code [CA3912] 1335
Failure Code [CA3918] 1337
Failure Code [CA3921] 1339
Failure Code [CA3928] 1340
Failure Code [CA3932] 1341
Failure Code [CA3933] 1343
Failure Code [CA3934] 1345
Failure Code [CA3935] 1348
Failure Code [CA3936] 1350
Failure Code [CA4152] 1352
Failure Code [CA4155] 1356
Failure Code [CA4156] 1359
Failure Code [CA4157] 1362
Failure Code [CA4159] 1364
Failure Code [CA4164] 1365
Failure Code [CA4165] 1367
Failure Code [CA4166] 1369
Failure Code [CA4168] 1370
Failure Code [CA4169] 1373
Failure Code [CA4171] 1375
Failure Code [CA4249] 1379
Failure Code [CA4251] 1381
Failure Code [CA4261] 1383
Failure Code [CA4277] 1386
Failure Code [CA4281] 1390
Failure Code [CA4459] 1394
Failure Code [CA4461] 1397
Failure Code [CA4533] 1400
Failure Code [CA4534] 1401
Failure Code [CA4731] 1402
Failure Code [CA4732] 1403
Failure Code [CA4739] 1404
Failure Code [CA4768] 1405
Failure Code [CA4769] 1407
Failure Code [CA4842] 1409
Failure Code [CA4952] 1413
Failure Code [CA5115] 1415
Failure Code [CA5179] 1418
Failure Code [CA5181] 1420
Failure Code [CA5271] 1422
Failure Code [CA5272] 1424
Failure Code [CA5273] 1426
Failure Code [CA5274] 1428
Failure Code [CA5275] 1429
Failure Code [CA5276] 1431
Failure Code [CA5387] 1433
Failure Code [CA5388] 1435
Failure Code [CA5389] 1437
Failure Code [CA5391] 1439
Failure Code [CA5392] 1443
Failure Code [CA5393] 1444
Failure Code [CA5394] 1447
Failure Code [CA5395] 1450
Failure Code [CA5396] 1453
Failure Code [CA5631] 1454
Failure Code [CA5938] 1456
Failure Code [D130KA] 1458
Failure Code [D130KB] 1460
Failure Code [D130KY] 1462
Failure Code [D19JKZ] 1464
Failure Code [D811MC] 1467
Failure Code [D862KA] 1468
Failure Code [D8ALKA] 1469
Failure Code [D8ALKB] 1472
Failure Code [D8AQKR] 1474
Failure Code [D8G1KT] 1477
Failure Code [D8G6KT] 1478
Failure Code [DAF0MB] 1479
Failure Code [DAF0MC] 1480
Failure Code [DAF8KB] 1481
Failure Code [DAF9KQ] 1483
Failure Code [DAFGMC] 1484
Failure Code [DAFLKA] 1485
Failure Code [DAFLKB] 1488
Failure Code [DAFQKR] 1490
Failure Code [DAJ000] 1494
Failure Code [DAJ0KQ] 1495
Failure Code [DAJ0KT] 1496
Failure Code [DAJ0MC] 1497
Failure Code [DAJ1KK] 1498
Failure Code [DAJ2KK] 1500
Failure Code [DAJ5KK] 1502
Failure Code [DAJ6KK] 1505
Failure Code [DAJLKA] 1507
Failure Code [DAJLKB] 1509
Failure Code [DAJPMA] 1511
Failure Code [DAJQKR] 1512
Failure Code [DAJRKR] 1513
Failure Code [DB2QKR] 1517
Failure Code [DB2RKR] 1524
Failure Code [DD12KA] 1528
Failure Code [DD12KB] 1530
Failure Code [DD13KA] 1532
Failure Code [DD13KB] 1534
Failure Code [DD14KA] 1536
Failure Code [DD14KB] 1538
Failure Code [DDKAKA] 1540
Failure Code [DDKAKB] 1542
Failure Code [DDKFL4] 1544
Failure Code [DDKGL4] 1546
Failure Code [DDKHKA] 1548
Failure Code [DDKHKB] 1550
Failure Code [DDNLKA] 1552
Failure Code [DDNLKB] 1554
Failure Code [DDP6KA] 1556
Failure Code [DDP6KB] 1558
Failure Code [DDP6MA] 1560
Failure Code [DDU1FS] 1562
Failure Code [DDU1KA] 1564
Failure Code [DDU1KY] 1566
Failure Code [DFA4KX] 1568
Failure Code [DFA4KZ] 1569
Failure Code [DFA4L8] 1570
Failure Code [DFA5KA] 1571
Failure Code [DFA5KB] 1573
Failure Code [DFA6KA] 1575
Failure Code [DFA6KB] 1577
Failure Code [DFA7KX] 1579
Failure Code [DFA7KZ] 1580
Failure Code [DFA7L8] 1581
Failure Code [DFA8KA] 1582
Failure Code [DFA8KB] 1584
Failure Code [DFA9KA] 1586
Failure Code [DFA9KB] 1588
Failure Code [DGS1KA] 1590
Failure Code [DGS1KX] 1592
Failure Code [DH21KA] 1594
Failure Code [DH21KB] 1596
Failure Code [DHA4KA] 1597
Failure Code [DHH7KA] 1599
Failure Code [DHH7KB] 1601
Failure Code [DHH8KA] 1603
Failure Code [DHH8KB] 1605
Failure Code [DHH9KA] 1607
Failure Code [DHH9KB] 1609
Failure Code [DHHAKA] 1611
Failure Code [DHHAKB] 1613
Failure Code [DHRUKA] 1615
Failure Code [DHRUKB] 1617
Failure Code [DHRVKA] 1619
Failure Code [DHRVKB] 1621
Failure Code [DK30KA] 1623
Failure Code [DK30KB] 1625
Failure Code [DK30KX] 1627
Failure Code [DK30KZ] 1628
Failure Code [DK30L8] 1629
Failure Code [DK31KA] 1632
Failure Code [DK31KB] 1634
Failure Code [DK40KA] 1636
Failure Code [DK40KB] 1638
Failure Code [DK55KX] 1640
Failure Code [DK55KZ] 1641
Failure Code [DK55L8] 1642
Failure Code [DK56KA] 1644
Failure Code [DK56KB] 1646
Failure Code [DK57KA] 1648
Failure Code [DK57KB] 1650
Failure Code [DLM0KX] 1652
Failure Code [DLM0MA] 1653
Failure Code [DLM1KA] 1654
Failure Code [DLM1KB] 1656
Failure Code [DLM1MA] 1658
Failure Code [DLM2KA] 1659
Failure Code [DLM2KB] 1661
Failure Code [DLM2MA] 1663
Failure Code [DLM3KA] 1664
Failure Code [DLM3KB] 1666
Failure Code [DLM3MB] 1668
Failure Code [DN21FS] 1669
Failure Code [DR21KX] 1671
Failure Code [DR31KX] 1672
Failure Code [DV20KB] 1673
Failure Code [DW4BKA] 1675
Failure Code [DW4BKB] 1677
Failure Code [DW4BKY] 1679
Failure Code [DW7BKA] 1680
Failure Code [DW7BKB] 1682
Failure Code [DW7EKA] 1683
Failure Code [DW7EKB] 1686
Failure Code [DW7EKY] 1688
Failure Code [DWN5KA] 1690
Failure Code [DWN5KB] 1692
Failure Code [DWN5KY] 1693
Failure Code [DXA4KA] 1694
Failure Code [DXA4KB] 1696
Failure Code [DXA4KY] 1698
Failure Code [DXA5KA] 1699
Failure Code [DXA5KB] 1701
Failure Code [DXA5KY] 1703
Failure Code [DXA6KA] 1704
Failure Code [DXA6KB] 1706
Failure Code [DXA6KY] 1708
Failure Code [DXA7KA] 1709
Failure Code [DXA7KB] 1711
Failure Code [DXA7KY] 1713
Failure Code [DXHRKA] 1714
Failure Code [DXHRKB] 1716
Failure Code [DXHRKY] 1717
Failure Code [DXHSKA] 1718
Failure Code [DXHSKB] 1720
Failure Code [DXHSKY] 1721
Failure Code [DXHTKA] 1722
Failure Code [DXHTKB] 1724
Failure Code [DXHTKY] 1725
Failure Code [DXHUKA] 1726
Failure Code [DXHUKB] 1728
Failure Code [DXHUKY] 1729
Failure Code [DXJ4KA] 1730
Failure Code [DXJ4KB] 1732
Failure Code [DXJCKA] 1734
Failure Code [DXJCKB] 1736
Failure Code [DXJCKY] 1737
Failure Code [DXJDKA] 1738
Failure Code [DXJDKB] 1740
Failure Code [DXJDKY] 1741
Failure Code [DXK1KA] 1742
Failure Code [DXK1KB] 1744
Failure Code [DXK1KY] 1745
Failure Code [DXK2KA] 1746
Failure Code [DXK2KB] 1748
Failure Code [DXK2KY] 1749
Failure Code [F311KA] 1750
Failure Code [F311KB] 1752
Failure Code [F312KA] 1754
Failure Code [F312KB] 1756
Failure Code [F313KA] 1758
Failure Code [F313KB] 1760
Failure Code [F314KA] 1763
Failure Code [F314KB] 1765
Failure Code [F315KB] 1767
Failure Code [F315KY] 1769
Failure Code [F316KB] 1771
Failure Code [F316KY] 1773
Failure Code [F318KB] 1775
Failure Code [F318KY] 1778
Failure Code [F31AKB] 1780
Failure Code [F31AKY] 1782
Failure Code [F31BKB] 1784
Failure Code [F31BKY] 1786
Failure Code [F31CKB] 1788
Failure Code [F31CKY] 1790
Failure Code [F31DKB] 1792
Failure Code [F31DKY] 1794
Failure Code [F31EKB] 1796
Failure Code [F31EKY] 1798
Failure Code [FS10ZE] 1800
Troubleshooting of Electrical System (E-Mode) 1801
Engine Does Not Start (Engine Does Not Crank) 1801
Manual Preheating System Does Not Operate 1808
Automatic Preheating System Does Not Operate 1811
While Preheating is in Operation, Preheating Monitor Does Not Come On 1813
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1815
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 1818
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1819
Charge Level Monitor Comes On in Red While Engine is in Operation 1820
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1821
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1822
HST Charge Pressure Monitor Comes On in Red While Engine Runs 1823
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1824
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 1825
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1826
DEF Level is Not Shown Correctly 1827
Fuel Gauge Does Not Show Normally 1830
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1833
Operation Mode Does Not Change 1834
When You Operate Customize Switch Does Not Show Customize Screen 1835
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1836
Service Meter is Not Shown While Starting Switch is in OFF Position 1837
Service Mode Cannot be Selected 1838
Work Equipment Does Not Operate 1839
Foot Heater Does Not Operate 1841
Horn Does Not Sound 1847
Horn Does Not Stop 1849
Backup Alarm Does Not Sound 1850
Backup Alarm Does Not Stop Operation 1851
Headlamp Does Not Come On 1852
Rear Lamp Does Not Come On 1856
No Wiper Operates 1859
Front Wiper Does Not Operate 1861
Rear Wiper Does Not Operate 1863
Left Door Wiper Does Not Operate 1865
Right Door Wiper Does Not Operate 1869
Front Washer Does Not Operate 1873
Rear Washer Does Not Operate 1875
Left Door Washer Does Not Operate 1877
Right Door Washer Does Not Operate 1879
KOMTRAX System Does Not Operate Correctly 1881
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1882
Information Shown in Troubleshooting Table (H-Mode) 1882
Failure Mode and Cause Table 1883
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 1889
R H or L H Track Cannot Travel FORWARD and Reverse (One of R H or L H Travel Systems Cannot Operate) 1891
R H or L H Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction) 1893
Travel Speed or Power is Low 1895
Speed Range Does Not Change 1897
Shock is Large When Machine Moves Off or Stops 1898
Travel Deviation is Large 1899
Machine Drift on a Slope is Large 1902
Engine Speed Drops Largely or Engine Stops 1904
Unusual Noise is Heard from Around HST Pump or Motor 1906
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 1908
All Work Equipment Do Not Operate 1910
All Work Equipment Speed or Power is Low 1912
Blade Lift Speed or Power is Low 1913
Blade Tilt Speed or Power is Low 1915
Blade Angle Speed or Power is Low 1916
Time Lag of Blade Lift is Large 1917
Hydraulic Drift of Blade Lift is Large 1918
Hydraulic Drift of Tilted Blade is Large 1919
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 1920
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1921
Unusual Noise is Heard from Around Fan 1923
Troubleshooting of Engine (S-Mode) 1924
Information Shown in Troubleshooting Table (S-Mode) 1924
Engine Does Not Crank When Starting Switch is Turned to Start Position 1925
Engine Cranks but No Exhaust Smoke Comes Out 1926
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1927
Engine Startability is Unsatisfactory 1928
Engine Does Not Pick Up Smoothly 1930
Engine Stops During Operation 1932
Engine Does Not Rotate Smoothly 1934
Engine Lacks Output (or Lacks Power) 1935
Exhaust Smoke is Black 1937
Engine Oil Consumption is Excessive 1939
Engine Oil Becomes Dirty Quickly 1940
Fuel Consumption is Excessive 1941
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1942
Engine Oil Pressure Drops 1943
Fuel Mixes Into Engine Oil 1944
Water Mixes Into Engine Oil (Milky) 1945
Coolant Temperature Increases Too High (Overheat) 1946
Unusual Noise is Heard 1947
Vibration is Excessive 1949
Air Cannot be Bled from Fuel Circuit 1950
Active Regeneration is Done Frequently 1951
Active Regeneration Continues Long 1952
White Smoke is Exhausted During Active Regeneration 1953
DEF Consumption is Excessive 1954
There is an Unusual Smell (Irritating Odor) 1956
Foreign Materials Enter DEF (DEF Increases) 1957
50 Disassembly and Assembly 1959
Table of Contents 1960
Precautions Before Work 1964
Related Information on Disassembly and Assembly 1965
How to Read This Manual 1965
Coating Materials List 1966
Special Tool List 1971
Sketches of Special Tools 1988
Engine and Cooling System 2003
Remove and Install Supply Pump Assembly 2003
Remove Supply Pump Assembly 2003
Install Supply Pump Assembly 2007
Remove and Install Injector Assembly 2011
How to Remove Injector Assembly 2011
How to Install Injector Assembly 2014
Remove and Install Cylinder Head Assembly 2020
How to Remove Cylinder Head Assembly 2020
How to Install Cylinder Head Assembly 2034
Remove and Install EGR Valve Assembly 2055
Remove EGR Valve Assembly 2055
Install EGR Valve Assembly 2056
Remove and Install EGR Cooler Assembly 2058
How to Remove EGR Cooler Assembly 2058
How to Install EGR Cooler Assembly 2060
Remove and Install Starter Assembly 2063
Remove Starting Motor Assembly 2063
Install Starting Motor Assembly 2064
Remove and Install Alternator Belt 2066
Remove Alternator Belt 2066
Install Alternator Belt 2067
Remove and Install Automatic Tensioner 2069
Remove Automatic Tensioner 2069
Install Automatic Tensioner 2069
Remove and Install Radiator Assembly 2070
How to Remove Radiator Assembly 2070
How to Install Radiator Assembly 2073
Remove and Install Hydraulic Oil Cooler Assembly 2077
How to Remove Hydraulic Oil Cooler Assembly 2077
How to Install Hydraulic Oil Cooler Assembly 2079
Remove and Install Aftercooler Assembly 2083
Remove Aftercooler Assembly 2083
Install Aftercooler Assembly 2085
Remove and Install Cooling Fan Drive Assembly 2089
Remove Cooling Fan Drive Assembly 2089
Install Cooling Fan Drive Assembly 2091
Remove and Install Cooling Fan Motor Assembly 2093
Remove Cooling Fan Motor Assembly 2093
Install Cooling Fan Motor Assembly 2094
Remove and Install Engine and HST Pump Assembly 2096
Remove Engine and HST Pump Assembly 2096
Install Engine and HST Pump Assembly 2102
Remove and Install Engine Front Oil Seal 2110
How to Remove Engine Front Oil Seal 2110
How to Install Engine Front Oil Seal 2111
Remove and Install Engine Rear Oil Seal 2113
How to Remove Engine Rear Oil Seal 2113
How to Install Engine Rear Oil Seal 2114
Remove and Install Engine Hood Assembly 2117
How to Remove Engine Hood Assembly 2117
How to Install Engine Hood Assembly 2119
Remove and Install KDOC Assembly 2123
How to Remove KDOC Assembly 2123
How to Install KDOC Assembly 2127
Remove and Install KDOC and SCR Assembly 2134
Remove KDOC and SCR Assembly 2135
Install KDOC and SCR Assembly 2144
Remove and Install Bellows Pipe Assembly 2154
Remove Bellows Pipe Assembly 2154
Install Bellows Pipe Assembly 2156
Remove and Install Fuel Tank Assembly 2161
Remove Fuel Tank Assembly 2161
Install Fuel Tank Assembly 2164
Remove and Install DEF Tank Assembly 2168
How to Remove DEF Tank Assembly 2168
How to Install DEF Tank Assembly 2174
Remove and Install DEF Tank Sensor Flange Assembly 2180
How to Remove DEF Tank Sensor Flange Assembly 2180
How to Install DEF Tank Sensor Flange Assembly 2181
Remove and Install DEF Tank Sensor 2185
Remove DEF Tank Sensor 2185
Install DEF Tank Sensor 2186
Remove and Install DEF Tank Strainer 2193
Remove DEF Tank Strainer 2193
Install DEF Tank Strainer 2194
Remove and Install SCR Assembly 2195
How to Remove SCR Assembly 2195
How to Install SCR Assembly 2199
Remove and Install KCCV Assembly 2203
Remove KCCV Assembly 2203
Install KCCV Assembly 2204
Remove and Install Turbo Charger Assembly 2205
How to Remove Turbo Charger Assembly 2205
How to Install Turbo Charger Assembly 2209
Remove and Install Exhaust Throttle Valve 2215
Remove Exhaust Throttle Valve 2215
Install Exhaust Throttle Valve 2219
Remove and Install DEF Mixing Tube 2225
Remove DEF Mixing Tube 2226
Install DEF Mixing Tube 2230
Remove and Install DEF Injector 2238
Remove DEF Injector 2238
Install DEF Injector 2241
Remove and Install DEF Pump 2245
Remove DEF Pump 2245
Install DEF Pump 2248
Remove and Install DEF Hose 2251
Remove DEF Hose 2251
Install DEF Hose 2259
Remove and Install Air Cleaner Assembly 2270
Remove Air Cleaner Assembly 2270
Install Air Cleaner Assembly 2271
Remove and Install Air Conditioner Compressor Assembly 2273
Remove Air Conditioner Compressor Assembly 2273
How to Install Air Conditioner Compressor Assembly 2274
Power Train 2276
Remove and Install Damper Assembly 2276
How to Remove Damper Assembly 2276
How to Install Damper Assembly 2277
Remove and Install HST Pump Assembly 2278
Remove HST Pump Assembly 2278
Install HST Pump Assembly 2281
Remove and Install HST Motor and Final Drive Assembly 2284
Remove HST Motor and Final Drive Assembly 2284
Install HST Motor and Final Drive Assembly 2286
Disassemble and Assemble Final Drive Assembly 2289
Disassemble Final Drive Assembly 2289
Assemble Final Drive Assembly 2295
Undercarriage and Frame 2304
Remove and Install Idler and Recoil Spring Assembly 2304
How to Remove Idler and Recoil Spring Assembly 2304
How to Install Idler and Recoil Spring Assembly 2304
Disassemble and Assemble Idler Assembly 2306
Disassemble Idler Assembly 2306
Assemble Idler Assembly 2308
Disassemble and Assemble Recoil Spring Assembly 2312
Disassemble Recoil Spring Assembly 2313
Assemble Recoil Spring Assembly 2314
Disassemble and Assemble Track Roller Assembly 2316
Disassemble Track Roller Assembly 2316
Assemble Track Roller Assembly 2318
Disassemble and Assemble Carrier Roller Assembly 2322
Disassemble Carrier Roller Assembly 2322
Assemble Carrier Roller Assembly 2323
Separate and Connect Track Assembly 2326
Separate Track Assembly (Standard) 2326
Install Track Assembly 2327
Separate and Connect PLUS Type Track Assembly 2330
Separate PLUS Type Track Assembly Generally 2330
Install PLUS Type Track Assembly 2330
Disassemble and Assemble Track Assembly Generally 2332
How to Disassemble Full Track Shoes Assembly 2333
How to Assemble Full Track Shoes Assembly 2335
Disassemble and Assemble PLUS Type Track Assembly Generally 2348
Disassemble PLUS Type Track Assembly Generally 2349
How to Assemble PLUS Type Track Shoes Assembly Generally 2350
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2366
Disassemble One Track Link Assembly in Field (Track Assembly) 2368
Assemble One Track Link Assembly in Field (Track Assembly) 2369
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2377
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2378
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2380
Hydraulic System 2384
Remove and Install Hydraulic Tank Assembly 2384
Remove Hydraulic Tank Assembly 2384
How to Install Hydraulic Tank Assembly 2389
Remove and Install Control Valve Assembly 2394
How to Remove Control Valve Assembly 2394
How to Install Control Valve Assembly 2396
Work Equipment 2399
Remove and Install Blade Assembly (Power Angle Power Tilt Dozer) 2399
How to Remove Blade Assembly (Power Angle Power Tilt Dozer) 2399
How to Install Blade Assembly (Power Angle Power Tilt Dozer) 2401
Remove and Install Work Equipment Assembly (Power Angle Power Tilt Dozer) 2404
How to Remove Work Equipment Assembly (Power Angle Power Tilt Dozer) 2404
How to Install Work Equipment Assembly (Power Angle Power Tilt Dozer) 2405
Disassemble and Assemble Work Equipment Cylinder Assembly 2407
How to Disassemble Work Equipment Cylinder Assembly 2408
How to Assemble Work Equipment Cylinder Assembly 2409
Remove and Install U-Frame Assembly 2413
Remove U-Frame Assembly 2413
Install U-Frame Assembly 2414
CAB Related Parts 2417
Remove and Install Operator Cab Assembly 2417
How to Remove Operator Cab Assembly 2417
Install Operator CAB Assembly 2422
Remove and Install Wiper Arm 2428
How to Remove Wiper Arm 2428
How to Install Wiper Arm 2429
Remove and Install Operator Cab Glass (Adhered Glass) 2431
Remove Operator CAB Glass (Adhered Glass) 2433
Install Operator CAB Glass (Adhered Glass) 2433
Remove and Install Air Conditioner Unit Assembly 2439
Remove Air Conditioner Unit Assembly 2439
Install Air Conditioner Unit Assembly 2445
Remove and Install Operator Seat 2453
Remove Operator’s Seat 2453
Install Operator’s Seat 2454
How to Remove and Install Seat Belt 2455
How to Remove Seat Belt 2455
How to Install Seatbelt 2455
Remove and Install Foot Heater Assembly 2457
Remove Foot Heater Assembly 2457
Install Foot Heater Assembly 2459
Disassemble and Assemble Foot Heater Assembly 2461
Disassemble Foot Heater Assembly 2461
Assemble Foot Heater Assembly 2462
Electrical System 2463
Remove and Install Engine Controller Assembly 2463
Remove Engine Controller Assembly 2463
Install Engine Controller Assembly 2466
Remove and Install HST Controller Assembly 2469
Remove HST Controller Assembly 2469
How to Install HST Controller Assembly 2470
Remove and Install Machine Monitor Assembly 2471
Remove Machine Monitor Assembly 2471
Install Machine Monitor Assembly 2472
Remove and Install Mass Air Flow and Temperature Sensor 2474
How to Remove Mass Air Flow and Temperature Sensor 2474
How to Install Mass Air Flow and Temperature Sensor 2476
Remove and Install KCCV Crankcase Pressure Sensor 2477
How to Remove KCCV Crankcase Pressure Sensor 2477
How to Install KCCV Crankcase Pressure Sensor 2478
Remove and Install SCR Temperature Sensor 2480
Remove SCR Temperature Sensor 2480
Install SCR Temperature Sensor 2482
Remove and Install Gateway Function Controller Assembly 2485
How to Remove Gateway Function Controller Assembly 2485
How to Install Gateway Function Controller Assembly 2486
Remove and Install Communication Terminal 2487
How to Remove Communication Terminal 2487
How to Install Communication Terminal 2490
60 Maintenance Standard 2493
Table of Contents 2494
Engine and Cooling System 2496
Maintenance Standard for Engine Mount 2496
Maintenance Standard for Damper 2497
Maintenance Standard for Cooling System 2498
Maintenance Standard for Cooling Fan Motor 2500
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 2502
Power Train 2503
Maintenance Standard for HST Pump 2503
Maintenance Standard for EPC Valve of HST Pump 2504
Maintenance Standard for Tow Receiving Valve of HST Pump 2505
Maintenance Standard for HST Charge Pump 2506
Maintenance Standard for HST Motor 2508
Maintenance Standard for Final Drive 2509
Maintenance Standard for Sprocket for Conventional Type Track Shoes: D37EX-24, D37PX-24 2511
Maintenance Standard for Sprocket for Conventional Type Track Shoes: D39EX-24, D39PX-24 2512
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes: D37EX-24, D37PX-24 2513
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes: D39EX-24, D39PX-24 2514
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D37EX-24, D37PX-24 2515
Maintenance Standard for Sprocket for PLUS Type Track Shoes: D39EX-24, D39PX-24 2517
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D37EX-24, D37PX-24 2519
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes: D39EX-24, D39PX-24 2520
Undercarriage and Frame 2521
Maintenance Standard for Track Frame and Idler Cushion 2521
Maintenance Standard for Track Shoe for Conventional Type Track Shoes: D37EX-24, D37PX-24 2524
Maintenance Standard for Track Shoe for Conventional Type Track Shoes: D39EX-24, D39PX-24 2526
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D37EX-24, D37PX-24 2528
Maintenance Standard for Track Shoe for Conventional PLUS Type Track Shoes: D39EX-24, D39PX-24 2530
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2532
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2534
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2536
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2538
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2540
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2542
Maintenance Standard for Conventional Type Track Shoes 2544
Maintenance Standard for PLUS Type Track Shoes 2548
Maintenance Standard for Single Shoes 2552
Hydraulic System 2553
Maintenance Standard for Hydraulic Tank 2553
Maintenance Standard for Work Equipment and Cooling Fan Pump 2554
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump 2555
Maintenance Standard for Control Valve 2557
Maintenance Standard for Ripper PPC Valve 2564
Maintenance Standard for 5-Spool EPC and Solenoid Valve 2566
Maintenance Standard for EPC Valve 2567
Maintenance Standard for Angle Control EPC Valve 2568
Work Equipment 2569
Maintenance Standard for Front Work Equipment 2569
Maintenance Standard for Cutting Edge and End Bit 2572
Maintenance Standard for Blade Lift Cylinder 2573
Maintenance Standard for Blade Tilt Cylinder 2574
Maintenance Standard for Blade Angle Cylinder 2575
Maintenance Standard for Fixed Multi-Shank Ripper 2576
Maintenance Standard for Ripper Lift Cylinder 2578
CAB Related Parts 2579
Maintenance Standard for CAB Mount 2579
Electrical System 2580
Maintenance Standard for Steering Electric Lever 2580
80 Appendix 2581
Table of Contents 2582
Precautions Before Work 2583
Air Conditioner System 2584
Precautions for Refrigerant 2584
Air Conditioner Component 2585
Specifications of Air Conditioner 2588
Structure and Function of Refrigeration Cycle 2589
Outline of Refrigeration Cycle 2590
Component Parts of Air Conditioner System 2592
Air Conditioner Unit 2592
Configuration Diagram of Air Conditioner Unit 2592
Function of Air Conditioner Unit 2593
Component Parts of Air Conditioner Unit 2594
Function of Evaporator as Air Conditioner Unit Component 2594
Function of Heater Core as Air Conditioner Unit Component 2594
Function of Thermostat as Air Conditioner Unit Component 2594
Structure of Expansion Valve as Air Conditioner Unit Component 2595
Function of Expansion Valve as Air Conditioner Unit Component 2595
Operate Expansion Valve as Air Conditioner Unit Component 2595
Function of Dual Pressure Switch 2596
Function of Pressure Switch 2596
Compressor 2597
Structure of Compressor 2597
Specifications of Compressor 2597
Function of Compressor 2597
Condenser 2598
Structure of Condenser 2598
Specifications of Condenser 2598
Function of Condenser 2599
Receiver Drier 2600
Structure of Receiver Dryer 2600
Specifications of Receiver Dryer 2600
Function of Receiver Dryer 2600
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2602
Circuit Diagram of Air Conditioner 2605
System Diagram of Air Conditioner 2606
Control Function of Air Conditioner 2607
Locations of Air Conditioner Parts and Layout of Connectors 2608
Examine Relay 2612
How to Examine Relay 2612
Air Conditioner Troubleshooting Chart 1 2614
Air Conditioner Troubleshooting Chart 2 2615
Information Shown in Troubleshooting Table 2618
Troubleshooting for Condenser Fan 2619
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2622
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2626
Troubleshooting for Temperature Control Function 2629
Troubleshooting by Gauge Pressure 2633
Connect Service Tool 2635
How to Connect Service Tool 2635
Precautions for Disconnection and Connection of Air Conditioner Piping 2636
Handle Compressor Oil 2638
90 Circuit Diagrams 2641
Table of Contents 2642
Hydraulic Circuit Diagram 2643
Symbols Used in Hydraulic Circuit Diagram 2643
Hydraulic Circuit Diagram (D37EX-24, D37PX-24, D39EX-24, D39PX-24) 2647
Electrical Circuit Diagram 2649
Symbols Used in Electric Circuit Diagram 2649
Electrical Circuit Diagram (1/13) 2653
Electrical Circuit Diagram (2/13) 2655
Electrical Circuit Diagram (3/13) 2657
Electrical Circuit Diagram (4/13) 2659
Electrical Circuit Diagram (5/13) 2661
Electrical Circuit Diagram (6/13) 2663
Electrical Circuit Diagram (7/13) 2665
Electrical Circuit Diagram (8/13) 2667
Electrical Circuit Diagram (9/13) 2669
Electrical Circuit Diagram (10/13) 2671
Electrical Circuit Diagram (11/13) 2673
Electrical Circuit Diagram (12/13) 2675
Electrical Circuit Diagram (13/13) 2677
INDEX 2679

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24