Komatsu D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Bulldozer Shop Manual PDF

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Komatsu D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Bulldozer Shop Manual SEN06593-08 – PDF DOWNLOAD

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Komatsu D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Bulldozer Shop Manual SEN06593-08 – PDF DOWNLOAD 

Language : English
Pages : 2950
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Bulldozer Shop Manual SEN06593-08 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EXi-85001 and up
D37PXi-85001 and up
D39EXi-95001 and up
D39PXi-95001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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.

TABLE OF CONTENTS:

Komatsu D37EXi-24 D37PXi-24 D39EXi-24 D39PXi-24 Bulldozer Shop Manual SEN06593-08 – PDF DOWNLOAD 

SERIAL NUMBERS
D37EXi-85001 and up
D37PXi-85001 and up
D39EXi-95001 and up
D39PXi-95001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D37EXI-24 104
SPECIFICATION DRAWING: D37PXI-24 105
SPECIFICATION DRAWING: D39EXI-24 106
SPECIFICATION DRAWING: D39PXI-24 107
SPECIFICATIONS 109
SPECIFICATIONS: D37EXI-24 109
SPECIFICATIONS: D37PXI-24 114
SPECIFICATIONS: D39EXI-24 118
SPECIFICATIONS: D39PXI-24 123
WEIGHT TABLE 131
WEIGHT TABLE: D37EXI-24 132
WEIGHT TABLE: D37PXI-24 134
WEIGHT TABLE: D39EXI-24 136
WEIGHT TABLE: D39PXI-24 138
TABLE OF FUEL, COOLANT, AND LUBRICANTS 142
10 STRUCTURE AND FUNCTION 143
CONTENTS 144
ABBREVIATION LIST 147
UREA SCR SYSTEM 153
LAYOUT DRAWING OF UREA SCR SYSTEM 153
UREA SCR SYSTEM DIAGRAM 155
FUNCTION OF UREA SCR SYSTEM 156
FUNCTION OF AdBlue/DEF SYSTEM 156
INDUCEMENT STRATEGY 158
COMPONENT PARTS OF UREA SCR SYSTEM 172
AdBlue/DEF MIXING TUBE 172
SCR ASSEMBLY 173
AdBlue/DEF TANK 175
AdBlue/DEF PUMP 177
AdBlue/DEF INJECTOR 178
AdBlue/DEF HOSE 179
AdBlue/DEF TANK HEATING VALVE 180
BOOT-UP SYSTEM 181
LAYOUT DRAWING OF BOOT-UP SYSTEM 181
SYSTEM OPERATING LAMP SYSTEM 182
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 182
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 183
BATTERY DISCONNECT SWITCH 184
FUNCTION OF BATTERY DISCONNECT SWITCH 184
ENGINE SYSTEM 185
LAYOUT DRAWING OF ENGINE SYSTEM 185
ENGINE CONTROL SYSTEM 187
LAYOUT OF ENGINE CONTROL SYSTEM 187
ENGINE CONTROL SYSTEM DIAGRAM 189
FUNCTION OF ENGINE CONTROL SYSTEM 191
AUTOMATIC IDLE STOP SYSTEM 193
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 193
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 194
COMPONENT PARTS OF ENGINE SYSTEM 196
DAMPER 196
VARIABLE FLOW TURBOCHARGER 197
EGR SYSTEM 200
EGR VALVE 203
EGR COOLER 205
KCCV SYSTEM 207
KCCV VENTILATOR 210
EXHAUST THROTTLE VALVE 212
KDOC 213
COOLING SYSTEM 216
LAYOUT DRAWING OF COOLING SYSTEM 216
SPECIFICATIONS OF COOLING SYSTEM 217
COOLING FAN CONTROL SYSTEM 218
COOLING FAN CONTROL SYSTEM DIAGRAM 218
FUNCTION OF COOLING FAN CONTROL SYSTEM 219
COMPONENT PARTS OF COOLING SYSTEM 221
COOLING FAN MOTOR 221
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 226
HYDRAULIC OIL COOLER BYPASS VALVE 228
HST CHARGE SAFETY VALVE 229
CONTROL SYSTEM 231
LAYOUT DRAWING OF CONTROL SYSTEM 231
MACHINE MONITOR SYSTEM 232
MACHINE MONITOR SYSTEM DIAGRAM 232
FUNCTION OF MACHINE MONITOR SYSTEM 233
KOMTRAX SYSTEM 234
KOMTRAX SYSTEM DIAGRAM 234
FUNCTION OF KOMTRAX SYSTEM 235
COMPONENT PARTS OF CONTROL SYSTEM 236
MACHINE MONITOR 236
KOMTRAX TERMINAL 251
HST CONTROLLER 253
ENGINE CONTROLLER 257
FUEL CONTROL DIAL 264
DECELERATOR AND BRAKE POTENTIOMETER 266
HYDRAULIC SYSTEM 268
LAYOUT DRAWING OF HYDRAULIC SYSTEM 268
CLSS 269
STRUCTURE OF CLSS 269
FUNCTION OF CLSS 270
COMPONENT PARTS OF HYDRAULIC SYSTEM 272
HYDRAULIC TANK 272
WORK EQUIPMENT AND COOLING FAN PUMP 274
LS VALVE 281
PC VALVE 282
CONTROL VALVE 285
POWER TRAIN SYSTEM 306
LAYOUT DRAWING OF HST SYSTEM 306
OPERATION OF HST SYSTEM 307
STEERING AND BRAKE CONTROL SYSTEM 309
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 309
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 310
HST CONTROL SYSTEM 311
HST CONTROL SYSTEM DIAGRAM 311
GEAR SHIFT CONTROL FUNCTION 312
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 316
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 317
DECELERATION AND BRAKE CONTROL FUNCTION 319
GEAR SHIFT CONTROL FUNCTION BY LOAD 321
TURN CONTROL FUNCTION 322
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 323
PARKING BRAKE CONTROL SYSTEM 324
PARKING BRAKE CONTROL SYSTEM DIAGRAM 324
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 325
OPERATION OF PARKING BRAKE CONTROL SYSTEM 326
COMPONENT PARTS OF POWER TRAIN SYSTEM 327
HST PUMP 327
HST CHARGE PUMP 344
HST MOTOR 345
FINAL DRIVE 357
ELECTRIC STEERING CONTROL LEVER 361
WORK EQUIPMENT SYSTEM 363
WORK EQUIPMENT CONTROL 363
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 363
FUNCTION OF WORK EQUIPMENT CONTROL 365
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 367
LAYOUT OF FIXED MULTI-SHANK RIPPER 368
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 369
RIPPER PPC VALVE 369
5-PORT VALVE OF EPC AND SOLENOID 373
PILOT CIRCUIT ACCUMULATOR 380
ANGLE CONTROL EPC VALVE 381
PISTON VALVE 384
ELECTRIC BLADE CONTROL LEVER 385
ICT SYSTEM 387
LAYOUT DRAWING OF ICT SYSTEM 387
ICT CONTROL SYSTEM DIAGRAM 389
BLADE CONTROL SYSTEM 391
FUNCTION OF BLADE CONTROL SYSTEM 392
LEVELING MODE SYSTEM DIAGRAM 394
FUNCTION OF LEVELING MODE 396
OPERATION OF LEVELING MODE 397
DOZING MODE SYSTEM DIAGRAM 398
FUNCTION OF DOZING MODE 399
OPERATION OF DOZING MODE 400
SMOOTH START SYSTEM 401
SMOOTH START SYSTEM DIAGRAM 401
FUNCTION OF SMOOTH START SYSTEM 402
OPERATION OF SMOOTH START SYSTEM 403
SLIP CONTROL SYSTEM 404
SLIP CONTROL SYSTEM DIAGRAM 404
FUNCTION OF SLIP CONTROL SYSTEM 405
OPERATION OF SLIP CONTROL SYSTEM 406
ASSIST CONTROL SYSTEM 407
ASSIST CONTROL SYSTEM DIAGRAM 407
FUNCTION OF ASSIST CONTROL SYSTEM 408
OPERATION OF ASSIST CONTROL SYSTEM 409
HST SPEED RANGE CONTROL SYSTEM 410
HST SPEED RANGE CONTROL SYSTEM DIAGRAM 410
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM 411
OPERATION OF HST SPEED RANGE CONTROL SYSTEM 412
COMPONENT PARTS OF ICT SYSTEM 413
ICT SENSOR CONTROLLER 413
CONTROL BOX 417
GNSS RECEIVER 420
GNSS ANTENNA 424
IMU SENSOR 425
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 429
STROKE SENSOR FOR BLADE TILT CYLINDER 432
STROKE SENSOR FOR BLADE ANGLE CYLINDER 434
UNDERCARRIAGE AND FRAME 436
MAIN FRAME 436
STRUCTURE OF MAIN FRAME 436
TRACK FRAME AND IDLER CUSHION 437
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 437
FUNCTION OF TRACK FRAME AND IDLER CUSHION 439
WORK EQUIPMENT 440
STRUCTURE OF FRONT WORK EQUIPMENT 440
STRUCTURE OF FIXED MULTI-SHANK RIPPER 441
CAB AND ITS ATTACHMENTS 442
ROPS CAB 442
STRUCTURE OF ROPS CAB 442
FUNCTION OF ROPS CAB 443
CAB MOUNT 444
STRUCTURE OF CAB MOUNT 444
FUNCTION OF CAB MOUNT 445
20 STANDARD VALUE TABLE 447
CONTENTS 448
ABBREVIATION LIST 449
STANDARD VALUE TABLE FOR ENGINE 455
STANDARD VALUE TABLE FOR ENGINE: D37EXI-24 455
STANDARD VALUE TABLE FOR ENGINE: D37PXI-24 458
STANDARD VALUE TABLE FOR ENGINE: D39EXI-24 461
STANDARD VALUE TABLE FOR ENGINE: D39PXI-24 464
STANDARD VALUE TABLE FOR MACHINE 467
STANDARD VALUE TABLE FOR MACHINE: D37EXI-24 467
STANDARD VALUE TABLE FOR MACHINE: D37PXI-24 484
STANDARD VALUE TABLE FOR MACHINE: D39EXI-24 499
STANDARD VALUE TABLE FOR MACHINE: D39PXI-24 516
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 531
30 TESTING AND ADJUSTING 533
CONTENTS 534
ABBREVIATION LIST 538
RELATED INFORMATION ON TESTING AND ADJUSTING 544
TOOLS FOR TESTING AND ADJUSTING 544
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 551
ENGINE AND COOLING SYSTEM 554
TEST ENGINE SPEED 554
METHOD FOR TESTING ENGINE SPEED 554
TEST EXHAUST GAS COLOR 556
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 556
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 557
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 558
METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 558
TEST AND ADJUST VALVE CLEARANCE 560
METHOD FOR TESTING VALVE CLEARANCE 560
METHOD FOR ADJUSTING VALVE CLEARANCE 561
TEST COMPRESSION PRESSURE 562
METHOD FOR TESTING COMPRESSION PRESSURE 562
TEST BLOWBY PRESSURE 565
METHOD FOR TESTING BLOWBY PRESSURE 565
TEST ENGINE OIL PRESSURE 567
METHOD FOR TESTING ENGINE OIL PRESSURE 567
TEST FUEL PRESSURE 569
METHOD FOR TESTING FUEL PRESSURE 569
TEST FUEL RETURN RATE AND LEAKAGE 571
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 572
BLEEDING AIR FROM FUEL SYSTEM 576
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 576
TEST FUEL CIRCUIT FOR LEAKAGE 578
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 578
HANDLE CYLINDER CUT-OUT MODE OPERATION 580
HANDLE NO-INJECTION CRANKING OPERATION 581
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 582
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 582
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 583
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 583
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 584
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 584
TEST ALTERNATOR BELT 585
METHOD FOR TESTING ALTERNATOR BELT 585
TEST AUTOMATIC TENSIONER 586
METHOD FOR TESTING AUTOMATIC TENSIONER 586
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 588
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 588
TEST SCR RELATED FUNCTIONS 594
TEST AdBlue/DEF PUMP RAISED PRESSURE 598
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 601
TEST AdBlue/DEF LINE HEATER RELAY 1 606
TEST AdBlue/DEF LINE HEATER RELAY 2 609
TEST AdBlue/DEF PUMP HEATER RELAY 612
TEST AdBlue/DEF TANK HEATER VALVE 616
TEST DENITRATION EFFICIENCY OF SCR 620
CLEAN AdBlue/DEF TANK 623
METHOD FOR CLEANING AdBlue/DEF TANK 623
CLEAN AdBlue/DEF TANK MOUNTING PORTION 628
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 628
POWER TRAIN 629
TEST AND ADJUST HST OIL PRESSURE 629
METHOD FOR TESTING HST OIL PRESSURE 629
METHOD FOR ADJUSTING HST OIL PRESSURE 632
BLEED AIR FROM HST PUMP 634
METHOD FOR BLEEDING AIR FROM HST PUMP 634
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP 634
TEST OUTLET PRESSURE OF SOLENOID VALVE 636
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 636
TEST TRAVEL DEVIATION 641
METHOD FOR TESTING TRAVEL DEVIATION 641
TEST BRAKE PERFORMANCE SIMPLY 643
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 643
TEST AND ADJUST DECELERATION/BRAKE PEDAL 644
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 644
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 646
ADJUST PARKING BRAKE LEVER 648
METHOD FOR ADJUSTING PARKING BRAKE LEVER 648
MOVE MACHINE WHEN IT CANNOT TRAVEL 650
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 650
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 652
UNDERCARRIAGE AND FRAME 654
ADJUST IDLER CLEARANCE 654
METHOD FOR ADJUSTING IDLER CLEARANCE 654
TESTING SPROCKET WEAR 655
METHOD FOR TESTING SPROCKET WEAR 655
TEST AND ADJUST TRACK TENSION 656
METHOD FOR TESTING TRACK TENSION 656
METHOD FOR ADJUSTING TRACK TENSION 656
HYDRAULIC SYSTEM 658
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 658
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 658
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 659
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 659
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 660
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 662
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 662
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 663
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 664
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 664
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 666
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 666
TEST COOLING FAN SPEED 667
METHOD FOR TESTING COOLING FAN SPEED 667
TEST COOLING FAN CIRCUIT OIL PRESSURE 668
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 668
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 671
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 672
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 672
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 674
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 674
WORK EQUIPMENT 675
ADJUST WORK EQUIPMENT LOCK LEVER 675
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 675
ELECTRICAL SYSTEM 677
SET AND OPERATE MACHINE MONITOR 677
OPERATOR MODE 681
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 681
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 681
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 682
CHECKING FUNCTION OF SERVICE METER 682
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 682
SERVICE MODE 685
METHOD FOR OPERATING SERVICE MODE 685
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 687
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 693
ABNORMALITY RECORD MENU 704
METHOD FOR CONFIRMING MAINTENANCE RECORD 708
METHOD FOR OPERATING MAINTENANCE MODE SETTING 709
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 713
DEFAULT MENU 714
DIAGNOSTIC TESTS MENU 721
ADJUSTMENT MENU 729
METHOD FOR PERFORMING NO-INJECTION CRANKING 798
KOMTRAX SETTINGS MENU 801
METHOD FOR DISPLAYING SERVICE MESSAGE 803
METHOD FOR STARTING UP KOMTRAX TERMINAL 805
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 810
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 810
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 816
ADJUST REARVIEW CAMERA ANGLE 818
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 818
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 819
HANDLE BATTERY DISCONNECT SWITCH 820
TEST DIODES 821
METHOD FOR TESTING DIODE USING DIGITAL TESTER 821
METHOD FOR TESTING DIODE USING ANALOG TESTER 821
ICT SYSTEM 822
SET AND OPERATE CONTROL BOX 822
TEST AND ADJUST ICT RELATED DEVICES 823
CALIBRATE BLADE EDGE POSITION 826
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION) 827
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) 830
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) 835
CALIBRATE IMU SENSOR 849
METHOD FOR CALIBRATING IMU SENSOR 849
RESET CYLINDER STROKE END 856
RESET LIFT CYLINDER STROKE END 856
RESET TILT CYLINDER STROKE END 857
RESET ANGLE CYLINDER STROKE END 857
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 859
CHECK BLADE ELEVATION, ADJUST 861
CHECK BLADE ELEVATION (FOR OLD CONTROL BOX) 861
CHECK BLADE ELEVATION (FOR NEW CONTROL BOX) 863
ADJUST BLADE ELEVATION (FOR OLD CONTROL BOX) 866
ADJUST BLADE ELEVATION (FOR NEW CONTROL BOX) 867
TEST STROKE SENSOR FOR LIFT CYLINDER 869
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 869
TEST STROKE SENSOR FOR TILT CYLINDER 871
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER 871
TEST STROKE SENSOR FOR ANGLE CYLINDER 873
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER 873
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 875
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER 875
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER 876
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED 877
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED 877
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 880
Pm CLINIC 883
Pm CLINIC SERVICE 883
Pm CLINIC CHECK SHEET: D37EXI-24 885
Pm CLINIC CHECK SHEET: D37PXI-24 893
Pm CLINIC CHECK SHEET: D39EXI-24 901
Pm CLINIC CHECK SHEET: D39PXI-24 908
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37EXI-24 915
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37PXI-24 922
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39EXI-24 929
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39PXI-24 936
40 TROUBLESHOOTING 945
CONTENTS 946
ABBREVIATION LIST 957
RELATED INFORMATION ON TROUBLESHOOTING 963
GENERAL TROUBLESHOOTING POINTS 963
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 964
SEQUENCE OF EVENTS IN TROUBLESHOOTING 976
CHECKS BEFORE TROUBLESHOOTING 978
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 980
WALK-AROUND CHECK 980
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 982
CHECK FUEL LEVEL AND TYPE 982
CHECK IMPURE INGREDIENT IN FUEL 982
CHECK AdBule/DEF LEVEL AND TYPE 983
CHECK FUEL PREFILTER 983
CHECK MAIN FILTER 985
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 987
CHECK COOLANT LEVEL (RESERVOIR TANK) 988
CHECK CLOGGING OF AIR CLEANER 988
CLEAN OUTER ELEMENT 989
REPLACE ELEMENT 990
CHECK HYDRAULIC OIL LEVEL 991
CHECK HYDRAULIC OIL STRAINER 992
CHECK OIL LEVEL IN FINAL DRIVE CASE 996
BLEED AIR FROM FUEL SYSTEM 996
BLEED AIR FROM HYDRAULIC SYSTEM 996
METHOD FOR CHECKING ELECTRIC EQUIPMENT 996
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 1003
PROCEDURE FOR TROUBLESHOOTING 1010
SYMPTOM AND TROUBLESHOOTING NUMBERS 1013
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1018
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1020
CONNECTORS LIST AND LAYOUT 1023
CONNECTOR CONTACT IDENTIFICATION 1040
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1080
FUSE LOCATION TABLE 1086
PRECAUTIONS FOR REPLACING KDOC 1090
FAILURE CODES TABLE 1091
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1111
FAILURE CODE [6091NX] 1111
FAILURE CODE [989L00] 1113
FAILURE CODE [989M00] 1114
FAILURE CODE [989N00] 1115
FAILURE CODE [A1U0N3] 1116
FAILURE CODE [A1U0N4] 1118
FAILURE CODE [A900FR] 1120
FAILURE CODE [A900N6] 1121
FAILURE CODE [A900NY] 1122
FAILURE CODE [AA10NX] 1123
FAILURE CODE [AB00KE] 1125
FAILURE CODE [AQ10MB] 1127
FAILURE CODE [AQ10N3] 1129
FAILURE CODE [AS00R2] 1130
FAILURE CODE [AS00R3] 1131
FAILURE CODE [AS00R4] 1132
FAILURE CODE [AS00R5] 1133
FAILURE CODE [AS00R6] 1134
FAILURE CODE [AS00ZK] 1135
FAILURE CODE [AS10KM] 1136
FAILURE CODE [AS10NR] 1137
FAILURE CODE [AS10NT] 1138
FAILURE CODE [AU10QA] 1139
FAILURE CODE [B@BAZG] 1140
FAILURE CODE [B@BCNS] 1141
FAILURE CODE [B@CRNS] 1142
FAILURE CODE [B@CRZG] 1143
FAILURE CODE [CA115] 1144
FAILURE CODE [CA122] 1145
FAILURE CODE [CA123] 1147
FAILURE CODE [CA131] 1149
FAILURE CODE [CA132] 1151
FAILURE CODE [CA144] 1153
FAILURE CODE [CA145] 1155
FAILURE CODE [CA153] 1157
FAILURE CODE [CA154] 1160
FAILURE CODE [CA187] 1163
FAILURE CODE [CA221] 1165
FAILURE CODE [CA222] 1167
FAILURE CODE [CA227] 1169
FAILURE CODE [CA234] 1170
FAILURE CODE [CA238] 1171
FAILURE CODE [CA239] 1173
FAILURE CODE [CA249] 1175
FAILURE CODE [CA256] 1177
FAILURE CODE [CA271] 1179
FAILURE CODE [CA272] 1181
FAILURE CODE [CA322] 1183
FAILURE CODE [CA324] 1185
FAILURE CODE [CA331] 1187
FAILURE CODE [CA332] 1189
FAILURE CODE [CA343] 1191
FAILURE CODE [CA351] 1192
FAILURE CODE [CA352] 1193
FAILURE CODE [CA356] 1196
FAILURE CODE [CA357] 1198
FAILURE CODE [CA386] 1200
FAILURE CODE [CA435] 1201
FAILURE CODE [CA441] 1203
FAILURE CODE [CA442] 1205
FAILURE CODE [CA449] 1206
FAILURE CODE [CA451] 1207
FAILURE CODE [CA452] 1209
FAILURE CODE [CA515] 1211
FAILURE CODE [CA516] 1213
FAILURE CODE [CA553] 1215
FAILURE CODE [CA555] 1216
FAILURE CODE [CA556] 1217
FAILURE CODE [CA559] 1218
FAILURE CODE [CA689] 1222
FAILURE CODE [CA691] 1224
FAILURE CODE [CA692] 1226
FAILURE CODE [CA697] 1228
FAILURE CODE [CA698] 1229
FAILURE CODE [CA731] 1230
FAILURE CODE [CA778] 1232
FAILURE CODE [CA1117] 1237
FAILURE CODE [CA1664] 1238
FAILURE CODE [CA1669] 1240
FAILURE CODE [CA1673] 1241
FAILURE CODE [CA1677] 1242
FAILURE CODE [CA1678] 1243
FAILURE CODE [CA1682] 1244
FAILURE CODE [CA1683] 1249
FAILURE CODE [CA1684] 1251
FAILURE CODE [CA1686] 1253
FAILURE CODE [CA1691] 1254
FAILURE CODE [CA1694] 1256
FAILURE CODE [CA1695] 1258
FAILURE CODE [CA1696] 1259
FAILURE CODE [CA1712] 1261
FAILURE CODE [CA1713] 1264
FAILURE CODE [CA1714] 1266
FAILURE CODE [CA1715] 1267
FAILURE CODE [CA1776] 1268
FAILURE CODE [CA1777] 1271
FAILURE CODE [CA1843] 1274
FAILURE CODE [CA1844] 1276
FAILURE CODE [CA1885] 1279
FAILURE CODE [CA1887] 1281
FAILURE CODE [CA1896] 1283
FAILURE CODE [CA1938] 1284
FAILURE CODE [CA1942] 1286
FAILURE CODE [CA1961] 1287
FAILURE CODE [CA2185] 1288
FAILURE CODE [CA2186] 1290
FAILURE CODE [CA2249] 1292
FAILURE CODE [CA2272] 1293
FAILURE CODE [CA2311] 1296
FAILURE CODE [CA2349] 1297
FAILURE CODE [CA2353] 1299
FAILURE CODE [CA2357] 1301
FAILURE CODE [CA2555] 1302
FAILURE CODE [CA2556] 1304
FAILURE CODE [CA2636] 1306
FAILURE CODE [CA2637] 1309
FAILURE CODE [CA2765] 1311
FAILURE CODE [CA2771] 1312
FAILURE CODE [CA2976] 1318
FAILURE CODE [CA3142] 1320
FAILURE CODE [CA3143] 1321
FAILURE CODE [CA3144] 1322
FAILURE CODE [CA3146] 1324
FAILURE CODE [CA3147] 1325
FAILURE CODE [CA3148] 1326
FAILURE CODE [CA3151] 1328
FAILURE CODE [CA3165] 1334
FAILURE CODE [CA3229] 1336
FAILURE CODE [CA3231] 1338
FAILURE CODE [CA3232] 1340
FAILURE CODE [CA3235] 1344
FAILURE CODE [CA3239] 1346
FAILURE CODE [CA3241] 1349
FAILURE CODE [CA3242] 1352
FAILURE CODE [CA3251] 1355
FAILURE CODE [CA3313] 1357
FAILURE CODE [CA3314] 1358
FAILURE CODE [CA3315] 1359
FAILURE CODE [CA3419] 1361
FAILURE CODE [CA3421] 1363
FAILURE CODE [CA3497] 1365
FAILURE CODE [CA3498] 1366
FAILURE CODE [CA3543] 1367
FAILURE CODE [CA3545] 1373
FAILURE CODE [CA3547] 1375
FAILURE CODE [CA3558] 1376
FAILURE CODE [CA3559] 1378
FAILURE CODE [CA3562] 1380
FAILURE CODE [CA3563] 1382
FAILURE CODE [CA3567] 1385
FAILURE CODE [CA3568] 1388
FAILURE CODE [CA3571] 1393
FAILURE CODE [CA3572] 1395
FAILURE CODE [CA3574] 1397
FAILURE CODE [CA3575] 1399
FAILURE CODE [CA3577] 1401
FAILURE CODE [CA3578] 1403
FAILURE CODE [CA3582] 1405
FAILURE CODE [CA3583] 1412
FAILURE CODE [CA3596] 1414
FAILURE CODE [CA3649] 1417
FAILURE CODE [CA3681] 1419
FAILURE CODE [CA3682] 1424
FAILURE CODE [CA3713] 1429
FAILURE CODE [CA3717] 1432
FAILURE CODE [CA3718] 1433
FAILURE CODE [CA3724] 1434
FAILURE CODE [CA3725] 1435
FAILURE CODE [CA3748] 1438
FAILURE CODE [CA3755] 1441
FAILURE CODE [CA3866] 1443
FAILURE CODE [CA3867] 1447
FAILURE CODE [CA3868] 1450
FAILURE CODE [CA3899] 1454
FAILURE CODE [CA3911] 1456
FAILURE CODE [CA3912] 1460
FAILURE CODE [CA3918] 1462
FAILURE CODE [CA3921] 1464
FAILURE CODE [CA3928] 1465
FAILURE CODE [CA3932] 1466
FAILURE CODE [CA3933] 1468
FAILURE CODE [CA3934] 1470
FAILURE CODE [CA3935] 1473
FAILURE CODE [CA3936] 1475
FAILURE CODE [CA4152] 1477
FAILURE CODE [CA4155] 1481
FAILURE CODE [CA4156] 1484
FAILURE CODE [CA4157] 1487
FAILURE CODE [CA4159] 1489
FAILURE CODE [CA4164] 1490
FAILURE CODE [CA4165] 1492
FAILURE CODE [CA4166] 1494
FAILURE CODE [CA4168] 1495
FAILURE CODE [CA4169] 1498
FAILURE CODE [CA4171] 1500
FAILURE CODE [CA4249] 1504
FAILURE CODE [CA4251] 1506
FAILURE CODE [CA4261] 1508
FAILURE CODE [CA4277] 1511
FAILURE CODE [CA4281] 1515
FAILURE CODE [CA4459] 1519
FAILURE CODE [CA4461] 1522
FAILURE CODE [CA4533] 1525
FAILURE CODE [CA4534] 1526
FAILURE CODE [CA4731] 1527
FAILURE CODE [CA4732] 1528
FAILURE CODE [CA4739] 1529
FAILURE CODE [CA4768] 1530
FAILURE CODE [CA4769] 1532
FAILURE CODE [CA4842] 1535
FAILURE CODE [CA4952] 1539
FAILURE CODE [CA5115] 1541
FAILURE CODE [CA5179] 1544
FAILURE CODE [CA5181] 1546
FAILURE CODE [CA5271] 1548
FAILURE CODE [CA5272] 1550
FAILURE CODE [CA5273] 1552
FAILURE CODE [CA5274] 1554
FAILURE CODE [CA5275] 1555
FAILURE CODE [CA5276] 1557
FAILURE CODE [CA5277] 1559
FAILURE CODE [CA5387] 1560
FAILURE CODE [CA5388] 1562
FAILURE CODE [CA5389] 1564
FAILURE CODE [CA5391] 1566
FAILURE CODE [CA5392] 1570
FAILURE CODE [CA5393] 1571
FAILURE CODE [CA5394] 1574
FAILURE CODE [CA5395] 1577
FAILURE CODE [CA5396] 1580
FAILURE CODE [CA5631] 1581
FAILURE CODE [CA5938] 1583
FAILURE CODE [D130KA] 1585
FAILURE CODE [D130KB] 1587
FAILURE CODE [D130KY] 1589
FAILURE CODE [D19JKZ] 1591
FAILURE CODE [D811MC] 1594
FAILURE CODE [D862KA] 1595
FAILURE CODE [D8ALKA] 1596
FAILURE CODE [D8ALKB] 1598
FAILURE CODE [D8AQKR] 1600
FAILURE CODE [DAF0MB] 1603
FAILURE CODE [DAF0MC] 1604
FAILURE CODE [DAF8KB] 1605
FAILURE CODE [DAF9KQ] 1607
FAILURE CODE [DAFGMC] 1608
FAILURE CODE [DAFLKA] 1609
FAILURE CODE [DAFLKB] 1611
FAILURE CODE [DAFQKR] 1613
FAILURE CODE [DAJ000] 1617
FAILURE CODE [DAJ0KQ] 1618
FAILURE CODE [DAJ0KT] 1619
FAILURE CODE [DAJ0MC] 1620
FAILURE CODE [DAJ1KK] 1621
FAILURE CODE [DAJ2KK] 1623
FAILURE CODE [DAJ5KK] 1625
FAILURE CODE [DAJ6KK] 1628
FAILURE CODE [DAJLKA] 1630
FAILURE CODE [DAJLKB] 1632
FAILURE CODE [DAJPMA] 1634
FAILURE CODE [DAJQKR] 1635
FAILURE CODE [DAJRKR] 1639
FAILURE CODE [DB2QKR] 1643
FAILURE CODE [DB2RKR] 1647
FAILURE CODE [DBR0KT] 1651
FAILURE CODE [DBR0MC] 1652
FAILURE CODE [DBR1KK] 1653
FAILURE CODE [DBR2KK] 1656
FAILURE CODE [DBR5KK] 1659
FAILURE CODE [DBRLKA] 1661
FAILURE CODE [DBRLKB] 1663
FAILURE CODE [DBRPMA] 1665
FAILURE CODE [DBRQKR] 1666
FAILURE CODE [DBRRKR] 1670
FAILURE CODE [DBTSKR] 1674
FAILURE CODE [DBUTKA] 1676
FAILURE CODE [DD12KA] 1677
FAILURE CODE [DD12KB] 1679
FAILURE CODE [DD13KA] 1681
FAILURE CODE [DD13KB] 1683
FAILURE CODE [DD14KA] 1685
FAILURE CODE [DD14KB] 1687
FAILURE CODE [DDKAKA] 1689
FAILURE CODE [DDKAKB] 1691
FAILURE CODE [DDKFL4] 1693
FAILURE CODE [DDKGL4] 1695
FAILURE CODE [DDKHKA] 1697
FAILURE CODE [DDKHKB] 1699
FAILURE CODE [DDKQKA] 1701
FAILURE CODE [DDKQKB] 1703
FAILURE CODE [DDKRKA] 1705
FAILURE CODE [DDKRKB] 1707
FAILURE CODE [DDKSKA] 1709
FAILURE CODE [DDKSKB] 1711
FAILURE CODE [DDNLKA] 1713
FAILURE CODE [DDNLKB] 1715
FAILURE CODE [DDP6KA] 1717
FAILURE CODE [DDP6KB] 1719
FAILURE CODE [DDP6MA] 1721
FAILURE CODE [DDU1FS] 1723
FAILURE CODE [DDU1KA] 1725
FAILURE CODE [DDU1KY] 1727
FAILURE CODE [DFA4KX] 1729
FAILURE CODE [DFA4KZ] 1730
FAILURE CODE [DFA4L8] 1731
FAILURE CODE [DFA5KA] 1732
FAILURE CODE [DFA5KB] 1734
FAILURE CODE [DFA6KA] 1736
FAILURE CODE [DFA6KB] 1738
FAILURE CODE [DFA7KX] 1740
FAILURE CODE [DFA7KZ] 1741
FAILURE CODE [DFA7L8] 1742
FAILURE CODE [DFA8KA] 1743
FAILURE CODE [DFA8KB] 1745
FAILURE CODE [DFA9KA] 1747
FAILURE CODE [DFA9KB] 1749
FAILURE CODE [DGS1KA] 1751
FAILURE CODE [DGS1KX] 1753
FAILURE CODE [DH21KA] 1755
FAILURE CODE [DH21KB] 1757
FAILURE CODE [DHA4KA] 1758
FAILURE CODE [DHH7KA] 1760
FAILURE CODE [DHH7KB] 1762
FAILURE CODE [DHH8KA] 1764
FAILURE CODE [DHH8KB] 1766
FAILURE CODE [DHH9KA] 1768
FAILURE CODE [DHH9KB] 1770
FAILURE CODE [DHHAKA] 1772
FAILURE CODE [DHHAKB] 1774
FAILURE CODE [DK30KA] 1776
FAILURE CODE [DK30KB] 1778
FAILURE CODE [DK30KX] 1780
FAILURE CODE [DK30KZ] 1781
FAILURE CODE [DK30L8] 1782
FAILURE CODE [DK31KA] 1785
FAILURE CODE [DK31KB] 1787
FAILURE CODE [DK40KA] 1789
FAILURE CODE [DK40KB] 1791
FAILURE CODE [DK55KX] 1793
FAILURE CODE [DK55KZ] 1794
FAILURE CODE [DK55L8] 1795
FAILURE CODE [DK56KA] 1797
FAILURE CODE [DK56KB] 1799
FAILURE CODE [DK57KA] 1801
FAILURE CODE [DK57KB] 1803
FAILURE CODE [DK80KA] 1805
FAILURE CODE [DKS0L8] 1807
FAILURE CODE [DKS1KA] 1808
FAILURE CODE [DKS1KB] 1810
FAILURE CODE [DKS2KA] 1811
FAILURE CODE [DKS2KB] 1813
FAILURE CODE [DKS3KA] 1814
FAILURE CODE [DKS3KB] 1816
FAILURE CODE [DKS3MB] 1817
FAILURE CODE [DKS4L8] 1819
FAILURE CODE [DKS5KA] 1820
FAILURE CODE [DKS5KB] 1822
FAILURE CODE [DKS6KA] 1823
FAILURE CODE [DKS6KB] 1825
FAILURE CODE [DKS7MB] 1826
FAILURE CODE [DKSCL8] 1827
FAILURE CODE [DKSDKA] 1828
FAILURE CODE [DKSDKB] 1830
FAILURE CODE [DKSEKA] 1831
FAILURE CODE [DKSEKB] 1833
FAILURE CODE [DKSFKA] 1834
FAILURE CODE [DKSFKB] 1836
FAILURE CODE [DKSFMB] 1837
FAILURE CODE [DLM0KX] 1838
FAILURE CODE [DLM0MA] 1839
FAILURE CODE [DLM1KA] 1840
FAILURE CODE [DLM1KB] 1842
FAILURE CODE [DLM1MA] 1844
FAILURE CODE [DLM2KA] 1845
FAILURE CODE [DLM2KB] 1847
FAILURE CODE [DLM2MA] 1849
FAILURE CODE [DLM3KA] 1850
FAILURE CODE [DLM3KB] 1852
FAILURE CODE [DLM3MB] 1854
FAILURE CODE [DN21FS] 1855
FAILURE CODE [DR21KX] 1857
FAILURE CODE [DR31KX] 1858
FAILURE CODE [DV20KB] 1859
FAILURE CODE [DW4BKA] 1861
FAILURE CODE [DW4BKB] 1863
FAILURE CODE [DW4BKY] 1865
FAILURE CODE [DW7BKA] 1866
FAILURE CODE [DW7BKB] 1868
FAILURE CODE [DW7EKA] 1869
FAILURE CODE [DW7EKB] 1872
FAILURE CODE [DW7EKY] 1875
FAILURE CODE [DWN5KA] 1877
FAILURE CODE [DWN5KB] 1879
FAILURE CODE [DWN5KY] 1880
FAILURE CODE [DXA4KA] 1881
FAILURE CODE [DXA4KB] 1883
FAILURE CODE [DXA4KY] 1885
FAILURE CODE [DXA5KA] 1886
FAILURE CODE [DXA5KB] 1888
FAILURE CODE [DXA5KY] 1890
FAILURE CODE [DXA6KA] 1891
FAILURE CODE [DXA6KB] 1893
FAILURE CODE [DXA6KY] 1895
FAILURE CODE [DXA7KA] 1896
FAILURE CODE [DXA7KB] 1898
FAILURE CODE [DXA7KY] 1900
FAILURE CODE [DXHRKA] 1901
FAILURE CODE [DXHRKB] 1903
FAILURE CODE [DXHRKY] 1904
FAILURE CODE [DXHSKA] 1905
FAILURE CODE [DXHSKB] 1907
FAILURE CODE [DXHSKY] 1908
FAILURE CODE [DXHTKA] 1909
FAILURE CODE [DXHTKB] 1911
FAILURE CODE [DXHTKY] 1912
FAILURE CODE [DXHUKA] 1913
FAILURE CODE [DXHUKB] 1915
FAILURE CODE [DXHUKY] 1916
FAILURE CODE [DXJ4KA] 1917
FAILURE CODE [DXJ4KB] 1919
FAILURE CODE [DXJCKA] 1921
FAILURE CODE [DXJCKB] 1923
FAILURE CODE [DXJCKY] 1924
FAILURE CODE [DXJDKA] 1925
FAILURE CODE [DXJDKB] 1927
FAILURE CODE [DXJDKY] 1928
FAILURE CODE [DXK1KA] 1929
FAILURE CODE [DXK1KB] 1931
FAILURE CODE [DXK1KY] 1932
FAILURE CODE [DXK2KA] 1933
FAILURE CODE [DXK2KB] 1935
FAILURE CODE [DXK2KY] 1936
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1937
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1937
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1944
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1947
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1949
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1951
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1954
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1955
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1956
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1957
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1958
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1959
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1960
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1961
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1962
E-15 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1963
E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1966
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1969
E-18 OPERATION MODE DOES NOT CHANGE 1970
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 1971
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 1972
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1973
E-22 SERVICE MODE CANNOT BE SELECTED 1974
E-23 WORK EQUIPMENT DOES NOT OPERATE 1975
E-24 FOOT HEATER DOES NOT OPERATE 1977
E-25 HORN DOES NOT SOUND 1983
E-26 HORN DOES NOT STOP SOUNDING 1985
E-27 BACKUP ALARM DOES NOT SOUND 1986
E-28 BACKUP ALARM DOES NOT STOP SOUNDING 1987
E-29 HEADLAMP DOES NOT LIGHT UP 1988
E-30 REAR LAMP DOES NOT LIGHT UP 1992
E-31 ALL WIPERS DO NOT OPERATE 1995
E-32 FRONT WIPER DOES NOT OPERATE 1997
E-33 REAR WIPER DOES NOT OPERATE 1999
E-34 LEFT DOOR WIPER DOES NOT OPERATE 2001
E-35 RIGHT DOOR WIPER DOES NOT OPERATE 2005
E-36 FRONT WASHER DOES NOT OPERATE 2009
E-37 REAR WASHER DOES NOT OPERATE 2011
E-38 LEFT DOOR WASHER DOES NOT OPERATE 2013
E-39 RIGHT DOOR WASHER DOES NOT OPERATE 2015
E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2017
E-41 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] 2018
E-42 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] 2022
E-43 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link ] 2027
E-44 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected] 2028
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites ] 2029
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] 2030
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal] 2032
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] 2033
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble] 2034
E-50 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize ] 2035
E-51 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing] 2036
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Initializing ] 2037
E-53 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS] 2038
E-54 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization ] 2039
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions ] 2040
E-56 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] 2041
E-57 CONTROL BOX DISPLAYS [Out of design area ] 2042
E-58 CONTROL BOX CAN NOT BE TURNED ON 2043
E-59 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN 2044
E-60 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE 2045
E-61 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE 2046
E-62 CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2047
E-63 CONTROL BOX TOUCH PANEL IS INACCURATE 2048
E-64 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT 2049
E-65 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT) 2050
E-66 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2052
E-67 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2053
E-68 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS) 2054
E-69 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE 2055
E-70 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) 2056
E-71 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) 2057
E-72 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION) 2058
E-73 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS) 2060
E-74 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 2061
E-75 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE 2062
E-76 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 2064
E-77 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT 2066
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2068
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2068
FAILURE MODE AND CAUSE TABLE 2069
H-1 NEITHER R H NOR L H OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) 2075
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) 2077
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) 2079
H-4 TRAVEL SPEED OR POWER IS LOW 2081
H-5 SPEED RANGE DOES NOT CHANGE 2083
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 2084
H-7 MACHINE DEVIATES LARGELY 2085
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 2088
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2090
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 2092
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 2094
H-12 ALL WORK EQUIPMENT DO NOT OPERATE 2096
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 2098
H-14 BLADE LIFT SPEED OR POWER IS LOW 2099
H-15 BLADE TILT SPEED OR POWER IS LOW 2101
H-16 BLADE ANGLE SPEED OR POWER IS LOW 2102
H-17 TIME LAG OF BLADE LIFT IS LARGE 2103
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 2104
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 2105
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 2106
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2107
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2109
TROUBLESHOOTING OF ENGINE (S-MODE) 2110
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2110
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2111
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2112
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2113
S-4 ENGINE STARTABILITY IS POOR 2114
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2116
S-6 ENGINE STOPS DURING OPERATION 2118
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2120
S-8 ENGINE LACKS POWER 2121
S-9 EXHAUST SMOKE IS BLACK 2123
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2125
S-11 OIL BECOMES CONTAMINATED QUICKLY 2126
S-12 FUEL CONSUMPTION IS EXCESSIVE 2127
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2128
S-14 OIL PRESSURE DROPS 2129
S-15 FUEL MIXES INTO ENGINE OIL 2130
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2131
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2132
S-18 UNUSUAL NOISE IS HEARD 2133
S-19 VIBRATION IS EXCESSIVE 2135
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2136
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2137
S-22 ACTIVE REGENERATION TAKES TIME 2138
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2139
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2140
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2142
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2143
50 DISASSEMBLY AND ASSEMBLY 2145
CONTENTS 2146
ABBREVIATION LIST 2151
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2157
HOW TO READ THIS MANUAL 2157
COATING MATERIALS LIST 2159
SPECIAL TOOLS LIST 2163
SKETCHES OF SPECIAL TOOLS 2182
ENGINE AND COOLING SYSTEM 2198
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2198
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2198
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2202
REMOVE AND INSTALL INJECTOR ASSEMBLY 2206
METHOD FOR REMOVING INJECTOR ASSEMBLY 2206
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2209
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2215
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2215
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2229
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2249
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2249
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2250
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2252
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2252
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2253
REMOVE AND INSTALL STARTER ASSEMBLY 2256
METHOD FOR REMOVING STARTER ASSEMBLY 2256
METHOD FOR INSTALLING STARTER ASSEMBLY 2257
REMOVE AND INSTALL ALTERNATOR BELT 2259
METHOD FOR REMOVING ALTERNATOR BELT 2259
METHOD FOR INSTALLING ALTERNATOR BELT 2260
REMOVE AND INSTALL AUTOMATIC TENSIONER 2262
METHOD FOR REMOVING AUTOMATIC TENSIONER 2262
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2262
REMOVE AND INSTALL RADIATOR ASSEMBLY 2263
METHOD FOR REMOVING RADIATOR ASSEMBLY 2263
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2266
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2270
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2270
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2272
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2275
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2275
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2277
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2281
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2281
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2283
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2285
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2285
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2286
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 2288
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2288
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2294
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2302
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2302
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2303
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2305
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2305
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2306
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2309
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2309
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2311
REMOVE AND INSTALL KDOC ASSEMBLY 2315
METHOD FOR REMOVING KDOC ASSEMBLY 2315
METHOD FOR INSTALLING KDOC ASSEMBLY 2319
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2326
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2327
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2336
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2346
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2346
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2348
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2353
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2353
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2356
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2360
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2360
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2366
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2372
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2372
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2373
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2376
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2376
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2377
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2384
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2384
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2385
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2386
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2386
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2387
REMOVE AND INSTALL SCR ASSEMBLY 2390
METHOD FOR REMOVING SCR ASSEMBLY 2390
METHOD FOR INSTALLING SCR ASSEMBLY 2394
REMOVE AND INSTALL KCCV ASSEMBLY 2398
METHOD FOR REMOVING KCCV ASSEMBLY 2398
METHOD FOR INSTALLING KCCV ASSEMBLY 2399
REMOVE AND INSTALL TURBO CHARGER ASSEMBLY 2400
METHOD FOR REMOVING TURBO CHARGER ASSEMBLY 2400
METHOD FOR INSTALLING TURBO CHARGER ASSEMBLY 2404
REMOVE AND INSTALL EXHAUST THROTTLE VALVE 2409
METHOD FOR REMOVING EXHAUST THROTTLE VALVE 2409
METHOD FOR INSTALLING EXHAUST THROTTLE VALVE 2413
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2419
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2420
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2424
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2432
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2432
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2435
REMOVE AND INSTALL AdBlue/DEF PUMP 2439
METHOD FOR REMOVING AdBlue/DEF PUMP 2439
METHOD FOR INSTALLING AdBlue/DEF PUMP 2442
REMOVE AND INSTALL AdBlue/DEF HOSE 2445
METHOD FOR REMOVING AdBlue/DEF HOSE 2445
METHOD FOR INSTALLING AdBlue/DEF HOSE 2453
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2463
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2463
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2464
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2466
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2466
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2467
POWER TRAIN 2469
REMOVE AND INSTALL DAMPER ASSEMBLY 2469
METHOD FOR REMOVING DAMPER ASSEMBLY 2469
METHOD FOR INSTALLING DAMPER ASSEMBLY 2470
REMOVE AND INSTALL HST PUMP ASSEMBLY 2471
METHOD FOR REMOVING HST PUMP ASSEMBLY 2471
METHOD FOR INSTALLING HST PUMP ASSEMBLY 2474
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY 2477
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY 2477
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY 2479
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2481
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2481
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2486
UNDERCARRIAGE AND FRAME 2496
REMOVE AND INSTALL IDLER AND RECOIL SPRING ASSEMBLY 2496
METHOD FOR REMOVING IDLER AND RECOIL SPRING ASSEMBLY 2496
METHOD FOR INSTALLING IDLER AND RECOIL SPRING ASSEMBLY 2496
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2498
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2498
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2500
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2504
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2505
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2506
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2508
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2508
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2510
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2514
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2514
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2515
SEPARATE AND CONNECT TRACK ASSEMBLY 2518
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2518
METHOD FOR CONNECTING TRACK ASSEMBLY 2519
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2521
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2521
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2521
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2523
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2524
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2526
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2539
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2540
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2541
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2556
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2558
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2559
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2567
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2568
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2570
HYDRAULIC SYSTEM 2574
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2574
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2574
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2579
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2584
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2584
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2586
WORK EQUIPMENT 2589
REMOVE AND INSTALL BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER) 2589
METHOD FOR REMOVING BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER) 2589
METHOD FOR INSTALLING BLADE ASSEMBLY 2591
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2594
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2594
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2596
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2599
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2599
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2601
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2603
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2604
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2608
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2616
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2616
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2619
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2623
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2623
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2627
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2632
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2632
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2634
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2638
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2638
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2642
REMOVE AND INSTALL U-FRAME ASSEMBLY 2648
METHOD FOR REMOVING U-FRAME ASSEMBLY 2648
METHOD FOR INSTALLING U-FRAME ASSEMBLY 2650
CAB AND ITS ATTACHMENTS 2653
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2653
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2653
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2659
REMOVE AND INSTALL WIPER ARM 2666
METHOD FOR REMOVING WIPER ARM 2666
METHOD FOR INSTALLING WIPER ARM 2667
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2669
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2671
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2671
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2677
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2677
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2683
REMOVE AND INSTALL OPERATOR’S SEAT 2691
METHOD FOR REMOVING OPERATOR’S SEAT 2691
METHOD FOR INSTALLING OPERATOR’S SEAT 2692
REMOVE AND INSTALL SEAT BELT 2693
METHOD FOR REMOVING SEAT BELT 2693
METHOD FOR INSTALLING SEAT BELT 2693
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2695
METHOD FOR REMOVING FOOT HEATER ASSEMBLY 2695
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY 2697
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2699
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2699
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY 2700
ELECTRICAL SYSTEM 2701
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2701
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2701
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2703
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2707
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2707
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2708
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2709
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2709
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2710
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2712
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2712
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2714
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2715
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2715
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2716
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2718
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2718
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2720
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2722
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2722
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2723
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY 2724
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY 2724
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY 2724
REMOVE AND INSTALL CONTROL BOX 2726
METHOD FOR REMOVING CONTROL BOX (FOR OLD CONTROL BOX) 2726
METHOD FOR REMOVING CONTROL BOX (FOR NEW CONTROL BOX) 2727
METHOD FOR INSTALLING CONTROL BOX (FOR OLD CONTROL BOX) 2727
METHOD FOR INSTALLING CONTROL BOX (FOR NEW CONTROL BOX) 2728
REMOVE AND INSTALL GNSS RECEIVER 2730
METHOD FOR REMOVING GNSS RECEIVER 2730
METHOD FOR INSTALLING GNSS RECEIVER 2730
REMOVE AND INSTALL GNSS ANTENNA 2732
METHOD FOR REMOVING GNSS ANTENNA 2732
METHOD FOR INSTALLING GNSS ANTENNA 2733
REMOVE AND INSTALL IMU SENSOR 2738
METHOD FOR REMOVING IMU SENSOR 2738
METHOD FOR INSTALLING IMU SENSOR 2739
60 MAINTENANCE STANDARD 2743
CONTENTS 2744
ABBREVIATION LIST 2746
ENGINE AND COOLING SYSTEM 2752
MAINTENANCE STANDARD OF ENGINE MOUNT 2752
MAINTENANCE STANDARD OF DAMPER 2753
MAINTENANCE STANDARD OF COOLING SYSTEM 2754
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2756
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2758
POWER TRAIN 2759
MAINTENANCE STANDARD OF HST PUMP 2759
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2760
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2761
MAINTENANCE STANDARD OF HST CHARGE PUMP 2762
MAINTENANCE STANDARD OF HST MOTOR 2764
MAINTENANCE STANDARD OF FINAL DRIVE 2765
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24 2767
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24 2769
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24 2771
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24 2772
UNDERCARRIAGE AND FRAME 2773
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2773
MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D37EXI-24,D37PXI-24 2778
MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D39EXI-24,D39PXI-24 2780
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2782
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2784
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2786
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2788
MAINTENANCE STANDARD OF SINGLE SHOE 2792
HYDRAULIC SYSTEM 2793
MAINTENANCE STANDARD OF HYDRAULIC TANK 2793
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2794
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP 2795
MAINTENANCE STANDARD OF CONTROL VALVE 2797
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2804
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 2806
MAINTENANCE STANDARD OF EPC VALVE 2807
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2808
WORK EQUIPMENT 2809
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 2809
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 2812
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER 2813
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER 2814
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER 2815
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 2816
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER 2817
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER 2818
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2819
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 2821
CAB AND ITS ATTACHMENTS 2822
MAINTENANCE STANDARD OF CAB MOUNT 2822
ELECTRICAL SYSTEM 2823
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2823
80 APPENDIX 2825
CONTENTS 2826
ABBREVIATION LIST 2827
AIR CONDITIONER SYSTEM 2833
PRECAUTIONS FOR REFRIGERANT 2833
AIR CONDITIONER COMPONENT 2834
SPECIFICATIONS OF AIR CONDITIONER 2837
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2838
OUTLINE OF REFRIGERATION CYCLE 2839
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2841
AIR CONDITIONER UNIT 2841
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2841
FUNCTION OF AIR CONDITIONER UNIT 2842
COMPONENT PARTS OF AIR CONDITIONER UNIT 2843
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2843
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2843
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT 2843
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2844
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2844
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2844
FUNCTION OF DUAL PRESSURE SWITCH 2845
FUNCTION OF PRESSURE SWITCH 2845
COMPRESSOR 2846
STRUCTURE OF COMPRESSOR 2846
SPECIFICATIONS OF COMPRESSOR 2846
FUNCTION OF COMPRESSOR 2846
CONDENSER 2847
STRUCTURE OF CONDENSER 2847
SPECIFICATIONS OF CONDENSER 2847
FUNCTION OF CONDENSER 2848
RECEIVER DRIER 2849
STRUCTURE OF RECEIVER DRIER 2849
SPECIFICATIONS OF RECEIVER DRIER 2849
FUNCTION OF RECEIVER DRIER 2849
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2851
CIRCUIT DIAGRAM OF AIR CONDITIONER 2854
AIR CONDITIONER SYSTEM DIAGRAM 2855
CONTROL FUNCTION OF AIR CONDITIONER 2856
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2857
TEST RELAYS 2861
METHOD FOR TESTING RELAYS 2861
AIR CONDITIONER TROUBLESHOOTING CHART 1 2863
AIR CONDITIONER TROUBLESHOOTING CHART 2 2864
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2867
A-1 TROUBLESHOOTING FOR CONDENSER FAN 2869
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2872
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2876
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 2879
TROUBLESHOOTING USING GAUGE PRESSURE 2883
CONNECTION OF SERVICE TOOL 2885
METHOD FOR CONNECTING SERVICE TOOL 2885
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2886
HANDLE COMPRESSOR OIL 2888
90 CIRCUIT DIAGRAMS 2891
CONTENTS 2892
ABBREVIATION LIST 2893
HYDRAULIC CIRCUIT DIAGRAM 2899
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2899
HYDRAULIC CIRCUIT DIAGRAM 2903
ELECTRICAL CIRCUIT DIAGRAM 2905
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2905
ELECTRICAL CIRCUIT DIAGRAM (1/11) 2909
ELECTRICAL CIRCUIT DIAGRAM (2/11) 2911
ELECTRICAL CIRCUIT DIAGRAM (3/11) 2913
ELECTRICAL CIRCUIT DIAGRAM (4/11) 2915
ELECTRICAL CIRCUIT DIAGRAM (5/11) 2917
ELECTRICAL CIRCUIT DIAGRAM (6/11) 2919
ELECTRICAL CIRCUIT DIAGRAM (7/11) 2921
ELECTRICAL CIRCUIT DIAGRAM (8/11) 2923
ELECTRICAL CIRCUIT DIAGRAM (9/11) 2925
ELECTRICAL CIRCUIT DIAGRAM (10/11) 2927
ELECTRICAL CIRCUIT DIAGRAM (11/11) 2929
INDEX 2931

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S.V 27/12/24