Komatsu D51EX-24 D51PX-24 Bulldozer Shop Manual SEN06617-06 PDF

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.

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 20
FOREWORD, SAFETY, BASIC INFORMATION 26
HOW TO READ THE SHOP MANUAL 26
SAFETY NOTICE FOR OPERATION 28
PRECAUTIONS TO PREVENT FIRE 36
ACTIONS IF FIRE OCCURS 38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 40
PRECAUTIONS FOR DEF 41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 41
PRECAUTIONS FOR ADDING 41
PRECAUTIONS FOR STORING 41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 41
THE OTHER PRECAUTIONS 41
STORE AdBlue/DEF 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: D51EX-24 101
SPECIFICATION DRAWING: D51PX-24 103
SPECIFICATIONS 105
SPECIFICATIONS: D51EX-24 105
SPECIFICATIONS: D51PX-24 110
WEIGHT TABLE 115
WEIGHT TABLE: D51EX-24 115
WEIGHT TABLE: D51PX-24 117
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 119
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 119
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 121
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 121
10 STRUCTURE AND FUNCTION 123
CONTENTS 124
ABBREVIATION LIST 127
UREA SCR SYSTEM 133
LAYOUT DRAWING OF UREA SCR SYSTEM 133
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF AdBlue/DEF SYSTEM 136
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 153
AdBlue/DEF MIXING TUBE 153
SCR ASSEMBLY 154
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM 162
LAYOUT DRAWING OF BOOT-UP SYSTEM 162
SYSTEM OPERATING LAMP SYSTEM 163
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 163
FUNCTION OF SYSTEM OPERATING 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 OF ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 170
FUNCTION OF ENGINE CONTROL SYSTEM 172
AUTOMATIC IDLE STOP SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 174
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 174
COMPONENT PARTS OF ENGINE SYSTEM 177
DAMPER 177
VGT 178
EGR SYSTEM 181
EGR VALVE 183
EGR COOLER 185
KCCV SYSTEM 187
KCCV VENTILATOR 189
KDOC 191
COOLING SYSTEM 194
LAYOUT DRAWING OF COOLING SYSTEM 194
SPECIFICATIONS OF COOLING SYSTEM 195
COOLING FAN CONTROL SYSTEM 196
COOLING FAN CONTROL SYSTEM DIAGRAM 196
FUNCTION OF COOLING FAN CONTROL SYSTEM 197
COMPONENT PARTS OF COOLING SYSTEM 199
COOLING FAN MOTOR 199
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 204
HYDRAULIC OIL COOLER BYPASS VALVE 205
HST CHARGE SAFETY VALVE 206
CONTROL SYSTEM 208
LAYOUT DRAWING OF CONTROL SYSTEM 208
MACHINE MONITOR SYSTEM 209
MACHINE MONITOR SYSTEM DIAGRAM 209
FUNCTION OF MACHINE MONITOR SYSTEM 209
KOMTRAX SYSTEM 210
KOMTRAX SYSTEM DIAGRAM 210
FUNCTION OF KOMTRAX SYSTEM 210
COMPONENT PARTS OF CONTROL SYSTEM 211
MACHINE MONITOR 211
KOMTRAX TERMINAL 226
HST CONTROLLER 228
ENGINE CONTROLLER 232
FUEL CONTROL DIAL 239
DECELERATOR AND BRAKE POTENTIOMETER 241
HYDRAULIC SYSTEM 243
LAYOUT DRAWING OF HYDRAULIC SYSTEM 243
CLSS 244
STRUCTURE OF CLSS 244
FUNCTION OF CLSS 245
COMPONENT PARTS OF HYDRAULIC SYSTEM 247
HYDRAULIC TANK 247
WORK EQUIPMENT AND COOLING FAN PUMP 249
LS VALVE 257
PC VALVE 258
CONTROL VALVE 261
POWER TRAIN SYSTEM 279
LAYOUT DRAWING OF HST SYSTEM 279
OPERATION OF HST SYSTEM 280
STEERING AND BRAKE CONTROL SYSTEM 282
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 282
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 282
HST CONTROL SYSTEM 284
HST CONTROL SYSTEM DIAGRAM 284
GEAR SHIFT CONTROL FUNCTION 285
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 288
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 289
DECELERATION AND BRAKE CONTROL FUNCTION 290
GEAR SHIFT CONTROL FUNCTION BY LOAD 292
TURN CONTROL FUNCTION 292
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 293
PARKING BRAKE CONTROL SYSTEM 295
PARKING BRAKE CONTROL SYSTEM DIAGRAM 295
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 296
OPERATION OF PARKING BRAKE CONTROL SYSTEM 297
COMPONENT PARTS OF POWER TRAIN SYSTEM 298
HST PUMP 298
HST CHARGE PUMP 313
HST MOTOR 314
FINAL DRIVE 327
ELECTRIC STEERING CONTROL LEVER 331
WORK EQUIPMENT SYSTEM 334
WORK EQUIPMENT CONTROL 334
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 334
FUNCTION OF WORK EQUIPMENT CONTROL 335
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 336
LAYOUT OF FIXED MULTI-SHANK RIPPER 337
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 338
RIPPER PPC VALVE 338
5-PORT VALVE OF EPC AND SOLENOID 342
PILOT CIRCUIT ACCUMULATOR 348
QUICK DROP VALVE 349
PISTON VALVE 351
ELECTRIC BLADE CONTROL LEVER 352
UNDERCARRIAGE AND FRAME 354
MAIN FRAME 354
STRUCTURE OF MAIN FRAME 354
SUSPENSION 355
STRUCTURE OF SUSPENSION 355
SPECIFICATIONS OF SUSPENSION 356
FUNCTION OF SUSPENSION 357
TRACK FRAME AND IDLER CUSHION 358
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 358
FUNCTION OF TRACK FRAME AND IDLER CUSHION 359
WORK EQUIPMENT 360
STRUCTURE OF FRONT WORK EQUIPMENT 360
STRUCTURE OF FIXED MULTI-SHANK RIPPER 361
CAB AND ITS ATTACHMENTS 362
ROPS CAB 362
STRUCTURE OF ROPS CAB 362
FUNCTION OF ROPS CAB 363
CAB MOUNT 364
STRUCTURE OF CAB MOUNT 364
FUNCTION OF CAB MOUNT 364
20 STANDARD VALUE TABLE 365
CONTENTS 366
ABBREVIATION LIST 367
STANDARD VALUE TABLE FOR ENGINE 373
STANDARD VALUE TABLE FOR ENGINE: D51EX-24 373
STANDARD VALUE TABLE FOR ENGINE: D51PX-24 377
STANDARD VALUE TABLE FOR MACHINE 381
STANDARD VALUE TABLE FOR MACHINE: D51EX-24 381
STANDARD VALUE TABLE FOR MACHINE: D51PX-24 397
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 411
30 TESTING AND ADJUSTING 413
CONTENTS 414
ABBREVIATION LIST 417
RELATED INFORMATION ON TESTING AND ADJUSTING 423
TOOLS FOR TESTING AND ADJUSTING 423
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 430
ENGINE AND COOLING SYSTEM 431
TEST ENGINE SPEED 431
METHOD FOR TESTING ENGINE SPEED 431
TEST BOOST PRESSURE 433
METHOD FOR TESTING BOOST PRESSURE 433
TEST EXHAUST GAS COLOR 434
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 434
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 435
TEST AND ADJUST VALVE CLEARANCE 436
METHOD FOR TESTING VALVE CLEARANCE 436
METHOD FOR ADJUSTING VALVE CLEARANCE 437
TEST COMPRESSION PRESSURE 438
METHOD FOR TESTING COMPRESSION PRESSURE 438
TEST BLOWBY PRESSURE 443
METHOD FOR TESTING BLOWBY PRESSURE 443
TEST ENGINE OIL PRESSURE 445
METHOD FOR TESTING ENGINE OIL PRESSURE 445
TEST FUEL PRESSURE 446
METHOD FOR TESTING FUEL PRESSURE 447
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 451
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 452
BLEED AIR FROM FUEL SYSTEM 457
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 457
TEST FUEL CIRCUIT FOR LEAKAGE 458
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 458
HANDLE CYLINDER CUT-OUT MODE OPERATION 460
HANDLE NO-INJECTION CRANKING OPERATION 461
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 462
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 462
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 463
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 463
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 464
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 464
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 465
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 465
TEST SCR RELATED FUNCTIONS 466
TEST AdBlue/DEF PUMP RAISED PRESSURE 470
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 473
TEST AdBlue/DEF LINE HEATER RELAY 1 478
TEST AdBlue/DEF LINE HEATER RELAY 2 481
TEST AdBlue/DEF PUMP HEATER RELAY 484
TEST AdBlue/DEF TANK HEATER VALVE 488
TEST DENITRATION EFFICIENCY OF SCR 492
CLEAN AdBlue/DEF TANK 495
METHOD FOR CLEANING AdBlue/DEF TANK 495
CLEAN AdBlue/DEF TANK MOUNTING PORTION 499
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 499
POWER TRAIN 500
TEST AND ADJUST HST OIL PRESSURE 500
METHOD FOR TESTING HST OIL PRESSURE 500
METHOD FOR ADJUSTING HST OIL PRESSURE 503
BLEED AIR FROM HST PUMP 505
METHOD FOR BLEEDING AIR FROM HST PUMP 505
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP 505
TEST OUTLET PRESSURE OF SOLENOID VALVE 507
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 507
TEST TRAVEL DEVIATION 511
METHOD FOR TESTING TRAVEL DEVIATION 511
TEST BRAKE PERFORMANCE SIMPLY 513
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 513
TEST AND ADJUST DECELERATION/BRAKE PEDAL 514
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 514
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 516
ADJUST PARKING BRAKE LEVER 518
METHOD FOR ADJUSTING PARKING BRAKE LEVER 518
MOVE MACHINE WHEN IT CANNOT TRAVEL 520
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 520
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 522
UNDERCARRIAGE AND FRAME 523
CHECK AND ADJUST IDLER CLEARANCE 523
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 523
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 523
TESTING SPROCKET WEAR 525
METHOD FOR TESTING SPROCKET WEAR 525
TEST AND ADJUST TRACK TENSION 526
METHOD FOR TESTING TRACK TENSION 526
METHOD FOR ADJUSTING TRACK TENSION 526
HYDRAULIC SYSTEM 528
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 528
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 528
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 529
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 529
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 530
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 532
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 532
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 533
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 534
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 534
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 536
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 536
TEST COOLING FAN SPEED 537
METHOD FOR TESTING COOLING FAN SPEED 537
TEST COOLING FAN CIRCUIT OIL PRESSURE 538
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 538
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 540
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 540
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 540
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 541
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 542
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 542
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 545
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 545
WORK EQUIPMENT 546
ADJUST WORK EQUIPMENT LOCK LEVER 546
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 546
ELECTRICAL SYSTEM 548
SET AND OPERATE MACHINE MONITOR 548
OPERATOR MODE 552
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 552
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 552
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 553
CHECKING FUNCTION OF SERVICE METER 553
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 553
SERVICE MODE 556
METHOD FOR OPERATING SERVICE MODE 556
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 558
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 564
ABNORMALITY RECORD MENU 574
METHOD FOR CONFIRMING MAINTENANCE RECORD 578
METHOD FOR OPERATING MAINTENANCE MODE SETTING 579
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 583
DEFAULT MENU 584
DIAGNOSTIC TESTS MENU 591
ADJUSTMENT MENU 599
METHOD FOR PERFORMING NO-INJECTION CRANKING 656
KOMTRAX SETTINGS MENU 658
METHOD FOR DISPLAYING SERVICE MESSAGE 660
METHOD FOR STARTING UP KOMTRAX TERMINAL 662
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 667
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 667
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 673
ADJUST REARVIEW CAMERA ANGLE 675
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 675
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 676
HANDLE BATTERY DISCONNECT SWITCH 677
TEST DIODES 678
METHOD FOR TESTING DIODE USING DIGITAL TESTER 678
METHOD FOR TESTING DIODE USING ANALOG TESTER 678
Pm CLINIC 679
Pm CLINIC SERVICE 679
Pm CLINIC CHECK SHEET: D51EX-24 681
Pm CLINIC CHECK SHEET: D51PX-24 689
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EX-24 697
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PX-24 701
40 TROUBLESHOOTING 705
CONTENTS 706
ABBREVIATION LIST 716
RELATED INFORMATION ON TROUBLESHOOTING 722
GENERAL TROUBLESHOOTING POINTS 722
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 723
SEQUENCE OF EVENTS IN TROUBLESHOOTING 735
CHECKS BEFORE TROUBLESHOOTING 737
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 739
WALK-AROUND CHECK 739
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 741
CHECK FUEL LEVEL AND TYPE 741
CHECK IMPURE INGREDIENT IN FUEL 741
CHECK AdBule/DEF LEVEL AND TYPE 742
CHECK FUEL PREFILTER 742
CHECK MAIN FILTER 744
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 745
CHECK COOLANT LEVEL (RESERVOIR TANK) 747
CHECK CLOGGING OF AIR CLEANER 747
CLEAN OUTER ELEMENT 748
REPLACE ELEMENT 750
CHECK HYDRAULIC OIL LEVEL 751
CHECK HYDRAULIC OIL STRAINER 752
CHECK OIL LEVEL IN FINAL DRIVE CASE 755
BLEED AIR FROM FUEL SYSTEM 756
BLEED AIR FROM HYDRAULIC SYSTEM 756
METHOD FOR CHECKING ELECTRIC EQUIPMENT 756
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 763
PROCEDURE FOR TROUBLESHOOTING 770
SYMPTOM AND TROUBLESHOOTING NUMBERS 773
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 776
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 778
CONNECTORS LIST AND LAYOUT 781
CONNECTOR CONTACT IDENTIFICATION 795
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 835
FUSE LOCATION TABLE 841
PRECAUTIONS FOR REPLACING KDOC 845
FAILURE CODES TABLE 846
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 864
FAILURE CODE [6091NX] 864
FAILURE CODE [989L00] 866
FAILURE CODE [989M00] 867
FAILURE CODE [989N00] 868
FAILURE CODE [A1U0N3] 869
FAILURE CODE [A1U0N4] 871
FAILURE CODE [A900FR] 873
FAILURE CODE [A900N6] 874
FAILURE CODE [A900NY] 875
FAILURE CODE [AA10NX] 876
FAILURE CODE [AB00KE] 878
FAILURE CODE [AQ10MB] 880
FAILURE CODE [AQ10N3] 882
FAILURE CODE [AS00R2] 884
FAILURE CODE [AS00R3] 885
FAILURE CODE [AS00R4] 886
FAILURE CODE [AS00R5] 887
FAILURE CODE [AS00R6] 888
FAILURE CODE [AS00ZK] 889
FAILURE CODE [AS10KM] 890
FAILURE CODE [AS10NR] 891
FAILURE CODE [AS10NT] 892
FAILURE CODE [B@BAZG] 893
FAILURE CODE [B@BCNS] 894
FAILURE CODE [B@CRNS] 895
FAILURE CODE [B@CRZG] 896
FAILURE CODE [CA115] 897
FAILURE CODE [CA122] 898
FAILURE CODE [CA123] 900
FAILURE CODE [CA131] 902
FAILURE CODE [CA132] 904
FAILURE CODE [CA144] 906
FAILURE CODE [CA145] 908
FAILURE CODE [CA153] 910
FAILURE CODE [CA154] 912
FAILURE CODE [CA187] 914
FAILURE CODE [CA221] 916
FAILURE CODE [CA222] 918
FAILURE CODE [CA227] 920
FAILURE CODE [CA234] 922
FAILURE CODE [CA238] 923
FAILURE CODE [CA239] 924
FAILURE CODE [CA249] 925
FAILURE CODE [CA256] 927
FAILURE CODE [CA271] 929
FAILURE CODE [CA272] 931
FAILURE CODE [CA295] 933
FAILURE CODE [CA322] 934
FAILURE CODE [CA324] 936
FAILURE CODE [CA331] 938
FAILURE CODE [CA332] 940
FAILURE CODE [CA343] 942
FAILURE CODE [CA351] 943
FAILURE CODE [CA352] 944
FAILURE CODE [CA356] 946
FAILURE CODE [CA357] 948
FAILURE CODE [CA386] 950
FAILURE CODE [CA428] 951
FAILURE CODE [CA429] 953
FAILURE CODE [CA435] 955
FAILURE CODE [CA441] 957
FAILURE CODE [CA442] 959
FAILURE CODE [CA451] 960
FAILURE CODE [CA452] 962
FAILURE CODE [CA488] 964
FAILURE CODE [CA515] 965
FAILURE CODE [CA516] 967
FAILURE CODE [CA553] 969
FAILURE CODE [CA555] 970
FAILURE CODE [CA556] 971
FAILURE CODE [CA559] 972
FAILURE CODE [CA595] 975
FAILURE CODE [CA687] 977
FAILURE CODE [CA689] 979
FAILURE CODE [CA691] 982
FAILURE CODE [CA692] 984
FAILURE CODE [CA697] 986
FAILURE CODE [CA698] 987
FAILURE CODE [CA731] 988
FAILURE CODE [CA778] 990
FAILURE CODE [CA1117] 995
FAILURE CODE [CA1664] 997
FAILURE CODE [CA1669] 999
FAILURE CODE [CA1673] 1000
FAILURE CODE [CA1677] 1001
FAILURE CODE [CA1678] 1002
FAILURE CODE [CA1682] 1003
FAILURE CODE [CA1683] 1005
FAILURE CODE [CA1684] 1007
FAILURE CODE [CA1686] 1009
FAILURE CODE [CA1691] 1010
FAILURE CODE [CA1694] 1012
FAILURE CODE [CA1695] 1014
FAILURE CODE [CA1696] 1015
FAILURE CODE [CA1712] 1017
FAILURE CODE [CA1713] 1020
FAILURE CODE [CA1714] 1022
FAILURE CODE [CA1715] 1023
FAILURE CODE [CA1776] 1024
FAILURE CODE [CA1777] 1027
FAILURE CODE [CA1843] 1030
FAILURE CODE [CA1844] 1032
FAILURE CODE [CA1885] 1035
FAILURE CODE [CA1887] 1037
FAILURE CODE [CA1896] 1039
FAILURE CODE [CA1898] 1040
FAILURE CODE [CA1938] 1042
FAILURE CODE [CA1942] 1044
FAILURE CODE [CA1961] 1045
FAILURE CODE [CA1962] 1046
FAILURE CODE [CA2185] 1047
FAILURE CODE [CA2186] 1049
FAILURE CODE [CA2198] 1051
FAILURE CODE [CA2272] 1053
FAILURE CODE [CA2288] 1055
FAILURE CODE [CA2311] 1056
FAILURE CODE [CA2349] 1057
FAILURE CODE [CA2353] 1059
FAILURE CODE [CA2357] 1061
FAILURE CODE [CA2373] 1062
FAILURE CODE [CA2374] 1064
FAILURE CODE [CA2375] 1066
FAILURE CODE [CA2376] 1068
FAILURE CODE [CA2387] 1071
FAILURE CODE [CA2554] 1072
FAILURE CODE [CA2555] 1073
FAILURE CODE [CA2556] 1076
FAILURE CODE [CA2634] 1079
FAILURE CODE [CA2635] 1081
FAILURE CODE [CA2636] 1082
FAILURE CODE [CA2637] 1084
FAILURE CODE [CA2771] 1086
FAILURE CODE [CA2961] 1090
FAILURE CODE [CA2973] 1091
FAILURE CODE [CA2976] 1092
FAILURE CODE [CA3142] 1094
FAILURE CODE [CA3143] 1095
FAILURE CODE [CA3144] 1096
FAILURE CODE [CA3146] 1098
FAILURE CODE [CA3147] 1099
FAILURE CODE [CA3148] 1100
FAILURE CODE [CA3151] 1102
FAILURE CODE [CA3165] 1107
FAILURE CODE [CA3228] 1109
FAILURE CODE [CA3229] 1111
FAILURE CODE [CA3231] 1113
FAILURE CODE [CA3232] 1115
FAILURE CODE [CA3235] 1119
FAILURE CODE [CA3239] 1121
FAILURE CODE [CA3241] 1124
FAILURE CODE [CA3242] 1127
FAILURE CODE [CA3251] 1130
FAILURE CODE [CA3313] 1132
FAILURE CODE [CA3314] 1133
FAILURE CODE [CA3315] 1134
FAILURE CODE [CA3419] 1136
FAILURE CODE [CA3421] 1138
FAILURE CODE [CA3497] 1140
FAILURE CODE [CA3498] 1141
FAILURE CODE [CA3545] 1142
FAILURE CODE [CA3547] 1144
FAILURE CODE [CA3558] 1145
FAILURE CODE [CA3559] 1147
FAILURE CODE [CA3562] 1149
FAILURE CODE [CA3563] 1151
FAILURE CODE [CA3567] 1154
FAILURE CODE [CA3568] 1158
FAILURE CODE [CA3571] 1162
FAILURE CODE [CA3572] 1164
FAILURE CODE [CA3574] 1166
FAILURE CODE [CA3575] 1168
FAILURE CODE [CA3577] 1170
FAILURE CODE [CA3578] 1172
FAILURE CODE [CA3582] 1174
FAILURE CODE [CA3583] 1179
FAILURE CODE [CA3596] 1181
FAILURE CODE [CA3649] 1184
FAILURE CODE [CA3681] 1186
FAILURE CODE [CA3682] 1191
FAILURE CODE [CA3713] 1196
FAILURE CODE [CA3717] 1199
FAILURE CODE [CA3718] 1200
FAILURE CODE [CA3724] 1201
FAILURE CODE [CA3725] 1202
FAILURE CODE [CA3741] 1205
FAILURE CODE [CA3748] 1206
FAILURE CODE [CA3755] 1208
FAILURE CODE [CA3866] 1210
FAILURE CODE [CA3868] 1213
FAILURE CODE [CA4152] 1217
FAILURE CODE [CA4155] 1221
FAILURE CODE [CA4156] 1224
FAILURE CODE [CA4157] 1227
FAILURE CODE [CA4159] 1229
FAILURE CODE [CA4164] 1230
FAILURE CODE [CA4165] 1232
FAILURE CODE [CA4166] 1234
FAILURE CODE [CA4168] 1235
FAILURE CODE [CA4169] 1238
FAILURE CODE [CA4171] 1240
FAILURE CODE [CA4249] 1242
FAILURE CODE [CA4251] 1244
FAILURE CODE [CA4261] 1246
FAILURE CODE [CA4277] 1249
FAILURE CODE [CA4459] 1253
FAILURE CODE [CA4461] 1255
FAILURE CODE [CA4533] 1258
FAILURE CODE [CA4534] 1259
FAILURE CODE [CA4731] 1260
FAILURE CODE [CA4732] 1261
FAILURE CODE [CA4739] 1262
FAILURE CODE [CA4768] 1263
FAILURE CODE [CA4769] 1265
FAILURE CODE [CA4842] 1268
FAILURE CODE [CA4952] 1271
FAILURE CODE [CA5115] 1273
FAILURE CODE [CA5179] 1276
FAILURE CODE [CA5181] 1278
FAILURE CODE [CA5387] 1280
FAILURE CODE [CA5388] 1282
FAILURE CODE [CA5389] 1285
FAILURE CODE [CA5391] 1287
FAILURE CODE [CA5392] 1291
FAILURE CODE [CA5393] 1293
FAILURE CODE [CA5394] 1296
FAILURE CODE [CA5395] 1299
FAILURE CODE [CA5396] 1302
FAILURE CODE [CA5631] 1303
FAILURE CODE [CA5632] 1305
FAILURE CODE [CA5938] 1306
FAILURE CODE [D130KA] 1308
FAILURE CODE [D130KB] 1311
FAILURE CODE [D130KY] 1313
FAILURE CODE [D19JKZ] 1315
FAILURE CODE [D811MC] 1318
FAILURE CODE [D862KA] 1319
FAILURE CODE [D8ALKA] 1320
FAILURE CODE [D8ALKB] 1322
FAILURE CODE [D8AQKR] 1324
FAILURE CODE [DAF0MB] 1326
FAILURE CODE [DAF0MC] 1327
FAILURE CODE [DAF8KB] 1328
FAILURE CODE [DAF9KQ] 1330
FAILURE CODE [DAFGMC] 1331
FAILURE CODE [DAFLKA] 1332
FAILURE CODE [DAFLKB] 1334
FAILURE CODE [DAFQKR] 1336
FAILURE CODE [DAJ000] 1337
FAILURE CODE [DAJ0KQ] 1338
FAILURE CODE [DAJ0KT] 1339
FAILURE CODE [DAJ0MC] 1340
FAILURE CODE [DAJ1KK] 1341
FAILURE CODE [DAJ2KK] 1343
FAILURE CODE [DAJ5KK] 1345
FAILURE CODE [DAJ6KK] 1348
FAILURE CODE [DAJLKA] 1350
FAILURE CODE [DAJLKB] 1352
FAILURE CODE [DAJPMA] 1354
FAILURE CODE [DAJQKR] 1355
FAILURE CODE [DAJRKR] 1356
FAILURE CODE [DB2QKR] 1357
FAILURE CODE [DB2RKR] 1362
FAILURE CODE [DD12KA] 1367
FAILURE CODE [DD12KB] 1369
FAILURE CODE [DD13KA] 1371
FAILURE CODE [DD13KB] 1373
FAILURE CODE [DD14KA] 1375
FAILURE CODE [DD14KB] 1377
FAILURE CODE [DDKAKA] 1379
FAILURE CODE [DDKAKB] 1381
FAILURE CODE [DDKFL4] 1383
FAILURE CODE [DDKGL4] 1385
FAILURE CODE [DDKHKA] 1387
FAILURE CODE [DDKHKB] 1389
FAILURE CODE [DDNLKA] 1391
FAILURE CODE [DDNLKB] 1393
FAILURE CODE [DDP6KA] 1395
FAILURE CODE [DDP6KB] 1398
FAILURE CODE [DDP6MA] 1400
FAILURE CODE [DDU1FS] 1402
FAILURE CODE [DDU1KA] 1404
FAILURE CODE [DDU1KY] 1407
FAILURE CODE [DFA4KX] 1409
FAILURE CODE [DFA4KZ] 1410
FAILURE CODE [DFA4L8] 1411
FAILURE CODE [DFA5KA] 1412
FAILURE CODE [DFA5KB] 1415
FAILURE CODE [DFA6KA] 1418
FAILURE CODE [DFA6KB] 1421
FAILURE CODE [DFA7KX] 1424
FAILURE CODE [DFA7KZ] 1425
FAILURE CODE [DFA7L8] 1426
FAILURE CODE [DFA8KA] 1427
FAILURE CODE [DFA8KB] 1430
FAILURE CODE [DFA9KA] 1433
FAILURE CODE [DFA9KB] 1436
FAILURE CODE [DGS1KA] 1439
FAILURE CODE [DGS1KX] 1442
FAILURE CODE [DH21KA] 1443
FAILURE CODE [DH21KB] 1445
FAILURE CODE [DHA4KA] 1447
FAILURE CODE [DHH7KA] 1449
FAILURE CODE [DHH7KB] 1452
FAILURE CODE [DHH8KA] 1454
FAILURE CODE [DHH8KB] 1457
FAILURE CODE [DHH9KA] 1459
FAILURE CODE [DHH9KB] 1462
FAILURE CODE [DHHAKA] 1464
FAILURE CODE [DHHAKB] 1467
FAILURE CODE [DK30KA] 1469
FAILURE CODE [DK30KB] 1472
FAILURE CODE [DK30KX] 1474
FAILURE CODE [DK30KZ] 1475
FAILURE CODE [DK30L8] 1476
FAILURE CODE [DK31KA] 1477
FAILURE CODE [DK31KB] 1480
FAILURE CODE [DK40KA] 1482
FAILURE CODE [DK40KB] 1485
FAILURE CODE [DK55KX] 1487
FAILURE CODE [DK55KZ] 1488
FAILURE CODE [DK55L8] 1489
FAILURE CODE [DK56KA] 1490
FAILURE CODE [DK56KB] 1493
FAILURE CODE [DK57KA] 1495
FAILURE CODE [DK57KB] 1498
FAILURE CODE [DLM0KX] 1500
FAILURE CODE [DLM1KA] 1501
FAILURE CODE [DLM1KB] 1503
FAILURE CODE [DLM1MA] 1505
FAILURE CODE [DLM2KA] 1506
FAILURE CODE [DLM2KB] 1508
FAILURE CODE [DLM2MA] 1510
FAILURE CODE [DLM3KA] 1511
FAILURE CODE [DLM3KB] 1513
FAILURE CODE [DLM3MB] 1515
FAILURE CODE [DN21FS] 1516
FAILURE CODE [DR21KX] 1518
FAILURE CODE [DR31KX] 1519
FAILURE CODE [DV20KB] 1520
FAILURE CODE [DW4BKA] 1522
FAILURE CODE [DW4BKB] 1524
FAILURE CODE [DW4BKY] 1526
FAILURE CODE [DW7BKA] 1528
FAILURE CODE [DW7BKB] 1530
FAILURE CODE [DW7EKA] 1532
FAILURE CODE [DW7EKB] 1534
FAILURE CODE [DW7EKY] 1536
FAILURE CODE [DWN5KA] 1538
FAILURE CODE [DWN5KB] 1540
FAILURE CODE [DWN5KY] 1542
FAILURE CODE [DXA4KA] 1544
FAILURE CODE [DXA4KB] 1546
FAILURE CODE [DXA4KY] 1548
FAILURE CODE [DXA5KA] 1550
FAILURE CODE [DXA5KB] 1552
FAILURE CODE [DXA5KY] 1554
FAILURE CODE [DXA6KA] 1556
FAILURE CODE [DXA6KB] 1558
FAILURE CODE [DXA6KY] 1560
FAILURE CODE [DXA7KA] 1562
FAILURE CODE [DXA7KB] 1564
FAILURE CODE [DXA7KY] 1566
FAILURE CODE [DXHRKA] 1568
FAILURE CODE [DXHRKB] 1570
FAILURE CODE [DXHRKY] 1572
FAILURE CODE [DXHSKA] 1574
FAILURE CODE [DXHSKB] 1576
FAILURE CODE [DXHSKY] 1578
FAILURE CODE [DXHTKA] 1580
FAILURE CODE [DXHTKB] 1582
FAILURE CODE [DXHTKY] 1584
FAILURE CODE [DXHUKA] 1586
FAILURE CODE [DXHUKB] 1588
FAILURE CODE [DXHUKY] 1590
FAILURE CODE [DXJ4KA] 1592
FAILURE CODE [DXJ4KB] 1594
FAILURE CODE [DXJCKA] 1596
FAILURE CODE [DXJCKB] 1598
FAILURE CODE [DXJCKY] 1600
FAILURE CODE [DXJDKA] 1602
FAILURE CODE [DXJDKB] 1604
FAILURE CODE [DXJDKY] 1606
FAILURE CODE [DXK1KA] 1608
FAILURE CODE [DXK1KB] 1610
FAILURE CODE [DXK1KY] 1612
FAILURE CODE [DXK2KA] 1614
FAILURE CODE [DXK2KB] 1616
FAILURE CODE [DXK2KY] 1618
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1620
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1620
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1627
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1630
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1632
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1634
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1638
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1639
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1640
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1641
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1642
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1643
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1644
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1645
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1646
E-15 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1647
E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1650
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1653
E-18 OPERATION MODE DOES NOT CHANGE 1654
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 1655
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 1656
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1657
E-22 SERVICE MODE CANNOT BE SELECTED 1658
E-23 WORK EQUIPMENT DOES NOT OPERATE 1659
E-24 FOOT HEATER DOES NOT OPERATE 1661
E-25 HORN DOES NOT SOUND 1667
E-26 HORN DOES NOT STOP SOUNDING 1669
E-27 BACKUP ALARM DOES NOT SOUND 1670
E-28 BACKUP ALARM DOES NOT STOP SOUNDING 1671
E-29 HEADLAMP DOES NOT LIGHT UP 1672
E-30 REAR LAMP DOES NOT LIGHT UP 1676
E-31 ALL WIPERS DO NOT OPERATE 1679
E-32 FRONT WIPER DOES NOT OPERATE 1681
E-33 REAR WIPER DOES NOT OPERATE 1683
E-34 LEFT DOOR WIPER DOES NOT OPERATE 1685
E-35 RIGHT DOOR WIPER DOES NOT OPERATE 1689
E-36 FRONT WASHER DOES NOT OPERATE 1693
E-37 REAR WASHER DOES NOT OPERATE 1695
E-38 LEFT DOOR WASHER DOES NOT OPERATE 1697
E-39 RIGHT DOOR WASHER DOES NOT OPERATE 1699
E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1701
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1702
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1702
FAILURE MODE AND CAUSE TABLE 1703
H-1 NEITHER R H NOR L H OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) 1709
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) 1711
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) 1713
H-4 TRAVEL SPEED OR POWER IS LOW 1715
H-5 SPEED RANGE DOES NOT CHANGE 1717
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 1718
H-7 MACHINE DEVIATES LARGELY 1719
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 1722
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1724
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 1726
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 1728
H-12 ALL WORK EQUIPMENT DO NOT OPERATE 1730
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1732
H-14 BLADE LIFT SPEED OR POWER IS LOW 1733
H-15 BLADE TILT SPEED OR POWER IS LOW 1735
H-16 BLADE ANGLE SPEED OR POWER IS LOW 1736
H-17 TIME LAG OF BLADE LIFT IS LARGE 1737
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1738
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 1739
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 1740
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1741
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1743
TROUBLESHOOTING OF ENGINE (S-MODE) 1744
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1744
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1745
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1746
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1747
S-4 ENGINE STARTABILITY IS POOR 1749
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1751
S-6 ENGINE STOPS DURING OPERATION 1753
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1755
S-8 ENGINE LACKS POWER 1756
S-9 EXHAUST SMOKE IS BLACK 1758
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1760
S-11 OIL BECOMES CONTAMINATED QUICKLY 1761
S-12 FUEL CONSUMPTION IS EXCESSIVE 1762
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1763
S-14 OIL PRESSURE DROPS 1764
S-15 FUEL MIXES INTO ENGINE OIL 1766
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1767
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1768
S-18 UNUSUAL NOISE IS HEARD 1769
S-19 VIBRATION IS EXCESSIVE 1770
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1771
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1772
S-22 ACTIVE REGENERATION TAKES TIME 1773
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1774
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1775
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1777
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1778
50 DISASSEMBLY AND ASSEMBLY 1779
CONTENTS 1780
ABBREVIATION LIST 1785
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1791
HOW TO READ THIS MANUAL 1791
COATING MATERIALS LIST 1793
SPECIAL TOOLS LIST 1797
SKETCHES OF SPECIAL TOOLS 1817
ENGINE AND COOLING SYSTEM 1830
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1830
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1830
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1840
REMOVE AND INSTALL INJECTOR ASSEMBLY 1850
METHOD FOR REMOVING INJECTOR ASSEMBLY 1850
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1861
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1875
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1875
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1894
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1918
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1918
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1921
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1925
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1925
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1929
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1933
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 1933
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 1935
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 1938
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 1938
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 1942
REMOVE AND INSTALL ALTERNATOR BELT 1947
METHOD FOR REMOVING ALTERNATOR BELT 1947
METHOD FOR INSTALLING ALTERNATOR BELT 1949
REMOVE AND INSTALL AUTOMATIC TENSIONER 1952
METHOD FOR REMOVING AUTOMATIC TENSIONER 1952
METHOD FOR INSTALLING AUTOMATIC TENSIONER 1953
REMOVE AND INSTALL RADIATOR ASSEMBLY 1955
METHOD FOR REMOVING RADIATOR ASSEMBLY 1956
METHOD FOR INSTALLING RADIATOR ASSEMBLY 1964
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1972
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 1973
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 1978
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1983
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 1984
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 1990
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 1997
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 1997
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2001
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2006
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2006
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2009
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 2012
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2012
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2023
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2035
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2035
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2037
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2040
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2040
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2041
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2044
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2044
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2047
REMOVE AND INSTALL KDOC ASSEMBLY 2051
METHOD FOR REMOVING KDOC ASSEMBLY 2051
METHOD FOR INSTALLING KDOC ASSEMBLY 2056
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2064
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2065
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2071
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2079
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2079
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2082
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2086
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2087
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2094
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2101
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2102
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2112
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2121
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2121
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2123
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2127
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2127
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2128
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2135
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2135
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2136
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2137
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2137
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2138
REMOVE AND INSTALL SCR ASSEMBLY 2141
METHOD FOR REMOVING SCR ASSEMBLY 2141
METHOD FOR INSTALLING SCR ASSEMBLY 2144
REMOVE AND INSTALL KCCV ASSEMBLY 2147
METHOD FOR REMOVING KCCV ASSEMBLY 2147
METHOD FOR INSTALLING KCCV ASSEMBLY 2148
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2151
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2151
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2155
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2159
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2159
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2164
REMOVE AND INSTALL AdBlue/DEF PUMP 2169
METHOD FOR REMOVING AdBlue/DEF PUMP 2169
METHOD FOR INSTALLING AdBlue/DEF PUMP 2173
REMOVE AND INSTALL AdBlue/DEF HOSE 2177
METHOD FOR REMOVING AdBlue/DEF HOSE 2179
METHOD FOR INSTALLING AdBlue/DEF HOSE 2198
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2219
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2219
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2221
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2224
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2224
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2228
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2233
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2233
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2237
POWER TRAIN 2241
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2241
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2242
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2246
UNDERCARRIAGE AND FRAME 2255
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2255
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2255
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2260
REMOVE AND INSTALL IDLER ASSEMBLY 2265
METHOD FOR REMOVING IDLER ASSEMBLY 2265
METHOD FOR INSTALLING IDLER ASSEMBLY 2267
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2270
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2270
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2272
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2277
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2277
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2277
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2278
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY 2278
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY 2281
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2284
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2284
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2286
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2289
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2289
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2290
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2294
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2294
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2295
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2297
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2297
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2298
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2301
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2301
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2302
SEPARATE AND CONNECT TRACK ASSEMBLY 2304
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2304
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2305
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2306
METHOD FOR CONNECTING TRACK ASSEMBLY 2307
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2309
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2309
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2309
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2310
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2310
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2315
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2328
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2329
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2330
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2339
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2340
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2341
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2348
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2349
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2351
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2355
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2355
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2357
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS 2360
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2360
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2361
REMOVE AND INSTALL SEGMENT TEETH 2362
METHOD FOR REMOVING SEGMENT TEETH 2362
METHOD FOR INSTALLING SEGMENT TEETH 2364
HYDRAULIC SYSTEM 2366
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2366
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2367
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2373
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2382
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2382
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2386
WORK EQUIPMENT 2390
REMOVE AND INSTALL BLADE ASSEMBLY 2390
METHOD FOR REMOVING BLADE ASSEMBLY 2390
METHOD FOR INSTALLING BLADE ASSEMBLY 2393
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY 2398
METHOD FOR REMOVING BLADE LIFT CYLINDER ASSEMBLY 2398
METHOD FOR INSTALLING BLADE LIFT CYLINDER ASSEMBLY 2400
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY 2402
METHOD FOR REMOVING BLADE TILT CYLINDER ASSEMBLY 2402
METHOD FOR INSTALLING BLADE TILT CYLINDER ASSEMBLY 2403
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY 2405
METHOD FOR REMOVING BLADE ANGLE CYLINDER ASSEMBLY 2405
METHOD FOR INSTALLING BLADE ANGLE CYLINDER ASSEMBLY 2407
REMOVE AND INSTALL U-FRAME ASSEMBLY 2409
METHOD FOR REMOVING U-FRAME ASSEMBLY 2409
METHOD FOR INSTALLING U-FRAME ASSEMBLY 2413
CAB AND ITS ATTACHMENTS 2416
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2416
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2417
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2424
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2432
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2434
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2434
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2440
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2440
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2446
REMOVE AND INSTALL RECEIVER DRIER 2453
METHOD FOR REMOVING RECEIVER DRIER 2453
METHOD FOR INSTALLING RECEIVER DRIER 2454
REMOVE AND INSTALL OPERATOR’S SEAT 2457
METHOD FOR REMOVING OPERATOR’S SEAT 2457
METHOD FOR INSTALLING OPERATOR’S SEAT 2458
REMOVE AND INSTALL SEAT BELT 2459
METHOD FOR REMOVING SEAT BELT 2459
METHOD FOR INSTALLING SEAT BELT 2459
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2461
METHOD FOR REMOVING FOOT HEATER ASSEMBLY 2461
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY 2463
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2466
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2466
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY 2467
ELECTRICAL SYSTEM 2468
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2468
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2468
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2471
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2475
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2475
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2476
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2477
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2477
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2478
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2480
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2480
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2482
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2484
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2484
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2486
60 MAINTENANCE STANDARD 2489
CONTENTS 2490
ABBREVIATION LIST 2491
ENGINE AND COOLING SYSTEM 2497
MAINTENANCE STANDARD OF ENGINE MOUNT 2497
MAINTENANCE STANDARD OF DAMPER 2498
MAINTENANCE STANDARD OF COOLING SYSTEM 2499
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2501
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 2503
POWER TRAIN 2504
MAINTENANCE STANDARD OF HST PUMP 2504
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2506
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2507
MAINTENANCE STANDARD OF HST CHARGE PUMP 2508
MAINTENANCE STANDARD OF HST MOTOR 2510
MAINTENANCE STANDARD OF FINAL DRIVE 2512
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2514
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2515
UNDERCARRIAGE AND FRAME 2516
MAINTENANCE STANDARD OF SUSPENSION 2516
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2519
MAINTENANCE STANDARD OF IDLER 2522
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2524
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2525
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2527
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2528
MAINTENANCE STANDARD OF SINGLE SHOE 2530
HYDRAULIC SYSTEM 2531
MAINTENANCE STANDARD OF HYDRAULIC TANK 2531
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2532
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP 2533
MAINTENANCE STANDARD OF CONTROL VALVE 2535
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2541
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 2543
MAINTENANCE STANDARD OF EPC VALVE 2544
MAINTENANCE STANDARD OF QUICK DROP VALVE 2545
WORK EQUIPMENT 2547
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 2547
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 2550
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2551
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2552
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER 2553
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2554
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 2556
CAB AND ITS ATTACHMENTS 2557
MAINTENANCE STANDARD OF CAB MOUNT 2557
ELECTRICAL SYSTEM 2559
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2559
80 APPENDIX 2561
CONTENTS 2562
ABBREVIATION LIST 2563
AIR CONDITIONER SYSTEM 2569
PRECAUTIONS FOR REFRIGERANT 2569
AIR CONDITIONER COMPONENT 2570
SPECIFICATIONS OF AIR CONDITIONER 2573
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2574
OUTLINE OF REFRIGERATION CYCLE 2575
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2577
AIR CONDITIONER UNIT 2577
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2577
FUNCTION OF AIR CONDITIONER UNIT 2578
COMPONENT PARTS OF AIR CONDITIONER UNIT 2579
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2579
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2579
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT 2579
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2579
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2580
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2580
FUNCTION OF DUAL PRESSURE SWITCH 2581
FUNCTION OF PRESSURE SWITCH 2581
COMPRESSOR 2582
STRUCTURE OF COMPRESSOR 2582
SPECIFICATIONS OF COMPRESSOR 2582
FUNCTION OF COMPRESSOR 2582
CONDENSER 2583
STRUCTURE OF CONDENSER 2583
SPECIFICATIONS OF CONDENSER 2583
FUNCTION OF CONDENSER 2584
RECEIVER DRIER 2585
STRUCTURE OF RECEIVER DRIER 2585
SPECIFICATIONS OF RECEIVER DRIER 2585
FUNCTION OF RECEIVER DRIER 2585
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2587
CIRCUIT DIAGRAM OF AIR CONDITIONER 2590
AIR CONDITIONER SYSTEM DIAGRAM 2591
CONTROL FUNCTION OF AIR CONDITIONER 2592
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2593
TEST RELAYS 2597
METHOD FOR TESTING RELAYS 2597
AIR CONDITIONER TROUBLESHOOTING CHART 1 2599
AIR CONDITIONER TROUBLESHOOTING CHART 2 2600
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2603
A-1 TROUBLESHOOTING FOR CONDENSER FAN 2605
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2608
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2612
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 2615
TROUBLESHOOTING USING GAUGE PRESSURE 2619
CONNECTION OF SERVICE TOOL 2621
METHOD FOR CONNECTING SERVICE TOOL 2622
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2623
HANDLE COMPRESSOR OIL 2625
90 CIRCUIT DIAGRAMS 2627
CONTENTS 2628
ABBREVIATION LIST 2629
HYDRAULIC CIRCUIT DIAGRAM 2635
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2635
HYDRAULIC CIRCUIT DIAGRAM 2639
ELECTRICAL CIRCUIT DIAGRAM 2641
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2641
ELECTRICAL CIRCUIT DIAGRAM (1/14) 2645
ELECTRICAL CIRCUIT DIAGRAM (2/14) 2647
ELECTRICAL CIRCUIT DIAGRAM (3/14) 2649
ELECTRICAL CIRCUIT DIAGRAM (4/14) 2651
ELECTRICAL CIRCUIT DIAGRAM (5/14) 2653
ELECTRICAL CIRCUIT DIAGRAM (6/14) 2655
ELECTRICAL CIRCUIT DIAGRAM (7/14) 2657
ELECTRICAL CIRCUIT DIAGRAM (8/14) 2659
ELECTRICAL CIRCUIT DIAGRAM (9/14) 2661
ELECTRICAL CIRCUIT DIAGRAM (10/14) 2663
ELECTRICAL CIRCUIT DIAGRAM (11/14) 2665
ELECTRICAL CIRCUIT DIAGRAM (12/14) 2667
ELECTRICAL CIRCUIT DIAGRAM (13/14) 2669
ELECTRICAL CIRCUIT DIAGRAM (14/14) 2671
INDEX 2673